1991 1999 ford explorer chilton User Manual

							
LIGHTING
Headlights
REMOVAL & INSTALLATION
Examples of various types of automotive light bulbs
LIGHTING 717 
						

							Exploded view of the front headlight assembly and related components
Click to enlarge
If equipped, open the headlight access panel by sliding the latch and lifting the panel upwards HOW TO USE THIS BOOK
718 REMOVAL & INSTALLATION 
						

							Exploded view of the headlight bulb, retainer and wire harness plug
Click to enlarge
Open the vehicles hood and secure it in an upright position.
1. 
If necessary, open the bulb access panel by depressing the latch then lifting.
2. 
To remove the bulb, grasp the retainer and rotate it counterclockwise to unlock it ... HOW TO USE THIS BOOK
REMOVAL & INSTALLATION 719 
						

							... then withdraw the bulb from the headlight lens housing
Unfasten the locking ring which secures the bulb and wire harness plug assembly, then withdraw the
assembly rearward.
3. 
Disconnect the electrical wire harness plug from the bulb and remove the locking ring as well.
4. 
Unplug the wire harness from the bulb and either slide the retainer over the plug, or remove it from the bulb
To install:
Before connecting a light bulb to the wire harness plug, ensure that all electrical contact surfaces are
free of corrosion or dirt.
5. 
Install the locking ring onto the bulb, then line up the replacement headlight bulb with the harness
plug. Firmly push the bulb onto the plug until the spring clip latches over the bulbs projection.
6. 
WARNING
Do not touch the glass bulb with your fingers. Oil from your fingers can severely shorten the life of the bulb.
If necessary, wipe off any dirt or oil from the bulb with rubbing alcohol before completing installation.
Position the headlight bulb and secure it with the locking ring.
7. 
To ensure that the replacement bulb functions properly, activate the applicable switch to illuminate
the bulb which was just replaced. (If this is a combination low and high beam bulb, be sure to check
both intensities.) If the replacement light bulb does not illuminate, either it too is faulty or there is a
problem in the bulb circuit or switch. Correct if necessary.
8.  HOW TO USE THIS BOOK
720 REMOVAL & INSTALLATION 
						

							Close the bulb access panel and the vehicles hood.
9. 
AIMING THE HEADLIGHTS
The headlights must be properly aimed to provide the best, safest road illumination. The lights should be
checked for proper aim and adjusted as necessary. Certain state and local authorities have requirements for
headlight aiming; these should be checked before adjustment is made.
CAUTION
About once a year, when the headlights are replaced or any time front end work is performed on your vehicle,
the headlight should be accurately aimed by a reputable repair shop using the proper equipment. Headlights
not properly aimed can make it virtually impossible to see and may blind other drivers on the road, possibly
causing an accident. Note that the following procedure is a temporary fix, until you can take your vehicle to a
repair shop for a proper adjustment.
Headlight adjustment may be temporarily made using a wall, as described below, or on the rear of another
vehicle. When adjusted, the lights should not glare in oncoming car or truck windshields, nor should they
illuminate the passenger compartment of vehicles driving in front of you. These adjustments are rough and
should always be fine-tuned by a repair shop which is equipped with headlight aiming tools. Improper
adjustments may be both dangerous and illegal.
For most of the vehicles covered by this manual, horizontal and vertical aiming of each sealed beam unit is
provided by two adjusting screws which move the retaining ring and adjusting plate against the tension of a
coil spring. There is no adjustment for focus; this is done during headlight manufacturing.
Because the composite headlight assembly is bolted into position, no adjustment should be necessary or
possible. Some applications, however, may be bolted to an adjuster plate or may be retained by
adjusting screws. If so, follow this procedure when adjusting the lights, BUT always have the
adjustment checked by a reputable shop.
Before removing the headlight bulb or disturbing the headlamp in any way, note the current settings in order
to ease headlight adjustment upon reassembly. If the high or low beam setting of the old lamp still works, this
can be done using the wall of a garage or a building:
Park the vehicle on a level surface, with the fuel tank about  1
/2  full and with the vehicle empty of all
extra cargo (unless normally carried). The vehicle should be facing a wall which is no less than 6 feet
(1.8m) high and 12 feet (3.7m) wide. The front of the vehicle should be about 25 feet from the wall.
1.  HOW TO USE THIS BOOK
AIMING THE HEADLIGHTS 721 
						

							Example of headlight adjustment screw location for composite headlamps
Click to enlarge
If aiming is to be performed outdoors, it is advisable to wait until dusk in order to properly see the
headlight beams on the wall. If done in a garage, darken the area around the wall as much as possible
by closing shades or hanging cloth over the windows.
2. 
Turn the headlights ONand mark the wall at the center of each lights low beam, then switch on the
brights and mark the center of each lights high beam. A short length of masking tape which is visible
from the front of the vehicle may be used. Although marking all four positions is advisable, marking
one position from each light should be sufficient.
3.  HOW TO USE THIS BOOK
722 AIMING THE HEADLIGHTS 
						

							Low-beam headlight pattern alignment
Click to enlarge
High-beam headlight pattern alignment Click to enlarge
If neither beam on one side is working, and if another like-sized vehicle is available, park the second
one in the exact spot where the vehicle was and mark the beams using the same-side light. Then
switch the vehicles so the one to be aimed is back in the original spot. It must be parked no closer to
or farther away from the wall than the second vehicle.
4. 
Perform any necessary repairs, but make sure the vehicle is not moved, or is returned to the exact spot
from which the lights were marked. Turn the headlights ONand adjust the beams to match the marks
on the wall.
5. 
Have the headlight adjustment checked as soon as possible by a reputable repair shop.
6. 
Signal and Marker Lights
REMOVAL & INSTALLATION
Front Marker and Turn Signal
1991-92 RANGER AND 1991-94 EXPLORER MODELS HOW TO USE THIS BOOK
Signal and Marker Lights 723 
						

							1991-92 Ranger and Explorer (up to 1994) front turn signal and side marker lens assembly
Click to enlarge
Remove the screws retaining the headlight and trim assembly. On Explorer, remove the grille.
1. 
Carefully rotate the headlight and trim assembly away from the vehicle, rotating the inboard side
away from the vehicle.
2. 
Remove the side marker, parking and turn signal bulbs and sockets from the headlamp and trim
assembly. They can be removed by turning them.
3. 
If replacing a lens, remove the retaining screws for the lens to be changed and remove it from the
headlight door.
4. 
To install: If removed, install the removed lens assembly
5. 
Install the bulbs and sockets.
6. 
Install the headlight and trim assembly.
7. 
Check the operation of the lights.
8. 
1993-99 RANGER AND 1995-99 EXPLORER/MOUNTAINEER MODELS HOW TO USE THIS BOOK
724 REMOVAL & INSTALLATION 
						

							1993-99 models front signal and marker lens assembly
Click to enlarge
Remove the marker/turn signal lens retaining screws or nut.
1. 
To change a turn signal/marker bulb, first unfasten the lens from the body, the reach behind the lens ...
HOW TO USE THIS BOOK
REMOVAL & INSTALLATION 725 
						

							... and grasp the lamp socket. Twist then pull the socket from the lens
Gently pull outward on the lens assembly to disengage the barbed retainers.
2. 
Twist the lamp socket and remove it from the lens.
3. 
Pull the bulb from the socket.
4. 
To remove the bulb from the socket, simply pull it straight out
To install:
Install the bulb into the lamp socket.
5. 
Install the lamp socket to the lens and twist it to lock it in position.
6. 
Position the lens assembly, ensure that the barbed retainers are aligned with their mounting clips, and
press the assembly until fully seated.
7. 
Install the marker/turn signal lens retaining screws or nut.
8. 
Check the operation of the lights.
9. 
Rear marker and Rear Lamps HOW TO USE THIS BOOK
726 REMOVAL & INSTALLATION