1991 1999 ford explorer chilton User Manual

							If necessary, remove the fill cap and add the proper amount and grade of oil to correct the level
Recheck the oil level and close the hood.
5. 
Use a multi-grade oil with API classification SG or better.
OIL & FILTER CHANGE
The engine oil and oil filter should be changed at the recommended intervals on the Maintenance
Chart. Though some manufacturers have at times recommended changing the filter only at every other
oil change, we recommend that you always change the filter with the oil. The benefit of fresh oil is
quickly lost if the old filter is clogged and unable to do its job. Also, leaving the old filter in place leaves
a significant amount of dirty oil in the system.
The oil should be changed more frequently if the vehicle is being operated in a very dusty area. Before
draining the oil, make sure that the engine is at operating temperature. Hot oil will hold more impurities in
suspension and will flow better, allowing the removal of more oil and dirt.
It is usually a good idea to place your ignition key in the box or bag with the bottles of fresh engine oil.
In this way it will be VERY HARD to forget to refill the engine crankcase before you go to start the
engine.
Raise and support the vehicle safely on jackstands. Make sure the oil drain plug is at the lowest point
on the oil pan. If not, you may have to raise the vehicle slightly higher on one jackstand (side) than
the other.
1. 
Before you crawl under the car, take a look at where you will be working and gather all the necessary
tools: such as a few wrenches or a strip of sockets, the drain pan, a clean rag, and, if the oil filter is
more accessible from underneath the vehicle, you will also want to grab a bottle of oil, the new filter
and a filter wrench at this time.
2. 
CAUTION
The EPA warns that prolonged contact with used engine oil may cause a number of skin disorders, including
cancer! You should make every effort to minimize you exposure to used engine oil. Protective gloves should
be worn when changing the oil. Wash your hands and any other exposed skin areas as soon as possible after
exposure to used engine oil. Soap and water, or waterless hand cleaner should be used.
Position the drain pan beneath the oil pan drain plug. Keep in mind that the fast flowing oil, which
will spill out as you pull the plug from the pan, will flow with enough force that it could miss the pan.
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OIL & FILTER CHANGE 107 
						

							Position the drain pan accordingly and be ready to move the pan more directly beneath the plug as the
oil flow lessens to a trickle.
Some 5.0L engines are equipped with 2 drain plugs (one in front of the crossmember and one behind it,
closer to the transmission). Both should be removed to assure proper pan draining, but if the front end
is raised and supported on ramps or jackstands, the oil may not fully drain from the front plug. The
best way to assure all oil has been drained is to pull the plugs, then remove the jackstands and carefully
lower the vehicle (make sure your drain pans are properly positioned because the relative positioning of
the drain holes will change as the vehicle is lowered). Once you are sure the front portion of the oil pan
has sufficiently drained, raise the vehicle and support it again with jackstands.
Loosen the oil pan drain plug ...
Unscrew the plug by hand. Keep an inward pressure on the plug as you unscrew it, so the oil wont escape until you pull the plug awayHOW TO USE THIS BOOK
108 OIL & FILTER CHANGE 
						

							Always install the new filter by hand (an oil filter wrench will usually lead to overtightening)
Loosen the drain plug with a wrench (or socket and driver), then carefully unscrew the plug with your
fingers. Use a rag to shield your fingers from the heat. Push in on the plug as you unscrew it so you
can feel when all of the screw threads are out of the hole (and so you will keep the oil from seeping
past the threads until you are ready to remove the plug). You can then remove the plug quickly to
avoid having hot oil run down your arm. This will also help assure that have the plug in your hand,
not in the bottom of a pan of hot oil.
4. 
CAUTION
Be careful of the oil; when at operating temperature, it is hot enough to cause a severe burn. HOW TO USE THIS BOOK
OIL & FILTER CHANGE 109 
						

							Quickly remove the plug, to help keep the HOT oil off your hands, and allow the oil to drain
completely
Allow the oil to drain until nothing but a few drops come out of the drain hole. Check the drain plug
to make sure the threads and sealing surface are not damaged. Carefully thread the plug into position
and tighten it with a torque wrench to 15-25 ft. lbs. (20-34 Nm). If a torque wrench is not available,
snug the drain plug and give a slight additional turn. You dont want the plug to fall out (as you would
quickly become stranded), but the pan threads are EASILY stripped from overtighening (and this can
be time consuming and/or costly to fix).
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110 OIL & FILTER CHANGE 
						

							Use an oil filter wrench to loosen the old filter
The oil filter is located on the bottom passenger side of the 4.0L (VIN X and E) engines and the
bottom driverside of all other engines; position the drain pan beneath it. To remove the filter, you may
need an oil filter wrench since the filter may have been fitted too tightly and/or the heat from the
engine may have made it even tighter. A filter wrench can be obtained at any auto parts store and is
well-worth the investment. Loosen the filter with the filter wrench. With a rag wrapped around the
filter, unscrew the filter from the boss on the side of the engine. Be careful of hot oil that will run
down the side of the filter. Make sure that your drain pan is under the filter before you start to remove
it from the engine; should some of the hot oil happen to get on you, there will be a place to dump the
filter in a hurry and the filter will usually spill a good bit of dirty oil as it is removed.
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OIL & FILTER CHANGE 111 
						

							Before installing a new oil filter, lightly coat the rubber gasket with clean engine oil
Wipe the base of the mounting boss with a clean, dry cloth. When you install the new filter, smear a
small amount of fresh oil on the gasket with your finger, just enough to coat the entire contact surface.
When you tighten the filter, rotate it about a half-turn after it contacts the mounting boss (or follow
any instructions which are provided on the filter or parts box).
7. 
WARNING
Never operate the engine without engine oil, otherwise SEVERE engine damage will be the result.
Remove the jackstands and carefully lower the vehicle, then IMMEDIATELY refill the engine
crankcase with the proper amount of oil. DO NOT WAIT TO DO THIS because if you forget and
someone tries to start the car, severe engine damage will occur.
8. 
Remove the engine oil fill cap and, using a funnel to avoid spills, add the proper amount and grade of oil
Refill the engine crankcase slowly, checking the level often. You may notice that it usually takes less
than the amount of oil listed in the capacity chart to refill the crankcase. But, that is only until the
engine is run and the oil filter is filled with oil. To make sure the proper level is obtained, run the
engine to normal operating temperature. While the engine is warming, look under the vehicle for any
oil leaks, and if found, shut the engine OFFimmediately then fix the leak. Shut the engine OFF, allow
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112 OIL & FILTER CHANGE 
						

							the oil to drain back into the oil pan, and recheck the level. Top off the oil at this time to the fill mark.
If the vehicle is not resting on level ground, the oil level reading on the dipstick may be slightly off. Be
sure to check the level only when the car is sitting level.
Drain your used oil in a suitable container for recycling and clean-up your tools, as you will be
needing them again in a couple of thousand more miles (kilometers).
10. 
Manual Transmission
FLUID RECOMMENDATION
The lubricant in the transmission should be checked and changed periodically, except when the vehicle has
been operated in deep water and water has entered the transmission. When this happens, change the lubricant
in the transmission as soon as possible. Use Standard Transmission Lube SAE 80 in the Mitsubishi 5-speed
transmission, and Mercon in the Mazda M5OD transmission.
LEVEL CHECK
The fluid level should be checked every six months or 6000 miles (9600 km), whichever comes first. Park the truck on a level surface, turn the engine OFF, FIRMLY apply the parking brake and block
the drive wheels.
1. 
Ground clearance may make access to the transmission filler plug impossible without raising and
supporting the vehicle, BUT, if this is done, the truck MUST be supported at four corners and level. If
only the front or rear is supported, an improper fluid level will be indicated. If you are going to place
the truck on four jackstands, this might be the perfect opportunity to rotate the tires as well.
Remove the filler plug from the side of the transmission case using a  3
/8  in. drive ratchet and
extension. The fluid level should be even with the bottom of the filler hole.
2. 
If additional fluid is necessary, add it through the filler hole using a siphon pump or squeeze bottle.
3. 
When you are finished, carefully install the filler plug, but DO NOT overtighten it and damage the
housing.
4. 
DRAIN & REFILL
Under normal conditions, the manufacturer feels that manual transmission fluid should not need to be
changed. However, if the truck is driven in deep water (as high as the transmission casing) it is a good idea to
replace the fluid. Little harm can come from a fluid change when you have just purchased a used vehicle,
especially since the condition of the transmission fluid is usually not known.
If the fluid is to be drained, it is a good idea to warm the fluid first so it will flow better. This can be
accomplished by 15-20 miles of highway driving. Fluid which is warmed to normal operating temperature
will flow faster, drain more completely and remove more contaminants from the housing.
Drive the vehicle to assure the fluid is at normal operating temperature.
1. 
Raise and support the vehicle securely on jackstands. Remember that the vehicle must be supported
level (usually at four points) so the proper amount of fluid can be added.
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Manual Transmission 113 
						

							Place a drain pan under the transmission housing, below the drain plug. Remember that the fluid will
likely flow with some force at first (arcing outward from the transmission), and will not just drip
straight downward into the pan. Position the drain pan accordingly and move it more directly beneath
the drain plug as the flow slows to a trickle.
3. 
To insure that the fill plug is not frozen or rusted in place, remove it from the transmission BEFORE
removing the drain plug. It would be unfortunate to drain all of your transmission fluid and then
realize that the fill plug is stripped or frozen in place.
Remove the fill plug, then the drain plug and allow the transmission fluid to drain out.
4. 
The transmission drain plug is usually a square receiver which is designed to accept a  3
/8  in. driver such
as a ratchet or extension.
Once the transmission has drained sufficiently, install the drain plug until secure.
5. 
Fill the transmission to the proper level with the required fluid.
6. 
Reinstall the filler plug once you are finished.
7. 
Remove the jackstands and carefully lower the vehicle.
8. 
Automatic Transmission
FLUID RECOMMENDATION
Refer to the dipstick to confirm automatic transmission fluid specifications. All transmissions use Mercon®
automatic transmission fluid. DO NOT use improper fluids such as Dexron® or gear oil. Use of improper
fluids could lead to leaks or transmission damage.
LEVEL CHECK
It is very important to maintain the proper fluid level in an automatic transmission. If the level is either too
high or too low, poor shifting operation and internal damage are likely to occur. For this reason, a regular
check of the fluid level is essential.
Although it is best to check fluid at normal operating temperature, it can be checked overnight cold, if the
ambient temperatures are 50-95°F (21-35°C). If so, refer to the dots on the transmission dipstick instead of
the cross-hatched area and level marking lines.
Drive the vehicle for 15-20 minutes, allowing the transmission to reach operating temperature.
1. 
If the car is driven at extended highway speeds, is driven in city traffic in hot weather or is being used
to pull a trailer, fluid temperatures will likely exceed normal operating and checking ranges. In these
circumstances, give the fluid time to cool (about 30 minutes) before checking the level.
Park the car on a level surface, apply the parking brake and leave the engine idling. Make sure the
parking brake is FIRMLY ENGAGED. Shift the transmission and engage each gear, then place the
selector in P(PARK).
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114 DRAIN & REFILL 
						

							If fluid is needed, use a funnel (to avoid spills) and add the required type and amount of ATF
If the level is below the lower mark, use a funnel and add fluid in small quantities through the dipstick
filler neck. Keep the engine running while adding fluid and check the level after each small amount.
DO NOT overfill as this could lead to foaming and transmission damage or seal leaks.
5. 
Since the transmission fluid is added through the dipstick tube, if you check the fluid too soon after
adding fluid an incorrect reading may occur. After adding fluid, wait a few minutes to allow it to fully
drain into the transmission.
DRAIN, PAN/FILTER SERVICE & REFILL
Transmission Fluid Pan and Filter
Under normal service (moderate highway driving excluding excessive hot or cold conditions), the
manufacturer feels that automatic transmission fluid should not need periodic changing. However, if a major
service is performed to the transmission, if transmission fluid becomes burnt or discolored through severe
usage or if the vehicle is subjected to constant stop-and-go driving in hot weather, trailer towing, long
periods of highway use at high speeds, fluid should be changed to prevent transmission damage. A preventive
maintenance change is therefore recommended for most vehicles at least every 90,000 miles (145,000 km).
Although not a required service, transmission fluid changing can help assure a trouble-free
transmission. Likewise, changing the transmission filter at this time is also added insurance.
Raise the car and support it securely on jackstands.
1. 
The torque converters on some transmissions are equipped with drain plugs. Because it may take some
time to drain the fluid from the converter, you may wish to follow that procedure at this time, then
come back to the pan and filter removal. HOW TO USE THIS BOOK
116 DRAIN, PAN/FILTER SERVICE & REFILL