1991 1999 ford explorer chilton User Manual

							
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 stud and bolts that connect the radius arm bracket and radius arm to the axle arm.
Remove the bracket and radius arm.
10. 
Position another jack under the differential housing. Remove the bolt that connects the left axle arm to
the axle pivot bracket. Lower the jacks and remove the left axle arm assembly.
11. 
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).
12. 
Do not remove the jack from the 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 190-230 ft. lbs. (258-311Nm). Install the bolts in the
front of the bracket and tighten to 27-37 ft. lbs. (37-50Nm).
13. 
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).
14. 
Connect the shock absorber to the radius arm. Install the nut and tighten to 42-3 ft. lbs. (57-97Nm).
15. 
Connect the tie rod ball joint to the knuckle. Install the nut and tighten to 50-75 ft. lbs. (68-101Nm).
Install the stabilizer bar mounting bracket and tighten to 203-240 ft. lbs. (275-325Nm).
16. 
Connect the front driveshaft shaft to the front axle yoke. Install the U-bolts and tighten the nuts to
8-15 ft. lbs. (11-20Nm).
17. 
Reassemble the yoke and driveshaft to the marks made during disassembly. Install the spindle, shaft and joint assemblies.
18. 
Remove the jacks and lower the vehicle.
19. 
Reconnect the negative battery cable.
20. 
MOUNTAINEER, 1995-99 Explorer and 1998-99 Ranger
Disconnect the axle vent tube at the axleHOW TO USE THIS BOOK
REMOVAL & INSTALLATION 833 
						

							With the axle supported, remove the left front axle-to-frame bolt first
Remove the two remaining axle-to-frame attaching bolts then lower the axle housing
The manufacturer recommends using new fasteners when installing the front axle. Before beginning
this procedure, make sure to acquire new mounting bolts.
Remove the front axle halfshafts. Refer to axle shaft and seal procedures earlier in this Section.
1. 
Matchmark the front driveshaft to the front axle companion flange.
2. 
Unbolt the front driveshaft retaining straps from the front axle assembly and support it out of the way.
3. 
WARNING
Do not allow the driveshaft to hang unsupported, damage to the shaft and or U-joint can occur.
Disconnect the axle vent tube.
4. 
Place a jack under the front axle to support it.
5. 
Remove the left front axle-to-frame attaching bolt.
6. 
Remove the remaining two axle-to-frame bolts.
7. 
Lower the axle assembly and remove it from under the vehicle.
8. 
To install: Place the axle assembly on a jack and position it under the vehicle.
9. 
Raise the axle assembly up and align the three mounting holes.
10. 
Install the three mounting bolts and tighten them to 45-59 ft. lbs. (60-90 Nm).
11. 
Connect the axle vent tube.
12. 
Install the front driveshaft to the axle companion flange, aligning the matchmarks made earlier, then
install the retaining straps and tighten the bolts.
13.  HOW TO USE THIS BOOK
834 REMOVAL & INSTALLATION 
						

							Install the axle halfshafts.
14. 
Chilton® Automotive Information Systems. © 2004 Thomson Delmar Learning. HOW TO USE THIS BOOK
REMOVAL & INSTALLATION 835 
						

							
REAR AXLE
Determining Axle Ratio
The drive axle is said to have a certain axle ratio. This number (usually a whole number and a decimal
fraction) is actually a comparison of the number of gear teeth on the ring gear and the pinion gear. For
example, a 4.11 rear means that theoretically, there are 4.11 teeth on the ring gear and one tooth on the pinion
gear or, put another way, the driveshaft must turn 4.11 times to turn the wheels once. Actually, on a 4.11 rear,
there might be 37 teeth on the ring gear and 9 teeth on the pinion gear. By dividing the number of teeth on the
pinion gear into the number of teeth on the ring gear, the numerical axle ratio (4.11) is obtained. This also
provides a good method of ascertaining exactly what axle ratio one is dealing with.
Another method of determining gear ratio is to jack up and support the truck so that both rear wheels are off
the ground. Make a chalk mark on the rear wheel and the driveshaft. Put the transmission in neutral. Turn the
rear wheel one complete turn and count the number of turns that the driveshaft makes. The number of turns
that the driveshaft makes in one complete revolution of the rear wheel is an approximation of the rear axle
ratio.
Axle Shaft, Bearing and Seal
REMOVAL & INSTALLATION
REAR AXLE 837 
						

							Integral axle carrier, exploded view
Click to enlarge
Disconnect the negative battery cable.
1. 
Raise and support the vehicle safely.
2.  HOW TO USE THIS BOOK
838 REMOVAL & INSTALLATION 
						

							To remove the axle, first remove the rear axle cover and drain the fluid
Next, loosen the pinion shaft lock bolt ...HOW TO USE THIS BOOK
REMOVAL & INSTALLATION 839 
						

							... and remove it from the axle carrier
Remove the rear wheels and brake drums.
3. 
Drain the rear axle lubricant.
4. 
For all axles except 3.73:1 and 4.10:1 ratio: Remove the differential pinion shaft lock bolt and differential pinion shaft.
1. 
5. 
The pinion gears may be left in place. Once the axle shafts are removed, reinstall the pinion shaft and
lock bolt.
Push the flanged end of the axle shafts toward the center of the vehicle and remove the
C-lockwasher from the end of the axle shaft.
2. 
Remove the axle shafts from the housing. If the seals and/or bearing are not being replaced,
be careful not to damage the seals with the axle shaft splines upon removal.
3. 
For 3.73:1 and 4.10:1 ratio axles:
6. 
Remove the pinion shaft lock bolt. Place a hand behind the differential case and push out the
pinion shaft until the step contacts the ring gear.
1. 
Remove the C-lockwasher from the axle shafts.
2. 
Remove the axle shafts from the housing. If the seals and/or bearing are not being replaced,
be careful not to damage the seals with the axle shaft splines upon removal.
3.  HOW TO USE THIS BOOK
840 REMOVAL & INSTALLATION 
						

							Pull the pinion shaft out of the axle carrier. DO NOT rotate the axle with the pinion shaft
removed!
Push in on the axle flange (wheel side) and remove the axle C-lock (A) from the end of the axle (B)
HOW TO USE THIS BOOK
REMOVAL & INSTALLATION 841 
						

							Slide the axle out of the axle tube. Use care to not damage the bearing or seal
Insert the wheel bearing and seal remover, T85L-1225-AH or equivalent, and a slide hammer into
the axle bore and position it behind the bearing so the tanks on the tool engage the bearing outer race.
Remove the bearing and seal as a unit.
7. 
Axle shaft seal and bearing removalClick to enlarge
To install: If removed, lubricate the new bearing with rear axle lubricant and install the bearing into the housing
bore. Use axle tube bearing replacer, T78P-1225-A or equivalent.
8. 
Apply Multi-Purpose Long-Life Lubricant, C1AZ-19590-B or equivalent, between the lips of the
axle shaft seal.
9.  HOW TO USE THIS BOOK
842 REMOVAL & INSTALLATION 
						

							Axle shaft bearing and seal installation
Click to enlarge
Install a new axle shaft seal using axle tube seal replacer T78P-1177-A or equivalent.
10. 
To permit axle shaft installation on 3.73:1 and 4.10:1 ratio axles, make sure the differential pinion shaft
contacts the ring gear before performing Step 11.
Carefully slide the axle shaft into the axle housing, making sure not to damage the oil seal. Start the
splines into the side gear and push firmly until the button end of the axle shaft can be seen in the
differential case.
11. 
Install the C-lockwasher on the end of the axle shaft splines, then pull the shaft outboard until the
shaft splines engage the C-lockwasher seats in the counterbore of the differential side gear.
12. 
Position the differential pinion shaft through the case and pinion gears, aligning the hole in the shaft
with the lock screw hole. Install the lock bolt and tighten to 15-22 ft. lbs. (21-29Nm).
13. 
Clean the gasket mounting surface on the rear axle housing and cover. Apply a continuous bead of
Silicone Rubber Sealant ESE-M4G195-A or equivalent to the carrier casting face.
14. 
Install the cover and tighten the retaining bolts to 25-35 ft. lbs. (20-34Nm).
15. 
The cover assembly must be installed within 15 minutes of application of the silicone sealant. Add lubricant until it is  1
/4  in. (6mm) below the bottom of the filler hole in the running position.
Install the filler plug and tighten to 15-30 ft. lbs. (20-41Nm).
16. 
Pinion Oil Seal
REMOVAL & INSTALLATION Disconnect the negative battery cable.
1. 
Raise and support the vehicle safely. Allow the axle to drop to rebound position for working
clearance.
2.  HOW TO USE THIS BOOK
Pinion Oil Seal 843