1991 1999 ford explorer chilton User Manual

							Ensure that the antenna is in the fully retracted position.
1. 
Remove the retaining screws for the right-hand front wheel splash shield for access to the lower
retaining screw.
2. 
Remove the lower antenna mounting bracket retaining screw.
3. 
Unsnap the antenna base cap from the antenna base and remove it.
4. 
Loosen and remove the antenna-to-base retaining nut.
5. 
Disconnect the electrical wire harness plug and the antenna lead-in wire at the antenna.
6. 
Remove the antenna through the fender/splash shield access.
7. 
Installation is the reverse of the removal procedure.
8. 
Fenders
REMOVAL & INSTALLATION
Ranger
Exploded view of the 1991-92 Ranger front fenderClick to enlarge
Clean out all dirt from the fender attaching hardware and lubricate them to ease removal.
1. 
Remove the grille.
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1094 Fenders 
						

							Remove the bolt attaching the rear lower end of the fender to the lower corner of the cab.
3. 
From inside the cab, remove the bolt attaching the rear end of the fender to the cowl.
4. 
Remove the screws around the wheel opening attaching the fender apron.
5. 
On 1993-99 models remove the bolt attaching the lower rear of the fender to the rocker.
6. 
Remove the bolts along the top of the apron attaching the fender.
7. 
Remove the bolt attaching the brace to radiator support assembly.
8. 
Remove the fender and remove the brace from the fender.
9. 
To install: Position the nuts, retainers and brace on the fender.
10. 
Position the fender on the apron and loosely install the apron retaining bolts.
11. 
Loosely install the bolt from inside the cab attaching the rear end of the fender to the cowl.
12. 
Loosely install the bolt attaching the rear lower end of the fender to the lower corner of the cab.
13. 
Loosely install the bolt attaching the brace to the radiator support assembly.
14. 
Loosely install the 4 bolts along the fender inner body attaching the fender.
15. 
Adjust the position of the fender and tighten all mounting bolts.
16. 
Install the grille.
17. 
Install the apron screws around the wheel opening.
18. 
Exploded view of the Explorer/Mountaineer front fender-1993-99 Ranger is similar Click to enlarge
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REMOVAL & INSTALLATION 1095 
						

							
Explorer and Mountaineer
Clean out all dirt from the fender attaching hardware and lubricate them to ease removal.
1. 
Remove the headlight door and side marker lamp.
2. 
Remove both bolts attaching the headlight assembly to the fender.
3. 
From inside the door opening, remove the bolt attaching the rear end of the fender to the cowl.
4. 
Remove the 4 bolts along the top of the fender inner body attaching the fender.
5. 
Raise the truck to a convenient height.
6. 
Remove the bolt attaching the brace to the radiator support assembly.
7. 
Remove the 4 screws attaching the fender apron to the fender.
8. 
Remove the 2 bolts attaching the fender to the rocker panel.
9. 
Lower the vehicle and remove the fender. Remove the brace from the fender.
10. 
To install: Install the fender and raise the truck.
11. 
Position the nuts, retainers and brace on the fender.
12. 
Install the 2 bolts attaching the fender to the rocker panel.
13. 
Install the 4 screws attaching the fender apron to the fender.
14. 
Install the bolt attaching the brace to the radiator support. Lower the truck.
15. 
Install the 4 bolts along the top of the fender inner body attaching the fender.
16. 
Install the bolt attaching the rear end of the fender to the cowl.
17. 
Install both bolts attaching the headlight assembly to the fender.
18. 
Install the headlight door and side marker lamp.
19. 
Pickup Truck Bed
REMOVAL & INSTALLATION HOW TO USE THIS BOOK
1096 REMOVAL & INSTALLATION 
						

							Pickup bed and mounting hardware
Click to enlarge
Clean out all dirt from the beds attaching hardware and lubricate them to ease removal.
1. 
Remove all bolts attaching the bed to the frame.
2. 
As necessary, disconnect any wire harnesses connected to the bed.
3. 
Unbolt the fuel filler neck from the bed opening.
4. 
Lift the bed off of the frame.
5. 
Installation is the reverse of removal.
6. 
Be sure to use new bolts and other mounting hardware when installing. Replacement parts should be
of the same specification as the original parts; i.e. do not use Grade 5 bolts where Grade 8 bolts were
originally used.
7. 
Chassis and Cab Mount Bushings
REMOVAL & INSTALLATION HOW TO USE THIS BOOK
REMOVAL & INSTALLATION 1097 
						

							Body-to-frame mounts and hardware-Ranger
Click to enlarge
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1098 REMOVAL & INSTALLATION 
						

							Body-to-frame mounts and hardware-Ranger Super Cab
Click to enlarge
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REMOVAL & INSTALLATION 1099 
						

							Body-to-frame mounts and hardware-Explorer
Click to enlarge
Use the accompanying illustrations as a guide Remove interior trim as required.
1. 
Back out the body mount bolt four or five turns.
2. 
If necessary, have an assistant hold the lower retainer with a wrench.
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1100 REMOVAL & INSTALLATION 
						

							When removing the body mount bolt, an assistant may need to hold the lower retainer from
turning
Strick the head of the bolt with a hammer to drive out the lower retainer.
4. 
Remove the bolt and lower retainer.
5. 
Use a jack and a block of wood and jack the body up enough to remove the old mount from between
the frame and body.
6. 
Some of the other body mounts may need to be loosened in order to lift the body enough to remove the
mount.
Installation is the reverse of the removal procedure.
7. 
Spare Tire Carrier
REMOVAL & INSTALLATION
Ranger
Under-frame spare tire carrierClick to enlarge
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Spare Tire Carrier 1101 
						

							Remove the spare tire from the carrier.
1. 
Remove the bolt attaching the hinge assembly to the channel.
2. 
Remove the stud plate and the nuts attaching the hinge to the rear crossmember.
3. 
Remove the eye bolt from the channel.
4. 
Remove the bolts attaching the support assembly to the frame and remove the support.
5. 
Installation is the reverse of removal.
6. 
Explorer/Mountaineer
Under-frame spare tire carrier-Explorer/MountaineerClick to enlarge
Lower the spare tire and work the lift cup through the wheel to release the cable.
1. 
Remove the 2 screws attaching the winch to the support and remove the winch assembly from the
underside of the truck.
2. 
To install: Position the winch assembly on its support and install the screws.
3. 
Insert the cable end through the center of the wheel and raise into position. Raise until the clutch
overrides. An audible snap will be felt.
4. 
Chilton® Automotive Information Systems. © 2004 Thomson Delmar Learning. HOW TO USE THIS BOOK
1102 REMOVAL & INSTALLATION 
						

							
INTERIOR
Door Panels
REMOVAL & INSTALLATION
1991-92 Ranger Open the window. Remove the armrest.
1. 
Remove the door handle screw and pull off the handle.
2. 
If equipped with manual windows, remove the window regulator handle screw and pull off the
handle. If equipped with power windows, remove the power window switch housing.
1. 
If equipped with manual door locks, remove the door lock control.
2. 
If equipped with power door locks, remove the power door lock switch housing.
3. 
3. 
If equipped with electric outside rear view mirrors, remove the power mirror switch housing.
4. 
Using a flat wood spatula, insert it carefully behind the panel and slide it along to find the push-pins.
When you encounter a pin, pry the pin outward. Do this until all the pins are out. NEVER PULL ON
THE PANEL TO REMOVE THE PINS!
5. 
Installation is the reverse of removal.
6. 
Explorer/Mountaineer and 1993-99 Ranger Open the window.
1. 
Unscrew the door lock knob.
2. 
On Explorer/Mountaineer, remove the 2 screws retaining the trim panel located above the door
handle.
3. 
On Ranger, remove the two screws in the armrest and remove it.
4. 
INTERIOR 1103