1991 1999 ford explorer chilton User Manual

							CV-joint exploded view
Click to enlarge
Removing the shroud from the outer bearing race and flange Click to enlarge
HOW TO USE THIS BOOK
812 DISASSEMBLY & ASSEMBLY 
						

							Removing the ball bearings
Click to enlarge
Assembling the inner bearing race and cage Click to enlarge
Place the driveshaft on a suitable workbench.
1. 
The CV joint components are matched. Extreme care should be take not to mix or substitute
components.
Remove the clamp retaining the shroud to the outer bearing race and flange assembly.
2. 
Carefully tap the shroud lightly with a blunt tool and remove the shroud. Be careful not to damage the
shroud, dust boot or outer bearing race and flange assembly.
3. 
Peel the boot upward and away from the outer bearing race and flange assembly.
4. 
Remove the wire ring that retains the inner race to the outer race.
5. 
Remove the inner race and shaft assembly from the outer race and flange assembly. Remove the cap
and spring from inside the outer retainer.
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DISASSEMBLY & ASSEMBLY 813 
						

							Remove the circlip retaining the inner race assembly to the shaft, using snapring pliers. Discard the
clip and remove the inner race assembly.
7. 
If required, remove the clamp retaining the boot to the shaft and remove the boot.
8. 
Carefully pry the ball bearings from the cage. Be careful not to scratch or damage the cage, race or
ball bearings.
9. 
Rotate the inner race to align with the cage windows and remove the inner race through the wider end
of the cage.
10. 
To assemble: Install the inner bearing race in the bearing cage. Install the race through the large end of the cage
with the counterbore facing the large end of the cage.
11. 
Push the race to the top of the cage and rotate the race until all the ball slots are aligned with the
windows. This will lock the race to the top of the cage.
12. 
With the bearing cage and inner race properly aligned, install the ball bearings. The bearings can be
pressed through the bearing cage with the heel of the hand. Repeat this step until the remaining ball
bearings are installed.
13. 
If removed, install a new dust boot on the shaft, using a new clamp. Make certain the boot is seated in
its groove.
14. 
The clamp is a fixed diameter push-on metal ring. Install the inner bearing assembly on the shaft. Make certain the circlip is exposed.
15. 
Install a new circlip on the shaft. Do not over-expand or twist the circlip during installation.
16. 
Install the spring and cap in the outer bearing retainer and flange.
17. 
Fill the outer bearing retainer with 3 oz. of Constant Velocity Joint Grease, D8RZ-19590-A or
equivalent.
18. 
Insert the inner race and shaft assembly in the outer bearing retainer and flange.
19. 
Push the inner race down until the wire spring groove is visible and install the wire ring.
20. 
Fill the top of the outer bearing retainer with Constant Velocity Joint Grease, D8RZ-19590-A or
equivalent. Remove all excess grease from the external surfaces.
21. 
Pull the dust boot over the retainer. Make certain the boot is seated in the groove and that any air
pressure which may have built up in the boot is relieved.
22. 
Insert a dulled screwdriver blade between the boot and outer bearing retainer and allow the trapped
air to escape from the boot.
Install the shroud over the boot and retainer and install the clamp.
23. 
Center Bearing
REMOVAL & INSTALLATION HOW TO USE THIS BOOK
814 Center Bearing 
						

							Cutaway view of the coupling shaft and center support bearing
Click to enlarge
Remove the driveshaft from the vehicle.
1. 
Separate the driveshaft from the coupling shaft maintaining proper orientation.
2. 
Remove the nut retaining the half round yoke to the coupling shaft and remove the yoke.
3. 
Check the center bearing support for wear by rotating the outer area while holding the coupling shaft.
If any wear or roughness is evident, replace the bearing.
4. 
Inspect the rubber insulator for evidence of hardness, cracking or deterioration. Replace if damaged in
any way.
5. 
Re-install the coupling shaft yoke.
6. 
Be sure the yoke is re-installed on the coupling shaft in the same orientation as it was originally
installed. The orientation is critical so that proper driveshaft balance and U-joint phasing is
maintained. Tighten the retaining nut to 100-120 ft. lbs. (135-162Nm).
Re-assemble the driveshaft to the coupling shaft, maintaining proper orientation.
7. 
Chilton® Automotive Information Systems. © 2004 Thomson Delmar Learning. HOW TO USE THIS BOOK
REMOVAL & INSTALLATION 815 
						

							
FRONT DRIVE AXLE
General Information
The front drive axle on the Ranger, Explorer and Mountaineer can be either the Dana 28 series, or the Dana 35
series. However, there are two versions of the Dana 35 and while both are an Independent Front Suspension
(IFS) axle, their differences are drastic.
The Mountaineer, 1995-99 Explorer and 1998-99 Rangers use a centrally mounted front differential with
unequal length upper and lower control arms and front axle halfshafts. Also, these axle assemblies do not use
hub-locks at the wheel ends. Instead, they use a vacuum operated disconnect system mounted to the axle
housing, which locks and unlocks the axles. See Vacuum Disconnect Axle Lock later in this section for
service procedures.
All other models use the twin I-beam style front axle assembly with either manual or automatic locking hubs
at the wheel ends.
Manual Locking Hubs
REMOVAL & INSTALLATION
Exploded view of the manual locking hub assembly and related components Click to enlarge
Loosen the front wheel lug nuts.
1. 
Raise and safely support the front of the vehicle.
2. 
Remove the lug nuts and wheel/tire assembly.
3. 
If equipped, remove the lug nut retainer washers from the wheel studs.
4. 
Some gentle tapping with a soft faced hammer may help to loosen the locking hub if it seems stuck.
FRONT DRIVE AXLE 817 
						

							To remove the manual locking hub, remove the wheel and stud retainers (if equipped), then pull
the hub off
Remove the manual locking hub assembly from the rotor by pulling straight outward.
5. 
Inspect the O-ring seal on the back side of the hub assembly and, if damaged, replace it.
6. 
Installation is the reverse of the removal procedure. Ensure that the rotor mounting face is flat and
free of burrs, dirt or grease, especially where the O-ring seal makes contact.
7. 
Turn the hub assembly over ...
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818 REMOVAL & INSTALLATION 
						

							... and inspect this rubber O-ring seal for damage. Replace as needed
Automatic Locking Hubs
REMOVAL & INSTALLATION
Except Mountaineer, 1995-99 Explorer and 1998-99 Ranger
OUTER HUB COVER
Exploded view of the automatic locking hubs and related components Click to enlarge
Loosen the front wheel lug nuts.
1. 
Raise and safely support the front of the vehicle.
2. 
Remove the lug nuts and wheel/tire assembly.
3. 
If equipped, remove the lug nut retainer washers from the wheel studs.
4. 
Some gentle tapping with a soft faced hammer may help to loosen the locking hub cover if it seems
stuck.
Remove the automatic locking hub cover assembly from the rotor by pulling straight outward.
5. 
Inspect the O-ring seal on the back side of the hub assembly and, if damaged, replace it.
6. 
Installation is the reverse of the removal procedure. Ensure that the rotor mounting face is flat and
free of burrs, dirt or grease, especially where the O-ring seal makes contact.
7. 
INNER HUB LOCKING CAM HOW TO USE THIS BOOK
Automatic Locking Hubs 819 
						

							Exploded view of the locking cam assembly
Click to enlarge
Remove the outer hub cover.
1. 
Remove the snap-ring from the end of the splined axle shaft.
2. 
Remove the axle shaft spacer(s).
3. 
WARNING
Do not pry on the locking cam or thrust spacers during removal. Prying may damage the cam or spacers.
Pull the locking cam assembly and the two thrust spacers (behind cam assembly) from the wheel
bearing adjusting nut.
4. 
Installation is the reverse of the removal procedure. Make sure to install the two thrust spacers first.
Also, when pushing or pressing the locking cam into position, ensure that the key in the cam assembly
is aligned with the keyway of the front spindle.
5. 
WARNING
Extreme care must be taken when aligning the locking cam key with the keyway on the front spindle to
prevent damage to the fixed cam. HOW TO USE THIS BOOK
820 REMOVAL & INSTALLATION 
						

							When installing the outer hub cover, ensure that the legs on the cover seat in the pockets on the
locking cam
Click to enlarge
Mountaineer, 1995-99 Explorer and 1998-99 Ranger
While the Mountaineer, 1995-99 Explorer and 1998-99 Rangers technically have automatic locking hubs, the
system is mounted to the axle housing itself and is called a vacuum disconnect axle lock. Refer to the
procedures in this section.
Vacuum Disconnect Axle Lock
The vacuum disconnect axle locking system was used on the Mountaineer, 1995-99 Explorer and 1998-99
Ranger models only. The axle locking controls are mounted to the axle housing. All other models use manual
or automatic locking hubs at the wheel ends.
REMOVAL & INSTALLATION HOW TO USE THIS BOOK
REMOVAL & INSTALLATION 821 
						

							
Exploded view of the vacuum disconnect axle lock assembly on Mountaineer, 1995-99 Explorer and 1998-99 Ranger
Click to enlarge
Raise and safely support the front of the vehicle.
1. 
If possible, support the right side of the vehicle slighly higher than the left. This will minimize the
amount of axle fluid lost when the center disconnect shift motor cover is removed.
Position a drain pan beneath the center disconnect shift motor cover.
2. 
Label and disconnect the vacuum lines at the shift motor.
3. 
Unplug the electrical wire harness connectors from the shift motor.
4. 
Remove the four shift motor cover-to-axle housing retaining bolts.
5. 
Pull the cover and shift motor assembly straight out from the axle housing.
6. 
To disassemble the shift fork and shift motor from the cover, proceed as follows: Note the position of the shift fork to assure proper assembly.
1. 
Remove the outboard snapring that retains the shift fork to the motor shaft and slide the fork
off of the shaft.
2. 
Remove the inboard snapring that located the shift fork.
3. 
Remove the snapring from the motor shaft where the shaft comes through the cover then slide
the motor and shaft out from the cover.
4. 
7. 
To install: Inspect all gaskets and O-ring seals for damage and replace them as required.
8.  HOW TO USE THIS BOOK
822 REMOVAL & INSTALLATION