1991 1999 ford explorer chilton User Manual

							
INSTRUMENTS AND SWITCHES
Instrument Cluster
REMOVAL & INSTALLATION
1991-94 Models Disconnect the negative battery cable.
1. 
Open the ash tray and remove the two retaining screws. Remove the ash tray assembly from the dash.
2. 
If necessary, remove the left and right A/C register vents from the dash.
3. 
Exploded views of the 1991-94 instrument cluster and trim panel assemblies Click to enlarge
Unsnap the instrument cluster trim panel by pulling rearwards around the edge of the panel. Depress
the hazard warning switch (4-way flashers) and remove the trim panel.
4. 
Remove the four screws securing the instrument cluster to the dash mounting.
5. 
INSTRUMENTS AND SWITCHES 705 
						

							Exploded view of the PRNDL indicator mounting
Click to enlarge
On vehicles equipped with an automatic transmission, perform the following: Remove the two screws attaching the PRNDL indicator to the cluster.
1. 
If necessary for clearance, block the wheels and apply the parking brake, then turn the
ignition switch to unlock the steering wheel and pull the gear select lever into the Low (L)
range.
2. 
6. 
Pull the cluster assembly rearward to gain access to the speedometer cable.
7. 
If there is insufficient slack in the cable for gaining access, disconnect the cable from the transmission.
Once disconnected pull the cluster out gently until enough clearance is gained. HOW TO USE THIS BOOK
706 REMOVAL & INSTALLATION 
						

							View of the speedometer cable end at the instrument cluster
Click to enlarge
Disconnect the speedometer cable from the cluster. The cable connection has a flat surface clip; press
the clip inward and pull the cable from the cluster.
8. 
Disconnect the wire harness plugs from the cluster and remove it from the dash.
9. 
To install: Apply approximately  3
/16  inch (4.8mm) diameter ball of silicone dielectric grease in the drive hole of
the speedometer head.
10. 
Position the instrument cluster near its opening and attach the electrical plugs to it.
11. 
Connect the speedometer cable to the speedometer head. If necessary, reconnect the speedometer
cable to the transmission.
12. 
If removed, install the two PRNDL indicator retaining screws.
13. 
Insert the cluster into the dash and install the four attaching screws.
14. 
Ensure that the hazard warning switch is depressed and install the cluster trim panel.
15. 
Connect the negative battery cable. Start the vehicle and check all gauges, lamps and signals for
proper operation.
16. 
1995-99 Models Disconnect the negative battery cable.
1. 
Remove the radio.
2.  HOW TO USE THIS BOOK
REMOVAL & INSTALLATION 707 
						

							Exploded view of the 1995-99 instrument cluster trim panels
Click to enlarge
Remove the center finish panel to access and remove the lower trim and knee bolster attaching
screws.
3. 
Remove the lower trim and knee bolster.
4. 
Remove the cluster finish panel and unplug the headlamp and dimmer switch harnesses from it.
5. 
Exploded view of the instrument cluster mountingClick to enlarge
Remove the four instrument cluster retaining screws.
6.  HOW TO USE THIS BOOK
708 REMOVAL & INSTALLATION 
						

							If equipped with an automatic transmission, remove the two PRNDL indicator attaching screws and
remove the indicator by sliding it straight down.
7. 
Disconnect the electrical wire harness plugs and remove the cluster.
8. 
View of the electrical connections on the back of the cluster
To install:
Connect the electrical wire harness plugs and install the instrument cluster.
9. 
If equipped with an automatic transmission, install the two PRNDL indicator attaching screws and
remove the indicator by sliding it straight down.
10. 
Install the four instrument cluster retaining screws.
11. 
Connect the headlamp and dimmer switch harnesses to the cluster finish panel then install it.
12. 
Install the lower trim and knee bolster panels and the attaching screws.
13. 
Install the center finish panel.
14. 
Install the radio.
15. 
Connect the negative battery cable. Start the vehicle and check all gauges, lamps and signals for
proper operation.
16. 
Fuel, Oil Pressure, Voltage and Coolant Temperature Gauges
REMOVAL & INSTALLATION
Each of the gauges can be removed in the same manner, once the instrument cluster is removed. Disconnect the negative battery cable.
1. 
Remove the instrument cluster assembly.
2.  HOW TO USE THIS BOOK
Fuel, Oil Pressure, Voltage and Coolant Temperature Gauges 709 
						

							Exploded view of the instrument cluster and gauge assemblies
Click to enlarge
Remove the lens from the instrument cluster.
3. 
Pull the gauge from the cluster.
4. 
To install: Install the gauge, by pushing it firmly into position.
5. 
Install the cluster lens and install the cluster into the instrument panel.
6.  HOW TO USE THIS BOOK
710 REMOVAL & INSTALLATION 
						

							
Rear Wiper Switch
REMOVAL & INSTALLATION Disconnect the negative battery cable.
1. 
Remove the instrument cluster finish panel.
2. 
Remove the switch from the instrument panel, by carefully prying upward.
3. 
Disconnect the electrical lead from the switch.
4. 
Exploded view of the rear wiper, rear defogger, fog light and headlight switch assemblies Click to enlarge
To install: Connect the wiring and install the switch in the instrument panel.
5. 
Install the cluster finish panel.
6. 
Connect the negative battery cable. Check the operation of the switch.
7. 
Headlight Switch HOW TO USE THIS BOOK
Rear Wiper Switch 711 
						

							
REMOVAL & INSTALLATION
Disconnect the battery ground cable.
1. 
On 1991-94 models, perform the following: Remove the ash tray assembly and the finish panel (snaps off).
1. 
On the Explorer, remove the rear window wiper and heated backlite switch assembly (snaps
out).
2. 
On the Ranger, remove the storage bin (snaps out).
3. 
Pull the headlight switch knob to the headlight on position. Depress the shaft release button
and remove the knob and shaft assembly.
View of the 1991-94 model headlight switch control knob release button Click to enlarge
4. 
2. 
On 1995-99 models, remove the instrument panel finish panel.
3. 
Unscrew the mounting nut and remove the switch from the instrument panel, then remove the wiring
connector from the switch.
4.  HOW TO USE THIS BOOK
712 REMOVAL & INSTALLATION 
						

							Exploded view of the 1995-99 model headlight switch components
Click to enlarge
To install: Connect the wiring connector to the headlamp switch, position the switch in the instrument panel and
install the mounting nut.
5. 
On 1995-99 models, install the instrument panel finish panel.
6. 
On 1991-94 models, perform the following: Install the headlamp switch knob and shaft assembly by pushing the shaft into the switch until
it locks into position.
1. 
On the Explorer, install the rear window wiper and heated backlite switch assembly.
2. 
On the Ranger, install the storage bin.
3. 
Install the finish panel and the ash tray assembly.
4. 
7. 
Connect the battery ground cable, and check the operation of the headlight switch.
8. 
Back-up Light Switch
The back-up light switch used on the automatic transmissions is also the neutral safety switch. Refer to
Section 7 for the proper procedures.
Ford used two different manual transmissions, the Mitsubishi and the Mazda made 5-speed OverDrive (OD)
transmissions. The back-up light switch is located on the right side of the transmission on the Mitsubishi, and
on the left side shift cover on the Mazda.
Manual Transmissions Apply the parking brake and place the gear shift lever in any position other than Neutral (N) or
Reverse (R).
1. 
Raise and safely support the vehicle.
2. 
According to the manufacturer, no fluid will leak from the transmission when the switch is removed,
but as a precautionary measure, bring a drain pan under the vehicle with you. HOW TO USE THIS BOOK
Back-up Light Switch 713 
						

							Disconnect the electrical wire harness plug from the transmission back-up light switch.
3. 
Remove the switch from the transmission.
4. 
Installation is the reverse of the removal procedure. If necessary, or since your there, check the
transmission fluid level and top-off as needed.
5. 
Location of the back-up light switch on the Mazda transmission Click to enlarge
Location of the back-up light switch on the Mitsubishi transmission Click to enlarge
HOW TO USE THIS BOOK
714 Manual Transmissions