1991 1999 ford explorer chilton User Manual

							Front driveshaft and related parts
Click to enlarge
Disconnect the negative battery cable.
1. 
Raise and support the vehicle safely.
2. 
The driveshaft is a balanced unit. Before removing the drive shaft, matchmark the driveshaft in
relationship to the end yoke so that it may be installed in its original position.
Using a shop cloth or gloves, pull back on the dust slinger to remove the boot from the transfer case
slip yoke.
3. 
Remove the bolts and straps that retains the driveshaft to the front driving axle yoke. Remove the
U-joint assembly from the front driving axle yoke.
4. 
Slide the splined yoke assembly out of the transfer case and remove the driveshaft assembly.
5. 
Inspect the boot for rips or tears. Inspect the stud yoke splines for wear or damage. Replace any
damage parts.
6. 
To install: Apply a light coating of Multi-purpose Long-Life lubricant C1AZ-19490-B or equivalent, to the
yoke splines and the edge of the inner diameter of the rubber boot.
7. 
Slide the driveshaft into the transfer case front output yoke assembly. Make certain the wide tooth
splines on the slip yoke are indexed to the output yoke in the transfer case.
8. 
Position the U-joint assembly in the front drive axle yoke in its original position. Install the retaining
bolts and straps. Tighten the bolts to 10-15 ft. lbs. (14-20Nm).
9. 
Firmly press the dust slinger until the boot is felt to engage the output yoke in the transfer case.
10. 
Lower the vehicle.
11. 
Connect the negative battery cable.
12. 
If replacement of the dust slinger/boot is necessary. Use the following procedure. HOW TO USE THIS BOOK
802 REMOVAL & INSTALLATION 
						

							
DUST SLINGER/BOOT REPLACEMENT
Dust slinger & bootClick to enlarge
Remove the boot clamp using cutter pliers and discard the clamp. Remove the boot from the stud
yoke.
1. 
Install a new dust slinger/boot on the stud yoke making certain the boot is seated in the groove in the
yoke.
2. 
Install a new clamp on the boot. Position the clamp tabs in the slots so each tab fits into a slot. Then,
crimp the clamp securely using a pair of clamp pliers T63P-9171-A or equivalent. Do not crimp to
the point where the clamp damage the boot.
3. 
Double Cardan Type Front and Rear Driveshaft
REMOVAL & INSTALLATION
Rear driveshaft-single & double cardan typeClick to enlarge
Disconnect the negative battery cable.
1. 
Raise and support the vehicle safely.
2.  HOW TO USE THIS BOOK
DUST SLINGER/BOOT REPLACEMENT 803 
						

							
The driveshaft is a balanced unit. Before removing the drive shaft, matchmark the driveshaft in
relationship to the axle flange so that it may be installed in its original position.
Remove the bolts retaining the flange to the transfer case. Disconnect the U-joint from the flange at
the transfer case.
3. 
Remove the bolts retaining the flange to the rear axle. Disconnect the U-joint from the flange at the
rear axle.
4. 
Remove the driveshaft.
5. 
To install: Position the single U-joint end of the driveshaft to the rear axle and install the retaining bolts. Tighten
the bolts to 61-87 ft. lbs. (83-118Nm).
6. 
Position the double Cardan U-joint to the transfer case and install the retaining bolts. Tighten the
bolts to 12-16 ft. lbs. (17-22Nm).
7. 
Lower the vehicle.
8. 
Re-connect the negative battery cable.
9. 
DISASSEMBLY & ASSEMBLY
Double Cardan type U-joint disassembledClick to enlarge
HOW TO USE THIS BOOK
804 REMOVAL & INSTALLATION 
						

							Pressing the bearing from the center yoke
Center yoke interference point Click to enlarge
Place the driveshaft on a suitable workbench.
1. 
Matchmark the positions of the spiders, the center yoke and the centering socket yoke as related to the
stud yoke which is welded to the front of the driveshaft tube.
2. 
The spiders must be assembled with the bosses in their original position to provide proper clearance. Remove the snaprings that secure the bearings in the front of the center yoke.
3. 
Position the U-joint tool, T74P-4635-C or equivalent, on the center yoke. Thread the tool clockwise
until the bearing protrudes approximately  3
/8  in. (10mm) out of the yoke.
4. 
Position the bearing in a vice and tap on the center yoke to free it from the bearing. Lift the 2 bearing
cups from the spider.
5. 
Re-position the tool on the yoke and move the remaining bearing in the opposite direction so that it
protrudes approximately  3
/8  in. (10mm) out of the yoke.
6. 
Position the bearing in a vice. Tap on the center yoke to free it from the bearing. Remove the spider
from the center yoke.
7. 
Pull the centering socket yoke off the center stud. Remove the rubber seal from the centering ball
stud.
8. 
remove the snaprings from the center yoke and from the driveshaft yoke.
9. 
Position the tool on the driveshaft yoke and press the bearing outward until the inside of the center
yoke almost contacts the slinger ring at the front of the driveshaft yoke. Pressing beyond this point
can distort the slinger ring interference point.
10.  HOW TO USE THIS BOOK
DISASSEMBLY & ASSEMBLY 805 
						

							Clamp the exposed end of the bearing in a vice and drive on the center yoke with a soft-faced
hammer to free it from the bearing.
11. 
Reposition the tool and press on the spider to remove the opposite bearing.
12. 
Remove the center yoke from the spider. Remove the spider form the driveshaft yoke.
13. 
Clean all serviceable parts in cleaning solvent. If using a repair kit, install all of the parts supplied in
the kit.
14. 
Remove the clamps on the driveshaft boot seal. Discard the clamps.
15. 
Note the orientation of the slip yoke to the driveshaft tube for installation during assembly. Mark the
position of the slip yoke to the driveshaft tube.
16. 
Carefully pull the slip yoke from the driveshaft. Be careful not to damage the boot seal.
17. 
Clean and inspect the spline area of the driveshaft.
18. 
To assemble: Lubricate the driveshaft slip splines with Multi-purpose Long-Life lubricant C1AZ-1920-B or
equivalent.
19. 
With the boot loosely installed on the driveshaft tube, install the slip yoke into the driveshaft splines
in their original orientation.
20. 
Using new clamps, install the driveshaft boot in its original position.
21. 
To assemble the double Cardan joint, position the spider in the driveshaft yoke. Make certain the
spider bosses (or lubrication plugs on kits) will be in the same position as originally installed. Press in
the bearing using the U-joint tool. Then, install the snaprings.
22. 
Pack the socket relief and the ball with Multi-purpose Long-Life lubricant C1AZ-1920-B or
equivalent, then position the center yoke over the spider ends and press in the bearing. Install the
snaprings.
23. 
Install a new seal on the centering ball stud. Position the centering socket yoke on the stud.
24. 
Place the front spider in the center yoke. Make certain the spider bosses (or lubrication plugs on kits)
are properly positioned.
25. 
With the spider loosely positioned on the center stop, seat the first pair of bearings into the centering
socket yoke. Then, press the second pair into the centering yoke. Install the snaprings.
26. 
Apply pressure on the centering socket yoke and install the remaining bearing cup.
27. 
If a kit was used, lubricate the U-joint through the grease fitting, using Multi-purpose Long-Life
lubricant C1AZ-1920-B or equivalent.
28. 
Single Cardan Type Rear Driveshaft
REMOVAL & INSTALLATION HOW TO USE THIS BOOK
806 Single Cardan Type Rear Driveshaft 
						

							Rear driveshaft-single cardan type
Click to enlarge
Except 4WD Ranger Disconnect the negative battery cable.
1. 
Raise and support the vehicle safely.
2. 
The driveshaft is a balanced unit. Before removing the drive shaft, matchmark the driveshaft yoke in
relationship to the axle flange so that it may be installed in its original position.
On Super Cab vehicles, remove the center bearing assembly-to-frame retaining bolts. Remove the
spacers under the center bearing bracket, if installed.
3. 
Remove the retaining bolts and disconnect the driveshaft from the axle companion flange. Pull the
driveshaft rearward until the slip yoke clears the transmission extension housing and seal. Plug the
extension housing to prevent lubricant leakage.
4. 
To install: Lubricate the slip yoke splines with Multi-purpose Long-Life lubricant C1AZ-19490-B or
equivalent. Remove the plug from the extension housing.
5. 
Inspect the extension housing seal. Replace, if necessary.
6. 
Install the driveshaft assembly. Do not allow the slip yoke assembly to bottom on the output shaft
with excessive force.
7. 
Install the driveshaft so the index mark on the rear yoke is in line with the index mark on the axle
companion flange. Tighten all circular flange bolts to 61-87 ft. lbs. (83-118Nm).
8. 
On Super Cab vehicles, tighten the center bearing retaining bolts to 27-37 ft. lbs. (37-50Nm).
9. 
Make certain the center bearing bracket assembly is reinstalled square to the vehicle. If the spacers
were installed under the center bearing be sure to reinstall them. HOW TO USE THIS BOOK
REMOVAL & INSTALLATION 807 
						

							Before unbolting the driveshaft, matchmark the shaft and axle flanges to maintain proper
balance ...
... then remove the driveshaft-to-axle flange retaining bolts
4WD Ranger
Disconnect the negative battery cable.
1. 
Raise and support the vehicle safely.
2. 
The driveshaft is a balanced unit. Before removing the drive shaft, matchmark the driveshaft yoke in
relationship to the axle flange so that it may be installed in its original position.
On Super Cab vehicles, remove the center bearing assembly-to-frame retaining bolts. Remove the
spacers under the center bearing bracket, if installed.
3. 
Remove the retaining bolts and disconnect the driveshaft from the axle companion flange.
4. 
Remove the retaining bolts that retains the driveshaft to the rear of the transfer case.
5. 
Remove the driveshaft.
6. 
To install: Install the driveshaft into the rear of the transfer case. Make certain that the driveshaft is positioned
with the slip yoke toward the front of the vehicle. Install the bolts and tighten to 41-55 ft. lbs.
(55-74Nm).
7. 
Install the driveshaft so the index mark on the rear yoke is in line with the index mark on the axle
companion flange.
8.  HOW TO USE THIS BOOK
808 REMOVAL & INSTALLATION 
						

							On Super Cab vehicles, tighten the center bearing retaining bolts to 27-37 ft. lbs. (37-50Nm).
9. 
Make certain the center bearing bracket assembly is reinstalled square to the vehicle. If the spacers
were installed under the center bearing be sure to reinstall them.
DISASSEMBLY & ASSEMBLY
U-joint bearing removalClick to enlarge
U-joint bearing installation
HOW TO USE THIS BOOK
DISASSEMBLY & ASSEMBLY 809 
						

							Click to enlarge
Prior to disassembly, mark the position of the driveshaft components relative to the driveshaft tube.
All components must be re-assembled in the same relationship to maintain proper balance.
1. 
Place the driveshaft on a suitable workbench.
2. 
Remove the snaprings that retain the bearing cups.
3. 
Position the U-joint removal tool, T74P-235-C or equivalent, on the slip yoke and press out the
bearing. If the bearing cup cannot be pressed all the way out of the slip yoke, remove it with vise grip
or channel lock pliers.
4. 
Reposition the tool 180° to press on the spider and remove the remaining bearing cup from the
opposite side.
5. 
On 2WD vehicles, remove the slip yoke form the spider. On 4WD vehicles, remove the spider from
the driveshaft.
6. 
Remove the remaining bearing cups and spiders from the driveshaft in the same manner.
7. 
Clean the yoke area at each end of the driveshaft.
8. 
Four Wheel Drive (4WD) vehicles only: Remove the clamps on the driveshaft boot seal. Discard the clamp.
1. 
Note the orientation of the slip yoke to the driveshaft tube for installation during assembly.
Mark the position of the slip yoke to the driveshaft tube.
2. 
Carefully pull the slip yoke from the driveshaft. Be careful not to damage the boot seal.
3. 
Clean and inspect the spline area of the driveshaft.
4. 
9. 
To assemble: Four Wheel Drive (4WD) vehicles only:Lubricate the driveshaft slip splines with Multi-purpose Long-Life lubricant
C1AZ-19490-B or equivalent.
1. 
With the boot loosely installed on the driveshaft tube, install the slip yoke into the driveshaft
splines in their original orientation.
2. 
Using new clamps, install the driveshaft boot in its original position.
3. 
10. 
Start a new bearing cup into the yoke at the rear of the driveshaft.
11. 
Position the new spider in the rear yoke and press the bearing cup  1
/4  in. (6mm) below the yoke
surface, using spacer.
12. 
Remove the tool and install a new snapring.
13. 
Start a new bearing cup into the opposite side of the yoke.
14. 
Position the U-joint tool and press on the bearing cup until the opposite bearing cup contacts the
snapring.
15. 
Remove the tool and install a new snapring. It may be necessary to grind the surface of the snapring to
permit easier entry.
16. 
Reposition the driveshaft and install the remaining bearing cups and spider in the same manner.
17. 
Check the universal joints for freedom of movement. If binding has resulted from misalignment
during assembly, a sharp rap on the yokes with a brass hammer will seat the bearing needles. Be sure
to support the shaft end during this procedure and do not strike the bearings themselves. Make certain
the universal joints are free to rotate easily without binding before installing the driveshaft.
18. 
Lubricate the U-joint assemblies with Multi-purpose Long-Life lubricant C1AZ-19490-B or
equivalent.
19. 
Constant Velocity (CV) Type Rear Driveshaft HOW TO USE THIS BOOK
810 Constant Velocity (CV) Type Rear Driveshaft 
						

							
REMOVAL & INSTALLATION
Rear driveshaft-CV typeClick to enlarge
Disconnect the negative battery cable.
1. 
Raise and support the vehicle safely.
2. 
The driveshaft is a balanced unit. Before removing the drive shaft, matchmark the driveshaft in
relationship to the flange on the transfer case and the flange on the rear axle so that it may be installed
in its original position.
Remove the bolts retaining the driveshaft to the transfer case.
3. 
Remove the bolts retaining the driveshaft to the rear axle flange.
4. 
Remove the driveshaft.
5. 
To install: Position the driveshaft to the rear axle flange so that the marks made previously are line up. Install
and tighten the retaining bolts to 61-87 ft. lbs. (83-118Nm).
6. 
Position the driveshaft to the transfer case flange so that the marks made previously are line up. Install
and tighten the retaining bolts to 61-87 ft. lbs. (83-118Nm).
7. 
Lower the vehicle.
8. 
Reconnect the negative battery cable.
9. 
DISASSEMBLY & ASSEMBLY HOW TO USE THIS BOOK
REMOVAL & INSTALLATION 811