1991 1999 ford explorer chilton User Manual

							Exploded view of the Explorer/Mountaineer rear liftgate trim panel
Click to enlarge
Instrument Panel
REMOVAL & INSTALLATION HOW TO USE THIS BOOK
1114 Instrument Panel 
						

							Exploded view of the 1991-92 instrument panel assembly
Click to enlarge
HOW TO USE THIS BOOK
REMOVAL & INSTALLATION 1115 
						

							Exploded view of the 1993-97 instrument panel assembly
Click to enlarge
Disconnect the negative battery cable.
1. 
Disconnect the instrument panel wiring connectors in the engine compartment.
2. 
Remove the 2 screws retaining the lower steering column cover and remove the cover.
3. 
Remove the ashtray and retainer.
4. 
Remove the upper and lower steering column shrouds.
5. 
Remove the instrument cluster finish panel. Remove the radio assembly and equalizer, if equipped.
6. 
Remove the screws retaining the instrument cluster. Remove the cluster, making sure to disconnect
the electrical leads.
7. 
Remove the screw that attaches the instrument panel to the brake and clutch pedal support.
8. 
Disconnect the wiring from the switches on the steering column.
9. 
Remove the front inside pillar mouldings.
10. 
Remove the right side cowl trim cover.
11. 
Remove the lower right insulator from under the instrument panel.
12. 
Remove the 2 bolts retaining the instrument panel to the lower right side of the cowl.
13. 
Remove the 2 screw retaining the instrument panel to the parking brake bracket, on the drivers side.
14. 
Remove the 4 screw retaining the top of the instrument panel.
15. 
Reach through the openings in the instrument panel and disconnect any remaining electrical
connectors. Disconnect the heater/air conditioning controls.
16. 
Removing the instrument panel will be much easier with the help of an assistant, as it is extremely
bulky and difficult to maneuver. HOW TO USE THIS BOOK
1116 REMOVAL & INSTALLATION 
						

							Carefully tilt the instrument panel forward and remove it from the vehicle. Work the instrument panel
around the steering wheel.
17. 
To install: If the instrument panel is being replaced, transfer all mounting brackets and switches to the new
panel.
18. 
Position the instrument panel inside the vehicle and install the 4 screw that retain it along the top.
19. 
Install the retaining screws on the left and right sides. Make sure the instrument panel is properly
mounted.
20. 
Making sure the instrument panel is positioned correctly at this point, will avoid problems with fit and
rattles, after its installed. Also check for pinched or cut wires.
Install the mouldings and the trim panels.
21. 
Connect the heater/air conditioning controls and all of the instrument panel switches.
22. 
Connect the wiring to the steering column switches.
23. 
Install the instrument cluster, radio and ashtray assemblies.
24. 
Install the instrument cluster finish panel.
25. 
Install the steering column shrouds.
26. 
Reconnect all wiring connectors in the engine compartment.
27. 
Connect the negative battery cable.
28. 
Check the operation of ALL accessories.
29. 
Center Console
REMOVAL & INSTALLATION HOW TO USE THIS BOOK
Center Console 1117 
						

							Exploded view of the standard center console (may have one or two cup holders)
Click to enlarge
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1118 REMOVAL & INSTALLATION 
						

							Exploded view of the high-end center console
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Remove the small arm rest screw covers.
1. 
Remove the 4 arm rest retaining bolts.
2. 
Remove the 2 rear arm rest retaining screws and the 2 screws in the front utility tray.
3. 
Remove the entire assembly, by lifting it from its mounting bracket.
4. 
Install the console in position and install all mounting screws.
5. 
Headliner
REMOVAL & INSTALLATION
Ranger Remove both sun visors.
1. 
Remove the assist handles if equipped.
2. 
Remove the upper windshield garnish molding.
3. 
Remove the front pillar moldings.
4. 
Remove the coat hooks.
5. 
Remove the lower back window garnish molding.
6.  HOW TO USE THIS BOOK
Headliner 1119 
						

							Remove the rear corner trim panels.
7. 
Remove the dome lamp lens and lamp assembly.
8. 
Carefully remove the headliner from the truck.
9. 
To install: If replacing the headliner, preshape the replacement one along the score marks to about the same
shape as the original.
10. 
Install the headliner to the roof of the truck.
11. 
Install the dome lamp assembly.
12. 
Install the rear corner trim panels and related items.
13. 
Install the lower back window garnish molding.
14. 
Install the coat hooks.
15. 
Install the front pillar moldings.
16. 
Install the upper windshield garnish molding.
17. 
Install the assist handles and sun visors.
18. 
Explorer/Mountaineer
Headliner installation-ExplorerClick to enlarge
Remove both sun visors and visor arm clips.
1. 
Remove the assist handles and coat hooks.
2. 
Remove the front pillar inside moldings
3. 
Remove the push pin at the roof centerline.
4. 
On 4-door models, remove the B pillar upper moldings.
5. 
Remove the top seat belt anchor cover and the anchor itself.
6. 
Remove the body side trim panels.
7. 
Remove the dome lamp and cargo lamp assemblies.
8. 
Remove the push pin retainers above the front doors, at the rear edges and at mid-vehicle.
9. 
If the original headliner is being reinstalled, install U channel reinforcements along the outboard
edges; these will prevent damage to the headliner. These pieces are sometimes used in shipping
containers.
Carefully remove the headliner from the truck.
10. 
To install: HOW TO USE THIS BOOK
1120 REMOVAL & INSTALLATION 
						

							Install the headliner to the roof. If you are installing a new headliner, leave the U channel
reinforcements in place until the retaining pins are secured.
11. 
Install the lamp assemblies.
12. 
Install the front outboard locating push pins, then install the remaining ones. If installing a new
headliner, remove the U reinforcements.
13. 
Install the body side trim panels.
14. 
Install the top seat belt anchor and cover.
15. 
On 4-door models, install the B pillar upper moldings. Install the push pins at the roof centerline.
16. 
Install the coat hooks.
17. 
Install the front pillar inside moldings.
18. 
Install the assist handles.
19. 
Install the sun visors and arm clips.
20. 
Door Locks
REMOVAL & INSTALLATION
Door Latch
Door latch assembly-RangerClick to enlarge
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Door Locks 1121 
						

							Front door latch-Explorer
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1122 REMOVAL & INSTALLATION 
						

							Rear door latch-Explorer
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Remove the door trim panel and watershield.
1. 
Disconnect the rods from the handle and lock cylinder, and from the remote control assembly.
2. 
Remove the latch assembly attaching screws and remove the latch from the door.
3. 
Installation is the reverse of removal.
4. 
Door Lock Cylinder Open the window.
1. 
Remove the trim panel and watershield.
2. 
Disconnect the actuating rod from the lock control link clip.
3. 
Slide the retainer away from the lock cylinder.
4. 
Remove the cylinder from the door.
5. 
Use a new gasket when installing to ensure a watertight fit.
6. 
Lubricate the cylinder with suitable oil recommended for this application.
7. 
Door Glass and Regulator HOW TO USE THIS BOOK
REMOVAL & INSTALLATION 1123