1991 1999 ford explorer chilton User Manual

							Check the flywheel surface for flatness and, if necessary, remove it from the engine for truing
To install:
Position the clutch disc on the flywheel so that the Clutch Alignment Shaft Tool T74P-727-K or
equivalent can enter the clutch pilot bearing and align the disc.
10. 
Be sure that the flywheel surface is clean before installing the clutch HOW TO USE THIS BOOK
REMOVAL & INSTALLATION 771 
						

							Typical clutch alignment tool, note how the splines match the transmissions input shaft
Use the clutch alignment tool to align the clutch disc during assembly.
When reinstalling the original pressure plate and cover assembly, align the assembly and flywheel
according to the marks made during the removal operations. Position the pressure plate and cover
assembly on the flywheel, align the pressure plate and disc, and install the retaining bolts that fasten
the assembly to the flywheel. Tighten the bolts to 15-25 ft. lbs. (21-35 Nm) in the proper sequence.
Remove the clutch disc pilot tool.
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							Be sure to use a torque wrench to tighten all of the bolts
Install the transmission into the vehicle.
1. 
Connect the coupling by pushing the male coupling into the slave cylinder.
2. 
Connect the hydraulic clutch master cylinder pushrod to the clutch pedal.
3. 
Chilton® Automotive Information Systems. © 2004 Thomson Delmar Learning. HOW TO USE THIS BOOK
REMOVAL & INSTALLATION 773 
						

							
AUTOMATIC TRANSMISSION
Understanding the Automatic Transmission
The automatic transmission allows engine torque and power to be transmitted to the rear wheels within a
narrow range of engine operating speeds. It will allow the engine to turn fast enough to produce plenty of
power and torque at very low speeds, while keeping it at a sensible rpm at high vehicle speeds (and it does this
job without driver assistance). The transmission uses a light fluid as the medium for the transmission of
power. This fluid also works in the operation of various hydraulic control circuits and as a lubricant. Because
the transmission fluid performs all of these functions, trouble within the unit can easily travel from one part to
another.
Identification
There are 5 automatic transmissions used in the Ford Ranger, Explorer and Mountaineer. They may be
identified by checking the transmission code on the Safety Standard Certification Label attached to the
drivers side door post, in the space marked Trans.The transmissions can also be identified by a tag attached
to the lower left hand extension attaching bolt. The transmission codes are as follows:
1991-94 code T is for the A4LD transmission
· 
1995-99 code T is for the 4R44E (2.3L, 2.5L & 3.0L) or 4R55E (4.0L) transmission
· 
1996-99 code U is for the 4R70W (5.0L) transmission
· 
1997-99 code D is for the 5R55E (5-speed automatic) transmission
· 
All of the automatic transmissions are 4-speed units with a lock-up torque converter, except the 1997-99
5R55E, which is a 5-speed unit with a lock-up torque converter.
Neutral Start Switch/Back-up Switch
REMOVAL & INSTALLATION
A4LD Transmissions
The Park/Neutral Position (PNP) switch, mounted on the transmission, allows the vehicle to start only in Por
N. The switch has a dual purpose, in that it is also the back-up lamp switch.
AUTOMATIC TRANSMISSION 775 
						

							View of the Park/Neutral Position (PNP) switch used on the A4LD transmission
Click to enlarge
Disconnect the negative battery cable.
1. 
Raise and support the vehicle safely.
2. 
Disconnect the harness connector from the neutral start switch.
3. 
Clean the area around the switch. Remove the switch and O-ring, using a thin wall socket (tool
T74P-77247-A or equivalent).
4. 
To install: Fit a new O-ring to the switch. Install the switch.
5. 
Reconnect the harness connector to the switch.
6. 
Lower the vehicle.
7. 
Reconnect the negative battery cable.
8. 
Check the operation of the switch, with the parking brake engaged. The engine should only start in
Nor P. The back-up lamps should come ON only in R.
9. 
Except A4LD Transmissions
Starting in 1995, the switch was used not only for neutral start sensing and back-up light activation, but also
as a gear position range sensor. The Powertrain Control Module reads the sensor to determine which gear
position the transmission is in, and adjusts fuel and spark timing accordingly. The new switch is called the
Transmission Range (TR) sensor.
To install the Transmission Range (TR) sensor requires a special Transmission Range Sensor
Alignment Tool T97L-70010-AH, or equivalent.
Disconnect the negative battery cable, block the rear wheels and apply the parking brake.
1. 
Place the transmission shift lever in the Neutral (N) position.
2. 
Raise and safely support the front of the vehicle
3. 
Disconnect the shift control cable from the transmission manual control lever.
4. 
Disconnect the electrical wire harness plug from the TR sensor.
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776 REMOVAL & INSTALLATION 
						

							Remove the two Transmission Range (TR) sensor retaining bolts
Click to enlarge
Remove the manual control lever retaining nut as well as the lever.
6. 
Remove the two retaining bolts and the sensor.
7. 
To install: Ensure that the transmission shift lever is in the Neutral (N) position.
8. 
Install the TR sensor and loosely install the retaining bolts.
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REMOVAL & INSTALLATION 777 
						

							Align the new sensor with the Digital TR Sensor Alignment Tool
Click to enlarge
Align TR sensor slots using the Transmission Range Sensor Alignment Tool T97L-70010-AH, or
equivalent.
10. 
Tighten the retaining bolts to 7-9 ft. lbs. (9-12 Nm).
11. 
Install the manual control lever to the sensor and tighten the retaining bolt HOW TO USE THIS BOOK
778 REMOVAL & INSTALLATION 
						

							Click to enlarge
Install the manual control lever to the sensor and tighten the retaining nut to 22-26 ft. lbs. (30-35
Nm).
12. 
Connect the TR sensor electrical wire harness plug.
13. 
Install the shift control cable to the transmission manual control lever.
14. 
Lower the vehicle and connect the negative battery cable.
15. 
Ensure that the wheels are still blocked and the parking brake is applied.
16. 
Check for proper operation of the switch. The engine should only start in Park (P) or Neutral (N).
17. 
ADJUSTMENT
A4LD Transmissions
No adjustment is necessary or possible on the A4LD transmission Park Neutral Position (PNP) switch.
Except the A4LD Transmissions
To adjust the Transmission Range (TR) sensor requires a special Transmission Range Sensor
Alignment Tool T97L-70010-AH, or equivalent.
Raise and safely support the vehicle.
1. 
Block the rear wheels and apply the parking brake.
2. 
Place the transmission shift control lever in the Neutral (N) position.
3. 
Remove the nut securing the transmission control manual lever to the TR sensor.
4. 
Loosen the two TR sensor retaining bolts.
5. 
Align the TR sensor slots using the Transmission Range Sensor Alignment Tool T97L-70010-AH,
or equivalent.
6. 
Tighten the TR sensor retaining bolts to 7-9 ft. lbs. (9-12 Nm).
7. 
Install the nut retaining the transmission manual control lever to the TR sensor. Tighten to 12-3 ft.
lbs. (3-22 Nm).
8. 
Lower the vehicle. Leave the wheels blocked and the parking brake applied.
9. 
Check the TR sensor operation. The engine should only start in Park (P) or Neutral (N).
10. 
Vacuum Diaphragm
Only the A4LD transmissions use a vacuum diaphragm (or modulator). All other models are PCM controlled
and do not require vacuum supply from the engine.
REMOVAL & INSTALLATION
A4LD Transmission HOW TO USE THIS BOOK
ADJUSTMENT 779 
						

							Remove the vacuum diaphragm retaining clamp and bolt, then pull the diaphragm out of the
transmission
Click to enlarge
Disconnect the negative battery cable.
1. 
Raise and support the vehicle safely.
2. 
Disconnect the hose from the vacuum diaphragm.
3. 
Remove the vacuum diaphragm retaining clamp bolt and clamp. Do not pry on the clamp.
4. 
Pull the vacuum diaphragm from the transmission case and remove the vacuum diaphragm control rod
from the transmission case.
5. 
To install: Install the vacuum diaphragm control rod from the transmission case.
6. 
Push the vacuum diaphragm into the case and secure it with the clamp and bolt. Tighten to 80-106
inch lbs. (9-12Nm).
7. 
Fit the vacuum hose to the diaphragm.
8. 
Lower the vehicle.
9. 
Reconnect the negative battery cable.
10. 
Extension Housing Seal
REMOVAL & INSTALLATION HOW TO USE THIS BOOK
780 REMOVAL & INSTALLATION 
						

							Extension housing seal removal
Disconnect the negative battery cable.
1. 
Raise and support the vehicle safely.
2. 
Matchmark the driveshaft end yoke and rear axle companion flange to assure proper positioning
during assembly. Remove the driveshaft.
3. 
Remove the oil seal from the extension housing, using seal remover T71P-7657-A or equivalent.
4. 
To install:
Before install the replacement seal, inspect the sealing surface of the universal joint yoke for scores. If scoring
is found, replace the yoke.
Install the new seal, using seal installer T74P-77052-A or equivalent. Coat the inside diameter at the
end of the rubber boot portion of the seal with long-life lubricant (C1AZ-1590-BA or equivalent).
5. 
Align the matchmarks and install the driveshaft.
6. 
Lower the vehicle.
7. 
Reconnect the negative battery cable.
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REMOVAL & INSTALLATION 781