1991 1999 ford explorer chilton User Manual

							Inspect the nylon bushings on the shift fork and if worn, replace them.
9. 
To assemble the shift motor and fork to the cover, proceed as follows: Lightly lubricate the O-ring on the motor shaft and slide it into the cover until it is fully
seated.
1. 
Install the motor shaft-to-cover snapring.
2. 
Install the inboard shift fork snapring.
3. 
Install the shift fork in the same position as was removed.
4. 
Install the outboard shift fork snapring.
5. 
10. 
Ensure that the locking collar inside the axle assembly slides freely back and forth. Position the
locking collar so that the shift fork will engage it when installing.
11. 
Install the center disconnect assembly into the axle housing. Ensure that the shift fork is engaging the
locking collar.
12. 
Install and tighten the four cover retaining bolts.
13. 
Connect the vacuum fittings and electrical harness plugs to the shift motor assembly.
14. 
Ensure that the vehicle is level and check the axle fluid level. Top off the fluid as needed.
15. 
Lower the vehicle, road test and check for leaks.
16. 
Spindles and Spindle Bearings
REMOVAL & INSTALLATION
Except Mountaineer, 1995-99 Explorer and 1998-99 Ranger Loosen the front wheel lug nuts.
1. 
Raise and support the vehicle safely. Remove the wheel and tire assembly.
2. 
Remove the disc brake calipers and support the caliper on the vehicles frame rail.
3. 
Remove the hub locks and lock nuts.
4. 
Remove the hub and rotor.
5. 
Remove the nuts retaining the spindle to the steering knuckle. Tap the spindle with a plastic or
rawhide hammer to jar the spindle from the knuckle.
6. 
Inspect the needle bearings inside the spindle bore. If worn or damaged, replace as follows: Place the spindle in a vise on the second step of the spindle. Wrap a shop towel around the
spindle or use a brass-jawed vise to protect the spindle.
1. 
Remove the oil seal and needle bearing from the spindle with a slide hammer and seal
remover tool, 1175-AC or equivalent.
2. 
Clean all dirt and grease from the spindle bearing bore. Bearing bore must be free from nicks
and burrs.
3. 
Place the bearing in the bore with the manufacturers identification facing outward. Drive the
bearing into the bore using spindle bearing replacer tool, T83T-3123-A and drive handle
T80T-4000-W or equivalent.
4. 
Install the grease seal in the bearing bore with the lip side of the seal facing towards the tool.
Drive the seal in the bore using spindle bearing replacer tool, T83T-3123-A and drive handle
T80T-4000-W or equivalent. Coat the bearing seal lip with Multi-Purpose Long Life
Lubricant C1AZ-19590-B or equivalent.
5. 
7. 
To install: Inspect the seal on the axle shaft, and if damaged or worn replace it. Refer to front axle shaft removal
& installation procedure in this Section.
8. 
Install the splash shield and spindle onto the steering knuckle. Install and tighten the spindle nuts to
35-45 ft. lbs. (47-61Nm).
9.  HOW TO USE THIS BOOK
Spindles and Spindle Bearings 823 
						

							
Since the rotor is removed, check that the wheel bearings are properly greased and that the rotor
grease seal is in acceptable condition.
Install the rotor on the spindle.
10. 
Install the wheel bearing, locknut, thrust bearing, snapring and locking hubs.
11. 
Install the disc brake calipers. Install the wheel and tire assembly.
12. 
Lower the vehicle. Tighten the lug nuts to specification.
13. 
Mountaineer, 1995-99 Explorer and 1998-99 Ranger
The Mountaineer, 1995-99 Explorer and 1998-99 Ranger models do not use spindles. Instead they use an
internally splined wheel hub which is pressed into a sealed bearing. If the assembly goes bad, it must be
replaced as an entire unit. For removal & installation procedures, refer to Section 8.
Axle Shafts and Seals
REMOVAL & INSTALLATION
Except Mountaineer, 1995-99 Explorer and 1998-99 Ranger
Exploded view of the left-hand axle shaft assembly and related components Click to enlarge
HOW TO USE THIS BOOK
824 REMOVAL & INSTALLATION 
						

							Exploded view of the right-hand axle shaft assembly and related components
Click to enlarge
Loosen the front wheel lug nuts.
1. 
Raise and support the vehicle safely. Remove the wheel and tire assembly.
2. 
Remove the disc brake calipers and support the caliper on the vehicles frame rail.
3. 
Remove the hub locks and lock nuts.
4. 
Remove the hub and rotor.
5. 
Remove the nuts retaining the spindle to the steering knuckle. Tap the spindle with a plastic or
rawhide hammer to jar the spindle from the knuckle.
6. 
Remove the front disc brake rotor shield.
7. 
The left-hand axle shaft is engaged inside of the front carrier assembly. Depending on how the truck is
sitting (especially if it is not level), some fluid may leak out of the front carrier assembly. A small drip
pan should can be placed underneath the front carrier as a precautionary measure. HOW TO USE THIS BOOK
REMOVAL & INSTALLATION 825 
						

							Pull the axle shaft assemble out through the hole in the steering knuckle
Remove the left-hand side axle shaft by pulling the assembly out of the carrier and through the hole
in the steering knuckle (spindle mount).
8. 
Remove the right-hand axle shaft by performing the following: Remove and discard the right front axle joint boot clamp from the outer axle assembly.
1. 
Pull the right-hand axle shaft out of the axle joint boot and stub shaft and through the hole in
the steering knuckle (spindle mount).
2. 
9. 
Inspect the seals on the outer axle shaft ends, and replace them if necessary. Replace the seals as
follows: Remove the old seal from the axle shaft by driving them off with a hammer.
1. 
Thoroughly clean the axle seal area of the shaft.
2. 
Place the shaft in a press and install the new seal using the Spindle/Axle Seal Installer Tool
T83T-3132-A, or equivalent.
3. 
10. 
To install: Install the right-hand axle shaft as follows:Ensure that the rubber boot is properly installed on the carrier stub shaft. Slide a new outer
axle shaft boot clamp onto the rubber boot.
1. 
11. 
The model 35 front axle does not use blind, or master, splines. Therefore, special attention should be
made to ensure that the yoke ears are in line (in phase) during assembly.
Slide the right axle shaft assemble through the hole in the steering knuckle, into the rubber boot and
engage the splines of the stub shaft. Ensure the splines are fully engaged.
2.  HOW TO USE THIS BOOK
826 REMOVAL & INSTALLATION 
						

							Position the rubber boot and clamp onto the outer axle shaft and crimp the clamp securely on the
rubber boot using Keystone Clamp Pliers T63P-9171-A.
3. 
Install the left-hand axle shaft by sliding it through the hole in the steering knuckle and engaging it
into the carrier. Ensure that the shaft is fully seated into the carrier and engage to the splines inside.
12. 
Install the front disc brake rotor shield, spindle and retaining nuts.
13. 
Install the front brake rotors, bearings, locknuts and hubs.
14. 
Install the brake caliper and wheel assembly.
15. 
Lower the vehicle. Tighten the lug nuts to specification.
16. 
Mountaineer, 1995-99 Explorer and 1998-99 Ranger WARNING
Do not perform this procedure unless a new wheel hub nut and washer assembly and a new axle shaft circlip
are available. Once removed, these parts must never be reused during assembly.
Loosen the front wheel lug nuts.
1. 
Raise and safely support the vehicle.
2. 
Remove the wheels.
3. 
Remove and discard the center wheel hub nut and washer.
4. 
WARNING
Never reuse the wheel hub nut and washer. This nut is a torque prevailing design and cannot be reused.
Remove the disc brake caliper and position it aside.
5. 
The hub shaft is a slip fit into the wheel hub and bearing; a press is not normally required. Ensure that the wheel hub shaft can be pushed inwards. If not, assemble a press to the front wheel
studs and press the wheel hub shaft inwards slightly to break it loose.
6. 
Place a jack under the lower control arm to support it.
7. 
Remove the upper ball joint-to-steering knuckle retaining bolt and separate the joint from the
knuckle.
8. 
WARNING
Support the steering knuckle and do not allow it to drop or swing downwards. This can overstress the
CV-boot and joint, causing damage. HOW TO USE THIS BOOK
REMOVAL & INSTALLATION 827 
						

							Remove the wheel hub nut (arrow) and discard it. NEVER reuse the wheel hub nut
Remove the upper ball joint-to-steering knuckle retaining bolt
Rotate the knuckle (1) downward and pull the CV-joint (2) out of the wheel hub by compressing the axle shaft (3) inwardHOW TO USE THIS BOOK
828 REMOVAL & INSTALLATION 
						

							Using a CV-joint puller (arrow) to remove the inboard joint from the axle housing
Pull the entire halfshaft from the vehicle
Remove the outboard CV-joint from the wheel hub by slightly rotating the steering knuckle down,
taking care not to overstress the joint or boot, and pulling the CV-joint out from the hub.
9. 
Use a CV joint puller and impact slide hammer to pull the inboard CV-joint from the axle housing.
You can also use a prytool to carefully pry the CV-joint outward to disengage the internal circlip.
Take care to not damage the axle housing seal.
10. 
Remove the halfshaft from the vehicle. Remove the circlip from the inboard CV-joint end and
discard it.
11. 
To install: Install a new circlip to the inboard CV-joint end.
12. 
Position the halfshaft into the vehicle. Slide the inboard CV-joint end into the axle housing until it is
fully seated. Ensure that the circlip is engaged in the housing by attempting to pull the joint outwards.
13. 
Install the outboard CV-joint end into the wheel hub.
14. 
Position the upper ball joint to the steering knuckle and install the retaining bolt.
15. 
Install the disc brake caliper back onto the rotor.
16. 
Install a new wheel hub nut and washer and tighten to 157-213 ft. lbs. (212-288 Nm).
17. 
Install the wheel and lug nuts.
18. 
Lower the vehicle and tighten the lug nuts.
19.  HOW TO USE THIS BOOK
REMOVAL & INSTALLATION 829 
						

							
Axle Housing
REMOVAL & INSTALLATION
Dana 28
Exploded view of the Dana 28 front drive axle found on Rangers-other models are similar Click to enlarge
Disconnect the negative battery cable.
1. 
Raise and support the vehicle safely. Remove the wheel and tire assembly.
2.  HOW TO USE THIS BOOK
830 Axle Housing 
						

							
Before removing the driveshaft from the front axle yoke, mark the yoke and driveshaft so that they can
be reassembled in the same relative position, thus eliminating driveshaft imbalance.
Disconnect the driveshaft from the front axle yoke.
3. 
Remove the disc brake calipers and support the caliper on the vehicles frame rail.
4. 
Remove the cotter pin and nut retaining the steering linkage to the spindle. Disconnect the linkage
from the spindle.
5. 
The axle arm assembly must be supported on the jack throughout spring removal and installation and
must not be permitted to hang by the brake hose. If the length of the brake hose is not sufficient to
provide adequate clearance for the removal and installation of the spring, the caliper must be removed.
Remove the bolt and nut and disconnect the shock absorber from the radius arm bracket.
6. 
Remove the stud and bolts that connect the radius arm bracket and radius arm to the axle arm.
Remove the bracket and radius arm.
7. 
Remove the pivot bolt securing the right handle axle arm assembly to the crossmember. Remove the
keystone clamps securing the axle shaft boot from the axle shaft slip yoke and axle shaft and slide the
rubber boot over. Disconnect the right driveshaft from the slip yoke assembly. Lower the jack and
remove the right axle arm assembly.
8. 
Position another jack under the differential housing. Remove the bolt that connects the left axle arm to
the crossmember. Lower the jacks and remove the left axle arm assembly.
9. 
To install: Position the under the left axle arm assembly. Raise the axle arm until the arm is in position in the left
pivot bracket. Install the nut and bolt and tighten to 120-150 ft. lbs. (163-203Nm).
10. 
Do not remove the jack from under the differential housing at this time. Place new keystone clamps for the axle shaft boot on the axle shaft assembly. Position the right axle
arm on a jack and raise the right axle arm so the right driveshaft slides onto the slip yoke stub shaft
and the axle arm is in position in the right pivot bracket. Install the nut and bolt and tighten to
120-150 ft. lbs. (163-203Nm).
11. 
Do not remove the jack from the right axle arm at this time. Position the radius arm and front bracket on the axle arms. Install a new stud and nut on the top of the
axle and radius arm assembly and tighten to 160-220 ft. lbs. (217-298Nm). Install the bolts in the
front of the bracket and tighten to 27-37 ft. lbs. (37-50Nm).
12. 
Install the seat, spacer retainer and coil spring on the stud and nut. Raise the jack to compress the coil
spring. Install the nut and tighten to 1-100 ft. lbs. (95-135Nm).
13. 
Connect the shock absorber to the axle arm assembly. Install the nut and tighten to 42-3 ft. lbs.
(57-97Nm).
14. 
Connect the tie rod ball joint to the spindle. Install the nut and tighten to 50-75 ft. lbs. (68-101Nm).
15. 
Lower the jacks from the axle arms.
16. 
Install the disc brake calipers. Install the wheel and tire assembly. Install the lug nuts and tighten to
85-115 ft. lbs. (115-155Nm).
17. 
Connect the front output shaft to the front axle yoke. Install the U-bolts and tighten to 8-15 ft. lbs.
(11-20Nm).
18. 
Remove the jacks and lower the vehicle.
19. 
Reconnect the negative battery cable.
20.  HOW TO USE THIS BOOK
REMOVAL & INSTALLATION 831 
						

							
Dana 35
EXCEPT MOUNTAINEER, 1995-99 Explorer and 1998-99 Ranger
Exploded view of the Dana 35 front drive axle on Rangers-other models are similar Click to enlarge
Disconnect the negative battery cable.
1. 
Raise and support the vehicle safely. Remove the wheel and tire assembly.
2. 
Remove the spindle, shaft and joint assembly.
3. 
Before removing the driveshaft from the front axle yoke, mark the yoke and driveshaft so that they can
be reassembled in the same relative position, thus eliminating driveshaft imbalance.
Disconnect the driveshaft from the front axle yoke.
4. 
Remove the cotter pin and nut retaining the steering linkage to the spindle. Disconnect the linkage
from the spindle.
5. 
Remove the left stabilizer bar link lower bolt. Remove the link from the radius arm bracket.
6. 
Position a jack under the left axle arm assembly ad slightly compress the coil spring.
7. 
Remove the shock absorber lower nut and disconnect the shock absorber from the radius arm bracket.
8. 
Remove the nut which retains the lower portion of the spring to the axle arm. Slowly lower the jack
and remove the coil spring, spacer, seat and stud.
9.  HOW TO USE THIS BOOK
832 REMOVAL & INSTALLATION