1991 1999 ford explorer chilton User Manual

							Remove the rear wheels and brake drums. No drag must be present on the axle.
3. 
Mark the companion flanges and U-joints for correct reinstallation position.
4. 
Remove the driveshaft.
5. 
Use a 2-jawed puller to remove the driveshaft companion flange Click to enlarge
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844 REMOVAL & INSTALLATION 
						

							Remove the seal by either prying it out, or grasping the lip edge with locking pliers and tapping
it out of the housing
Click to enlarge
Using an inch pound torque wrench and socket on the pinion yoke nut measure the amount of torque
needed to maintain differential rotation through several clockwise revolutions. Record the
measurement.
6. 
Use a suitable tool to hold the companion flange. Remove the pinion nut.
7. 
Place a drain pan under the differential. Clean the area around the seal and mark the yoke-to-pinion
relation.
8. 
Use a 2-jawed puller to remove the companion flange.
9. 
Remove the seal with a small prybar and/or locking pliers and hammer.
10. 
To install: Thoroughly clean the oil seal bore.
11. 
If you are not absolutely certain of the proper seal installation depth, the proper seal driver must be
used. If the seal is misaligned or damaged during installation, it must be removed and a new seal
installed.
Drive the new seal into place with a seal driver such as T83T-4676-A. Coat the seal lip with clean,
waterproof wheel bearing grease.
12. 
Coat the splines with a small amount of wheel bearing grease and install the yoke, aligning the
matchmarks. Never hammer the yoke onto the pinion!
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REMOVAL & INSTALLATION 845 
						

							Install a new nut on the pinion.
14. 
Hold the yoke with a holding tool. Tighten the pinion nut, taking frequent turning torque readings
until the original preload reading is attained. If the original preload reading, that you noted before
disassembly, is lower than the specified reading of 8-14 inch lbs. for used bearings; 16-29 inch lbs.
for new bearings, keep tightening the pinion nut until the specified reading is reached. If the original
preload reading is higher than the specified values, torque the nut just until the original reading is
reached.
15. 
WARNING
Under no circumstances should the nut be backed off to reduce the preload reading! If the preload is
exceeded, the yoke and bearing must be removed and a new collapsible spacer must be installed. The entire
process of preload adjustment must be repeated.
Install the driveshaft using the matchmarks. Torque the nuts to 15 ft. lbs.
16. 
Lower the vehicle.
17. 
Reconnect the negative battery cable.
18. 
Axle Housing
REMOVAL & INSTALLATION
View of the under-spring mounted axle assemblyClick to enlarge
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846 Axle Housing 
						

							Example of the over-spring mounted axle assembly
Click to enlarge
Disconnect the negative battery cable.
1. 
Raise and support the vehicle safely.
2. 
Matchmark and disconnect the driveshaft at the axle.
3. 
Remove the wheels and brake drums.
4. 
Disengage the brake line from the clips that retain the line to the housing.
5. 
Disconnect the vent tube from the housing.
6. 
Remove the axle shafts.
7. 
Remove the brake backing plate from the housing and support them with wire. Do not disconnect the
brake line.
8. 
If the rear lower shock absorber mounts are integral to the axle housing, disconnect each shock from
the mounting bracket.
9. 
Lower the axle slightly to reduce some of the spring tension. At each rear spring, remove the spring
clip (U-bolt) nuts, spring clips and spring seat caps.
10. 
If the axle housing is mounted on top of the springs, proceed as follows: Slide the axle housing to the right-side and lower the left-side axle tube end until it clears the
leaf spring.
1. 
Slide the axle housing to the left-side until the right-side axle tube end will clear the leaf
spring.
2. 
11. 
Lower the axle housing and remove it from under the vehicle.
12. 
To install: Position the axle housing to the rear springs. Install the spring clips (U-bolts), spring seat clamps and
nuts. Tighten the spring clamps evenly to 115 ft. lbs.
13. 
If a new axle housing is being installed, remove the bolts that attach the brake backing plate and
bearing retainer from the old housing flanges. Position the bolts in the new housing flanges to hold the
brake backing plates in position. Torque the bolts to 40 ft. lbs.
14. 
Install the axle shafts.
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REMOVAL & INSTALLATION 847 
						

							Connect the vent tube to the housing.
16. 
Position the brake line to the housing and secure it with the retaining clips.
17. 
Raise the axle housing and springs enough to allow connecting the rear shock absorbers to the
mounting bracket studs on the housing. Torque the nuts to 60 ft. lbs.
18. 
Connect the driveshaft to the axle. Torque the nuts to 8-15 ft. lbs.
19. 
Install the brake drums and wheels.
20. 
Lower the vehicle.
21. 
Reconnect the negative battery cable.
22. 
Chilton® Automotive Information Systems. © 2004 Thomson Delmar Learning. HOW TO USE THIS BOOK
848 REMOVAL & INSTALLATION 
						

							
WHEELS
Front Wheels
REMOVAL & INSTALLATION
Lug nut torque sequenceClick to enlarge
Set the parking brake. Block the diagonally opposite wheel.
1. 
On vehicles with automatic transmission position the selector lever in P.
2. 
On vehicles with manual transmission position the selector lever in N.
3. 
As necessary, remove the hubcap or wheel cover. Loosen the lug nuts, but do not remove them.
4. 
Raise the vehicle until the wheel and tire assembly clears the floor. Properly support the vehicle.
5. 
Remove the lug nuts. Remove the tire and wheel assembly from its mounting.
6. 
To install: Position the wheel and tire assembly on its mounting.
7. 
CAUTION
Whenever a wheel is installed be sure to remove any corrosion, dirt or foreign material that may be present on
the mounting surfaces of the hub, drum or rotor that contacts the wheel. Installing wheels without proper
metal to metal contact at the wheel mounting surfaces can cause the wheel lug nuts to loosen and could allow
the wheel to come off while the vehicle is in motion!
Install the lug nuts. Be sure that the cone end of the lug nut faces inward.
8. 
With the lug nuts loosely installed, turn the wheel until one nut is at the top of the bolt circle. Tighten
the lug nut until snug.
9. 
In a crisscross manner tighten the remaining lug nuts until snug in order to minimize run-out.
10. 
Lower the vehicle. Torque the lug nuts to 100 ft. lbs. in the proper sequence.
11. 
CAUTION
Retighten the wheel lug nuts to specification after about 500 miles of driving. Failure to do this could result in
the wheel coming off while the vehicle is in motion possibly causing loss of vehicle control or collision.
WHEELS 849 
						

							
INSPECTION
Replace wheels if they are bent, cracked, leaking air or heavily rusted or if the lug nuts often become loose.
Do not use bent wheels that have been straightened or do not use inner tubes in leaking wheels. Do not replace
wheels with used wheels. Wheels that have been straightened or are leaking air or are used may have
structural damage and could fail without warning.
Front Wheel Lug Studs
REMOVAL & INSTALLATION
Except Mountaineer, 1995-99 Explorer and 1998-99 Ranger
Front wheel studClick to enlarge
Pressing the stud from the hub HOW TO USE THIS BOOK
850 INSPECTION 
						

							Click to enlarge
Pressing the new stud into the hub Click to enlarge
Raise and support the vehicle safely.
1. 
Remove the tire and wheel assembly.
2. 
Remove the disc brake rotor. Be sure to properly support the brake caliper to avoid damage to the
brake line hose.
3. 
Position the disc brake rotor in a press so that press ram pressure is not directly exerted on the disc
brake rotor surface.
4. 
Using the proper press stock, press the lug stud from the disc brake rotor. Discard the lug stud.
Remove the disc brake rotor from its mounting in the press.
5. 
To install: Position a new lug stud in the disc brake rotor hole. Align the serrations of the new stud with the
serration marks from the old lug stud.
6. 
Using a hammer tap the lug stud until the serrations on the stud are started in the hole. Be sure that the
lug stud is not installed in an off centered position.
7. 
Reposition the disc brake rotor in the press so that the rotor is supported on the wheel mounting
flange. Be sure to allow enough clearance for the stud to pass through the hole.
8. 
Do not apply ram pressure directly to the rotor surface. Using the proper press stock, press the lug
stud in position until the stud is flush against the inner surface of the disc brake rotor hub.
9. 
Install the disc brake rotor. Reposition the brake caliper. Install the tire and wheel assembly. Lower
the vehicle.
10. 
CAUTION
Retighten the wheel lug nuts to specification after about 500 miles of driving. Failure to do this could result in
the wheel coming off while the vehicle is in motion possibly causing loss of vehicle control or collision.
Mountaineer, 1995-99 Explorer and 1998-99 Ranger
Loosen the wheel lug nuts.
1. 
Raise and safely support the vehicle.
2. 
Remove the wheel.
3. 
Remove the brake caliper, bracket and rotor.
4. 
Use a wheel stud removal tool, such as C-clamp Assembly Tool T73P-2033-A1, and press the wheel
stud out of the hub flange. A C-clamp and socket may also be used.
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REMOVAL & INSTALLATION 851 
						

							
To install:
Insert the new wheel stud through the hole in the hub flange. Rotate the new stud slowly and ensure
that the serrations are aligned with those made by the original stud.
6. 
Place four flat washers over the outside end of the stud and thread the lug nut onto the stud with the
flat side against the washers.
7. 
WARNING
Do not use air tools as the serrations may be stripped from the wheel stud.
Tighten the lug nut until the wheel stud head seat against the back side of the flange.
8. 
Remove the lug nut and washers.
9. 
Install the brake rotor, bracket and caliper.
10. 
Install the wheel and snug all of the lug nuts.
11. 
Lower the vehicle then tighten the wheel lug nuts to specification.
12. 
INSPECTION
Replace wheels if they are bent, cracked, leaking air or heavily rusted or if the lug nuts often become loose.
Do not use bent wheels that have been straightened or do not use inner tubes in leaking wheels. Do not replace
wheels with used wheels. Wheels that have been straightened or are leaking air or are used may have
structural damage and could fail without warning.
Rear Wheel Lug Studs
REMOVAL & INSTALLATION
Brake drum and stud
HOW TO USE THIS BOOK
852 INSPECTION 
						

							Forcing a new stud into place
Raise and support the vehicle safely.
1. 
Remove the tire and wheel assembly.
2. 
Except on Mountaineer and 1991-99 Explorer, remove the brake drum.
3. 
On Mountaineer and 1991-99 Explorer, remove the rear disc brake caliper, bracket and rotor.
4. 
Using wheel stud removal tool T74P-3044-A1 or equivalent, press the lug stud from its seat in the
hub.
5. 
WARNING
Never use a hammer to remove the lug stud, as damage to the hub or bearing may result.
To install:
Insert the new lug stud in the hole in the hub. Rotate the stud slowly to assure the serrations are
aligned with those made by the old lug nut stud.
2. 
Place 4 flat washers over the outside end of the lug nut stud and thread the wheel lug nut with the flat
washer side against the washers.
3. 
Tighten the wheel nut until the stud head seats against the back side of the hub. Do not use air tools as
the serrations may be stripped from the stud.
4. 
Remove the wheel lug nut and washers.
5. 
Except on Mountaineer and 1991-99 Explorer, install the brake drum.
6. 
On Mountaineer and 1991-99 Explorer, install the rear disc brake rotor, bracket and caliper.
7. 
Install the tire and wheel assembly and snug the lug nuts.
8. 
Lower the vehicle and tighten the wheel lug nuts to specification.
9. 
CAUTION
Retighten the wheel lug nuts to specification after about 100 miles of driving. Failure to do this could result in
the wheel coming off while the vehicle is in motion possibly causing loss of vehicle control or collision.
Chilton® Automotive Information Systems. © 2004 Thomson Delmar Learning. HOW TO USE THIS BOOK
REMOVAL & INSTALLATION 853