1991 1999 ford explorer chilton User Manual

							Before removing the transmission fluid pan, insure that the area is clean of dirt and debris
Place a large drain pan under the transmission.
2. 
Loosen all of the pan attaching bolts to within a few turns of complete removal
Loosen all of the pan attaching bolts to within a few turns of complete removal, then carefully break
the gasket seal allowing most of the fluid to drain over the edge of the pan.
3. 
CAUTION
DO NOT force the pan while breaking the gasket seal. DO NOT allow the pan flange to become bent or
otherwise damaged.
When fluid has drained to the level of the pan flange, remove the pan bolts and carefully lower the
pan doing your best to drain the rest of the fluid into the drain pan.
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DRAIN, PAN/FILTER SERVICE & REFILL 117 
						

							Once the pan is removed, discard the old gasket and insure that the mating surfaces are clean
Inspect this magnet inside of the pan for any large pieces of debris. A light gray coating is normal
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118 DRAIN, PAN/FILTER SERVICE & REFILL 
						

							Clean the pan thoroughly with a safe solvent and allow it to air dry
Clean the transmission oil pan thoroughly using a safe solvent, then allow it to air dry. DO NOT use a
cloth to dry the pan which might leave behind bits of lint. Discard the old pan gasket.
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DRAIN, PAN/FILTER SERVICE & REFILL 119 
						

							The transmission filter is secured by a mounting bolt (arrow). Some models may use two bolts
Click to enlarge
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120 DRAIN, PAN/FILTER SERVICE & REFILL 
						

							Remove the filter mounting bolt ...
... then pull the filter free from the transmission
If necessary, remove the Automatic Transmission Fluid (ATF) filter mounting bolts, then remove the
filter by pulling it down and off of the valve body. Make sure any gaskets or seals are removed with
the old filter. The transmission usually has one round seal and a rectangular gasket.
6. 
Install the new oil filter screen making sure all gaskets or seals are in place, then secure using the
retaining screws, if applicable.
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DRAIN, PAN/FILTER SERVICE & REFILL 121 
						

							Install a new pan gasket
Place a new gasket on the fluid pan, then install the pan to the transmission. Tighten the attaching
bolts to 71-119 inch lbs. (8-13 Nm).
8. 
Fill the transmission with the proper amount of ATF
Add three quarts (six quarts if the torque converter was drained) of fluid to the transmission through
the filler tube.
9. 
Remove the jackstands and carefully lower the vehicle.
10. 
Start the engine and move the gear selector through all gears in the shift pattern. Allow the engine to
reach normal operating temperature.
11. 
Check the transmission fluid level. Add fluid, as necessary, to obtain the correct level.
12. 
Torque Converter
If it is necessary to perform a complete drain and refill, it will be necessary to remove the remaining
fluid from the torque converter and the cooler lines.
Remove the converter housing lower cover
1. 
Rotate the torque converter until the drain plug comes into view.
2. 
Remove the drain plug and allow the transmission fluid to drain.
3. 
If necessary disconnect the cooler lines at the transmission and flush them using low pressure,
compressed air. Use care when applying air pressure to one of the cooler lines, as fluid will drain, or
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122 DRAIN, PAN/FILTER SERVICE & REFILL 
						

							even shoot, out of the other cooler line.
Transfer Case
FLUID RECOMMENDATION
Use Mercon® automatic transmission fluid when refilling or adding fluid to the transfer case.
LEVEL CHECK Position the vehicle on level ground.
1. 
The transfer case fill/level check plug is the upper most plug, located on the rear of the case HOW TO USE THIS BOOK
Transfer Case 123 
						

							Remove the plug using a 
3
/8  in. drive ratchet
Remove the transfer case fill plug (the upper plug) located on the rear of the transfer case. The fluid
level should be up to the fill hole.
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124 LEVEL CHECK 
						

							Once the plug is removed, fluid should trickle out of the hole. If not, add Mercon ATF fluid until
it does
If lubricant doesnt run out when the plug is removed, add lubricant until it does run out.
3. 
Replace the fill plug.
4. 
DRAIN & REFILL
The manufacturer recommends that the transfer case fluid should be changed every 60,000 miles (96,000km).
However, if the truck is driven in deep water (as high as the transfer case housing) 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 transfer case 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.
2. 
Place a drain pan under the transfer case 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 transfer case BEFORE
removing the drain plug. It would be unfortunate to drain all of your transfer case 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 transfer case fluid to drain out.
4. 
The transfer case 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 transfer case has drained sufficiently, install the drain plug until secure.
5. 
Fill the transfer case 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. 
Front and Rear Drive Axle
FLUID RECOMMENDATION
Use hypoid gear lubricant SAE 80W or 90W.
On models with the front locking differential, add 2 oz. of friction modifier Ford part No.
EST-M2C118-A. On models with the rear locking differential, use only locking differential fluid Ford
part No. ESP-M2C154-A or its equivalent, and add 4 oz. of friction modifier Ford part No.
EST-M2C118-A. HOW TO USE THIS BOOK
DRAIN & REFILL 125 
						

							
LEVEL CHECK
The fluid level in the drive axles should be checked at each oil change. Like the manual transmission which is
available, the rear axle does not have a dipstick to check fluid level. Instead, a filler plug is located in the side
of the housing (or in the side of the cover), at a level just barely above the level to which fluid should fill the
housing. To check the fluid level:
To check the front drive axle fluid level, loosen the fill plug ...... then remove it. Fluid should trickle out of the holeIf not, add the proper grade of lubricant until it does HOW TO USE THIS BOOK
126 LEVEL CHECK