1991 1999 ford explorer chilton User Manual

							Checking camshaft end-play-2.9L engines
Click to enlarge
Push the camshaft toward the rear of the engine. Install a dial indicator (Tool D78P-4201-C or
equivalent so that the indicator point is on the camshaft sprocket attaching screw.
1. 
Zero the dial indicator. Position a prybar between the camshaft gear and the block. Pull the camshaft
forward and release it. Compare the dial indicator reading with the specification. The camshaft
end-play specification is 0.0008-0.004 inch and the service limit is 0.009 inch (0.007 inch on 3.0L
engine). Camshaft specifications are sometimes modified by Ford after production.
2. 
If the end play is excessive, check the spacer for correct installation before it is removed. If the spacer
is correctly installed, replace the thrust plate.
3. 
The spacer ring and thrust plate are available in two thicknesses to permit adjusting the end play. Remove the dial indicator.
4. 
BEARING REMOVAL & INSTALLATION
If excessive camshaft wear is found, or if the engine is completely rebuilt, the camshaft bearings should be
replaced. Use these service repair procedures as a guide.
2.3L and 2.5L Engines HOW TO USE THIS BOOK
424 BEARING REMOVAL & INSTALLATION 
						

							Camshaft bearing installation-2.3L and 2.5L gasoline engine
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Remove the head and place it on a work stand.
1. 
Remove the camshaft.
2. 
Using a tool such as Bearing Replacer T71P-6250-A, remove the bearings.
3. 
Coat the new bearings with clean 50W engine oil and install them with the tool.
4. 
2.9L Engines HOW TO USE THIS BOOK
BEARING REMOVAL & INSTALLATION 425 
						

							Checking oil hole alignment-2.9L engine
Camshaft bearing installation on a V6 Click to enlarge
Remove the engine and place it on a work stand.
1. 
Remove the flywheel.
2. 
Remove the camshaft.
3. 
Using a sharp punch and hammer, drive a hole in the rear bearing bore plug and pry it out.
4. 
Using the special tools and instructions in Cam Bearing Replacer Kit T71P-6250-A, or their
equivalents, remove the bearings.
5. 
To remove the front and rear bearings, use the special adapter tube T72C-6250, or equivalent.
6. 
To install: Following the instructions in the tool kit, install the bearings. Make sure that you follow the
instructions carefully. Failure to use the correct expanding collets can cause severe bearing damage!
7. 
Make sure that the oil holes in the bearings and block are aligned! Install a new bearing bore plug coated with sealer.
8. 
Install the camshaft.
9. 
Install the flywheel.
10. 
Install the engine.
11.  HOW TO USE THIS BOOK
426 BEARING REMOVAL & INSTALLATION 
						

							
3.0L, 4.0L (VIN X) and 5.0L Engines
Remove the engine and place it on a work stand.
1. 
Remove the flywheel.
2. 
Remove the camshaft.
3. 
Using a sharp punch and hammer, drive a hole in the rear bearing bore plug and pry it out.
4. 
Using the special tools and instructions in Cam Bearing Replacer Kit T65L-6250-A, or their
equivalents, remove the bearings.
5. 
To remove the front bearing, install the tool from the rear of the block.
6. 
To install: Following the instructions in the tool kit, install the bearings. Make sure that you follow the
instructions carefully. Failure to use the correct expanding collets can cause severe bearing damage!
7. 
Make sure that the oil holes in the bearings and block are aligned! Make sure that the front bearing is
installed 0.51-0.89mm below the face of the block.
Install a new bearing bore plug coated with sealer.
8. 
Install the camshaft.
9. 
Install the flywheel.
10. 
Install the engine.
11. 
4.0L SOHC Engine (VIN E)
The bearings are integral with the cylinder heads and are not replaceable. If the bearing surfaces are damaged,
a new cylinder head will have to be installed.
Auxiliary Shaft
REMOVAL & INSTALLATION
2.3L and 2.5L Engines HOW TO USE THIS BOOK
BEARING REMOVAL & INSTALLATION 427 
						

							Auxiliary shaft installation-2.3L and 2.5L engines
Click to enlarge
Remove the camshaft drive belt cover.
1. 
Remove the drive belt. Remove the auxiliary shaft sprocket. A puller may be necessary to remove the
sprocket.
2. 
Remove the distributor and fuel pump.
3. 
Remove the auxiliary shaft cover and thrust plate.
4. 
Withdraw the auxiliary shaft from block.
5. 
The distributor drive gear and the fuel pump eccentric on the auxiliary shaft must not be allowed to
touch the auxiliary shaft bearings during removal and installation. Completely coat the shaft with oil
before sliding it into place.
Slide the auxiliary shaft into the housing and insert the thrust plate to hold the shaft.
6.  HOW TO USE THIS BOOK
428 REMOVAL & INSTALLATION 
						

							Install a new gasket and auxiliary shaft cover.
7. 
The auxiliary shaft cover and cylinder front cover share a gasket. Cut off the old gasket around the
cylinder cover and use half of the new gasket on the auxiliary shaft cover.
Fit a new gasket into the fuel pump and install the pump.
8. 
Insert the distributor and install the auxiliary shaft sprocket.
9. 
Align the timing marks and install the drive belt.
10. 
Install the drive belt cover.
11. 
Check the ignition timing.
12. 
Rear Main Oil Seal
REMOVAL & INSTALLATION
Rear main seal installation for the 2.3L and 2.5L enginesClick to enlarge
HOW TO USE THIS BOOK
Rear Main Oil Seal 429 
						

							Removing the rear main seal
Installing the rear main seal on the 2.9L engines Click to enlarge
If the crankshaft rear oil seal replacement is the only operation being performed, it can be done in the vehicle
as detailed in the following procedure. If the oil seal is being replaced in conjunction with a rear main bearing
replacement, the engine must be removed from the vehicle and installed on a work stand.
Remove the starter.
1. 
Remove the transmission from the vehicle, following the procedures in Section 7.
2. 
On a manual shift transmission, remove the pressure plate and cover assembly and the clutch disc
following the procedure in Section 7.
3. 
Remove the flywheel attaching bolts and remove the flywheel and engine rear cover plate.
4.  HOW TO USE THIS BOOK
430 REMOVAL & INSTALLATION 
						

							Use an awl to punch two holes in the crankshaft rear oil seal. Punch the holes on opposite sides of the
crankshaft and just above the bearing cap to cylinder block split line. Install a sheet metal screw in
each hole. Use two large screwdrivers or small pry bars and pry against both screws at the same time
to remove the crankshaft rear oil seal. It may be necessary to place small blocks of wood against the
cylinder block to provide a fulcrum point for the pry bars. Use caution throughout this procedure to
avoid scratching or otherwise damaging the crankshaft oil seal surface.
5. 
To install: Clean the oil seal recess in the cylinder block and main bearing cap.
6. 
Clean, inspect and polish the rear oil seal rubbing surface on the crankshaft. Coat a new oil seal and
the crankshaft with a light film of engine oil. Start the seal in the recess with the seal lip facing
forward and install it with a seal driver. Keep the tool, T82L-6701-A (4-cyl. engines) or T72C-6165
(6-cyl. engine) straight with the centerline of the crankshaft and install the seal until the tool contacts
the cylinder block surface. Remove the tool and inspect the seal to be sure it was not damaged during
installation.
7. 
Install the engine rear cover plate. Position the flywheel on the crankshaft flange. Coat the threads of
the flywheel attaching bolts with oil-resistant sealer and install the bolts. Tighten the bolts in
sequence across from each other to the specifications listed in the torque chart in this section.
8. 
On a manual shift transmission, install the clutch disc and the pressure plate assembly following the
procedure in Section 7.
9. 
Install the transmission, following the procedure in Section 7.
10. 
Flywheel and Ring Gear
REMOVAL & INSTALLATION
Flywheel assembly-3.0L engineClick to enlarge
HOW TO USE THIS BOOK
Flywheel and Ring Gear 431 
						

							Clutch pilot bearing removal
HOW TO USE THIS BOOK
432 REMOVAL & INSTALLATION 
						

							Flywheel assembly-2.3L and 2.5L engines
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Remove the transmission, following procedures in Section 7.
1. 
On a manual shift transmission, remove the clutch pressure plate and cover assembly and clutch disc,
following the procedures in Section 7.
2.  HOW TO USE THIS BOOK
REMOVAL & INSTALLATION 433