1991 1999 ford explorer chilton User Manual

							Extension housing seal installation
Click to enlarge
Transmission Assembly
REMOVAL & INSTALLATION Disconnect the negative battery cable.
1. 
Raise the vehicle and support it safely.
2. 
Position a drain pan under the transmission pan and drain the transmission fluid.
3. 
Remove the converter access cover from the lower right side of the converter housing on the 3.0L
engine. Remove the cover from the bottom of the engine oil pan on the 2.3L and 2.5L engine.
Remove a bolt on the access cover of the 2.9L engine and swing the cover open. Remove the access
cover and adapter plate bolts from the lower left side of the converter housing on all other
applications.
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782 Transmission Assembly 
						

							Torque converter nut access hole
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Remove the flywheel to converter attaching nuts. Use a socket and breaker bar on the crankshaft
pulley attaching bolt. Rotate the pulley clockwise as viewed from the front to gain access to each of
the nuts.
5. 
On belt driven overhead cam engines, never rotate the pulley in a counterclockwise direction as viewed
from the front. HOW TO USE THIS BOOK
REMOVAL & INSTALLATION 783 
						

							Remove the Vehicle Speed Sensor (VSS) clamp retaining bolt ...
... then pull the VSS sensor from the transfer case (4WD) or extension housing (2WD)
Remove the speedometer cable and/or vehicle speed sensor from the transfer case (4WD) or extension
housing (2WD).
6. 
On 2WD vehicles, scribe a mark indexing the driveshaft to the rear axle flange. Remove the
driveshaft.
7.  HOW TO USE THIS BOOK
784 REMOVAL & INSTALLATION 
						

							On 4WD vehicles, remove the transfer case.
8. 
Speedometer cable connectionClick to enlarge
Disconnect the shift rod or cable at the transmission manual lever and retainer bracket.
9. 
Disconnect the downshift cable from the downshift lever. Depress the tab on the retainer and remove
the kickdown cable from the bracket.
10. 
Disconnect all of the transmission wire harness plugs.
11. 
Remove the starter mounting bolts and the ground cable. Remove the starter.
12. 
If equipped, remove the vacuum line from the transmission vacuum modulator.
13. 
Remove the filler tube from the transmission.
14. 
Position a transmission jack under the transmission and raise it slightly.
15. 
Remove the engine rear support to crossmember bolts.
16. 
Remove the crossmember to frame side support attaching nuts and bolts. Remove the crossmember.
17. 
Remove the converter housing to engine bolts.
18. 
Slightly lower the jack to gain access to the oil cooler lines. Disconnect the oil cooler lines at the
transmission. Plug all openings to keep dirt and contamination out.
19. 
Move the transmission to the rear so it disengages from the dowel pins and the converter is
disengaged from the flywheel. Lower the transmission from the vehicle.
20. 
If necessary, remove the torque converter from the transmission.
21. 
If the transmission is to be removed for a period of time, support the engine with a safety stand and
wood block.
To install: WARNING
Before installing an automatic transmission, always check that the torque converter is fully seated into the
transmission. Typically, the converter has notches or tangs on the hub which must engage the transmission
fluid pump. If they are not engaged in the pump, the transmission will not mate to the engine properly, as the
converter will be holding it away. Severe damage to the pump, converter or transmission casing can occur if HOW TO USE THIS BOOK
REMOVAL & INSTALLATION 785 
						

							
the transmission-to-engine bolts are tightened as if to force the transmission to mate to the engine.
Proper installation of the converter requires full engagement of the converter hub in the pump gear. To
accomplish this, the converter must be pushed and at the same time rotated through what feels like 2 notches
or bumps. When fully installed, rotation of the converter will usually result in a clicking noise heard, caused
by the converter surface touching the housing to case bolts.
Lightly lubricate the converter hub with transmission fluid. Note the machined fluid pump drive flat on the very edge of the hub (arrow)HOW TO USE THIS BOOK
786 REMOVAL & INSTALLATION 
						

							Handles which thread onto the converter-to-flywheel studs can be use to ease the installation
process
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Check dimension A to ensure that the converter is fully seated into the transmission and pump
This should not be a concern, but an indication of proper converter installation since, when the converter is
attached to the engine flywheel, it will be pulled slightly forward away from the bolt heads. Besides the
clicking sound, the converter should rotate freely with no binding.
For reference, a properly installed converter will have a distance from the converter pilot nose from face to
converter housing outer face of  13
/11 -9
/16  in. (10.5-14.5mm).
Install the converter on the transmission.
1. 
With the converter properly installed, position the transmission on the jack.
2. 
Rotate the converter so that the drive studs are in alignment with the holes in the flywheel.
3. 
Move the converter and transmission assembly forward into position, being careful not to damage the
flywheel and converter pilot. The converter housing is piloted into position by the dowels in the rear
of the engine block.
4. 
During this move, to avoid damage, do not allow the transmission to get into a nose down position as
this will cause the converter to move forward and disengage from the pump gear.
Install the converter housing to engine attaching bolts and tighten to specification. The 2 longer bolts
are located at the dowel holes.
5. 
Remove the jack supporting the engine.
6. 
The rest of the installation procedure is the reverse of removal. Always tighten all fasteners to
specifications given. Follow the procedures outlined in Section 1 when filling the transmission with
fluid.
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REMOVAL & INSTALLATION 787 
						

							
ADJUSTMENTS
Shift/Manual Linkage
SHIFT SELECT LEVER
Exploded views of the shift cable assembly and mountingClick to enlarge
Before performing the linkage adjustment, confirm that the shift indicator is properly adjusted. Turn the vehicle OFF, block the rear wheels and engage the parking brake.
1. 
From inside the vehicle, place the gear shift lever in the overdrive position (shown as a circle with the
letter D in the middle). On 1991 vehicles, hang an 8 lb. (3.6Kg) weight on the lever. On 1992-99
vehicles, use a 3 lb. (1.4Kg) weight.
2. 
Raise and safely support the vehicle.
3. 
From underneath, use a prytool to remove the shift control cable end from the transmission manual
control lever ball stud.
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788 ADJUSTMENTS 
						

							Unlock the cable adjuster body by pushing down on the two tangs and releasing the lock tab.
5. 
Move the shift cable back and forth the full adjustment length four or five times to remove any
accumulated dirt. Ensure that the adjuster body moves freely.
6. 
Move the transmission manual control lever all the way rearward (counterclockwise) to its last
position, then move it forward three detent positions. The transmission is now set in the overdrive
position.
7. 
Holding the cable end fitting, push it rearward until the fitting lines up with the lever ball stud.
Connect the cable end to the ball stud.
8. 
Push up on the lock tab to lock the adjuster body into position. Ensure that the locator tab is properly
seated.
9. 
Ensure that the shift cable is properly clipped to the floorpan and that is routed into the tunnel.
10. 
Lower the vehicle.
11. 
Remove the weight from the gear select lever.
12. 
After adjustment, check for Park (P) engagement. Start the engine and check all the lever positions for
proper operation.
13. 
SHIFT SELECT INDICATOR
To test the shift select indicator:
Turn the engine OFF, apply the parking brake and place the transmission select lever in the OD
(overdrive) position.
1. 
Hang a 3 lb. (1.4Kg) weight on the select lever.
2. 
Look at the selector indicator on the instrument panel. The pointer should be centered on the D within
the overdrive (circle with a letter D in the middle) graphic. If it is not, adjust as follows.
3. 
Remove the steering column shroud fasteners, then remove the shrouds
To adjust the indicator:
Remove the steering wheel.
4. 
Remove the lower steering column trim panel from the dash board.
5. 
Remove the lower steering column shroud by removing the two securing screws.
6. 
Lift off the upper steering column shroud.
7. 
On 1996-99 vehicles, remove the ignition switch lock cylinder.
8. 
With the engine OFFand the parking brake set, move the transmission select lever into the overdrive
position. Hang a 3 lb. (1.4Kg) weight on the lever.
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ADJUSTMENTS 789 
						

							On 1991 vehicles, the pointer is adjusted by loosening the cable lock screw
Click to enlarge
On 1991 vehicles, loosen the indicator cable end screw, then move the cable end to properly position
the pointer until it is centered on the overdrive graphic. Tighten the cable end screw.
10. 
On 1992 and later vehicles, there are two styles of thumb wheel adjusters. One style is mounted to the indicator assembly ...
Click to enlarge
HOW TO USE THIS BOOK
790 ADJUSTMENTS 
						

							... the other style is mounted to the underside of the column
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On 1992-99 vehicles, turn the adjuster thumb wheel to properly position the pointer until it is
centered on the overdrive graphic.
11. 
If removed, install the ignition switch lock cylinder.
12. 
Install the upper and lower steering column shrouds and the steering wheel.
13. 
Remove the weight from the lever.
14. 
Operate the shift select lever in all positions and ensure that the indicator pointer aligns with all of the
position graphics.
15. 
KICKDOWN CABLE
The kickdown cable is self-adjusting over a tolerance range of 1 in. (4mm). If the cable requires
readjustment, reset the by depressing the semi-circular metal tab on the self-adjuster mechanism and pulling
the cable forward (toward the front of the vehicle) to the Zero position setting. The cable will then
automatically readjust to the proper length when kicked down. HOW TO USE THIS BOOK
KICKDOWN CABLE 791