1991 1999 ford explorer chilton User Manual

							
2-WHEEL DRIVE FRONT SUSPENSION
Introduction
View of the 2WD front suspension-except Mountaineer, 1995-99 Explorer and 1992-99 Ranger Click to enlarge
2-WHEEL DRIVE FRONT SUSPENSION 855 
						

							View of the Mountaineer, 1995-99 Explorer and 1992-99 Ranger 2WD front suspension
Click to enlarge
All vehicles, except the Mountaineer, 1995-99 Explorer and 1992-99 Ranger, use a twin I-beam front
suspension which utilizes coil springs to support the vehicle and radius rods to locate the I-beam.
Mountaineer, 1995-99 Explorer and 1992-99 Ranger models use unequal length control arms (Short/Long
Arm - SLA) which utilize torsion bars to support the vehicle.
Coil Springs
All models except the Mountaineer, 1115-11 Explorer and 1118-11 Ranger use coil springs.
REMOVAL & INSTALLATION HOW TO USE THIS BOOK
856 Introduction 
						

							Exploded view of the Ranger coil spring and related parts-1111-14 Explorer similar
Click to enlarge
Raise the front of the vehicle and place jackstands under the frame and a jack under the axle.
1. 
WARNING
The axle must not be permitted to hang by the brake hose. If the length of the brake hoses is not sufficient to
provide adequate clearance for removal and installation of the spring, the disc brake caliper must be removed
from the spindle. A Strut Spring Compressor, T81P-5310-A or equivalent may be used to compress the
spring sufficiently, so that the caliper does not have to be removed. After removal, the caliper must be placed
on the frame or otherwise supported to prevent suspending the caliper from the caliper hose. These
precautions are absolutely necessary to prevent serious damage to the tube portion of the caliper hose
assembly! HOW TO USE THIS BOOK
REMOVAL & INSTALLATION 857 
						

							Disconnect the shock absorber at the lower shock stud. Remove the nut securing the lower retainer to
spring seat. Remove the lower retainer.
2. 
Lower the axle as far as it will go without stretching the brake hose and tube assembly. The axle
should now be unsupported without hanging by the brake hose. If not, then either remove the caliper
or use Strut Spring Compressor Tool, T81P-5310-A or equivalent. Remove the spring.
3. 
If there is a lot of slack in the brake hose assembly, a pry bar can be used to lift the spring over the
bolt that passes through the lower spring seat.
4. 
Rotate the spring so the built-in retainer on the upper spring seat is cleared.
5. 
Remove the spring from the vehicle.
6. 
To install: If removed, install the bolt in the axle arm and install the nut all the way down. Install the spring
lower seat and lower insulator. On the 1111-14 Explorer, also install the stabilizer bar mounting
bracket and spring spacer.
7. 
With the axle in the lowest position, install the top of the spring in the upper seat. Rotate the spring
into position.
8. 
Lift the lower end of the spring over the bolt.
9. 
Raise the axle slowly until the spring is seated in the lower spring upper seat. Install the lower retainer
and nut.
10. 
Connect the shock absorber to the lower shock stud.
11. 
Remove the jack and jackstands and lower vehicle.
12. 
Torsion Bars
Only the Mountaineer, 1995-99 Explorer and 1998-99 Ranger models use torsion bars.
REMOVAL & INSTALLATION HOW TO USE THIS BOOK
858 Torsion Bars 
						

							Exploded view of the torsion bar rear mounting components
Click to enlarge
A special tool (Torsion Bar Tool T95T-5310-A) is required for removing the torsion bar. Also, anytime
the torsion bar or its adjuster is removed, the vehicle ride height must be checked.
Raise and safely support the front of the vehicle. Place the jackstands so as to support the frame of the
vehicle. Do not position the jackstands under the lower control arms and do not use car ramps. The
lower control arms must be free to hang unhindered.
1. 
Remove the torsion bar protector/skid plate from the frame.
2. 
Remove the torsion bar adjuster bolt from the support nut. Count the number of turns required to
remove the bolt and record it for installation.
3. 
Use Torsion Bar Tool T95T-5310-A, or equivalent, to raise the adjuster lever.
4.  HOW TO USE THIS BOOK
REMOVAL & INSTALLATION 859 
						

							Use the torsion bar tool to relieve the tension from the bar
Remove the support nut then lower the adjuster lever completely.
5. 
Slide the torsion bar forward, into the lower control arm, to allow the adjuster lever to be removed.
6. 
Lower the torsion bar and pull it from the lower control arm.
7. 
Ensure that you do not mix up the right and left-hand torsion bars. They must be installed to the side
they were originally removed. If installing a new torsion bar, ensure to order the bar for the proper side
of the vehicle.
To install: Raise the torsion bar and slide it forward into the lower control arm.
8. 
Slide the torsion bar rearward and engage it into the adjuster lever.
9. 
Use Torsion Bar Tool T95T-5310-A, or equivalent, to raise the adjuster lever.
10. 
Install the support nut and remove the tool.
11. 
Lubricate the tip of the adjuster bolt and start it into the support nut.
12. 
Tighten the adjuster the same number of turns you recorded earlier, then rotate two additional turns.
13. 
Install the torsion bar protector/skid plate. Tighten the bolts securely.
14. 
Lower the vehicle and check the ride height adjustment.
15. 
RIDE HEIGHT ADJUSTMENT
To perform the ride height check and adjustment requires the use of special slip plates under the front
wheels. These plates allow the front suspension to properly settle by bypassing the tires adhesion to the
ground.
Raise and support the vehicle. If equipped with ARC suspension, disconnect the front and rear air
lines at the shock absorbers.
1. 
Position frictionless slip plates under the tires then lower the vehicle onto the slip plates.
2. 
Bounce the vehicles front and rear suspensions several times to normalize the vehicle static ride
height.
3.  HOW TO USE THIS BOOK
860 RIDE HEIGHT ADJUSTMENT 
						

							Measure the distance between the center of the lower control arm bushing bolt and the ground.
Record the measurement as dimension A.
4. 
Measure the distance between the lowest point of the steering knuckle (but not the ball joint) and the
ground. Record the measurement as dimension B.
5. 
Subtract dimension B from dimension A for ride height.
6. 
For vehicles without ARC suspension, ride height should be 4.33-4.56 in. (10-16mm).
7. 
For vehicles with ARC suspension, ride height should be 3.26-3.50 in. (83-89mm).
8. 
To increase the ride height, raise the vehicle and tighten the torsion bar adjuster bolt. Recheck the ride
height.
9. 
To decrease the ride height, raise the vehicle and loosen the torsion bar adjuster bolt. Recheck the ride
height.
10. 
Once proper ride height is established, raise and support the vehicle.
11. 
If equipped with ARC suspension, connect the front and rear air lines at the shocks.
12. 
Remove the slip plates from under the wheels.
13. 
Lower the vehicle.
14. 
Shock Absorbers
REMOVAL & INSTALLATION
Low pressure gas shocks are charged with Nitrogen gas. Do not attempt to open, puncture or apply
heat to them. Prior to installing a new shock absorber, hold it upright and extend it fully. Invert it and
fully compress and extend it at least 3 times. This will bleed trapped air.
Except Mountaineer, 1995-99 Explorer and 1998-99 Ranger HOW TO USE THIS BOOK
Shock Absorbers 861 
						

							Exploded view of the front shock absorber-except Mountaineer, 1995-99 Explorer and
1998-99 Ranger
Click to enlarge
Raise the vehicle, as required to provide additional access and remove the nut attaching the shock
absorber to the lower mounting stud on the radius arm.
1. 
Slide the lower shock absorber end off of the stud.
2. 
Remove the nut, washer and insulator from the upper shock absorber mount at the frame bracket and
remove the shock absorber.
3. 
A second wrench may be needed to hold the shock absorber from turning while removing the upper
attaching nut. HOW TO USE THIS BOOK
862 REMOVAL & INSTALLATION 
						

							
To install:
Position the washer and insulator on the shock absorber rod and position the shock absorber to the
upper frame bracket mount.
4. 
Position the insulator and washer on the shock absorber rod and install the attaching nut loosely.
5. 
Position the shock absorber to the lower mounting stud and install the attaching nut loosely.
6. 
Tighten the lower shock attaching bolts to 39-53 ft. lbs. (53-72 Nm), and the upper shock attaching
bolts to 25-34 ft. lbs. (34-46 Nm).
7. 
Mountaineer, 1995-99 Explorer and 1998-99 Ranger
Exploded view of the Mountaineer, 1995-99 Explorer and 1998-99 Ranger front shock absorber
Click to enlarge
HOW TO USE THIS BOOK
REMOVAL & INSTALLATION 863 
						

							Raise the front of the vehicle and place jackstands under the lower control arms. Ensure that the lower
shock attaching nuts do not become obstructed by the jackstands.
1. 
Remove the upper shock-to-frame attaching nut, washer and insulator assembly.
2. 
Remove the two lower shock-to-control arm attaching nuts.
3. 
Slightly compress the shock absorber by hand and remove it from the vehicle.
4. 
To install: Position the lower washer and insulator on the shock absorber rod and position the shock absorber to
the upper frame bracket mount.
5. 
Position the upper insulator and washer on the shock absorber rod and install the attaching nut
loosely.
6. 
Position the lower shock absorber mounting studs into the control arm and install the attaching nuts
loosely.
7. 
Tighten the lower shock attaching nuts to 15-21 ft. lbs. (21-29 Nm), and the upper shock attaching
bolts to 30-40 ft. lbs. (40-55 Nm).
8. 
TESTING
The purpose of the shock absorber is simply to limit the motion of the spring during compression and rebound
cycles. If the vehicle is not equipped with these motion dampers, the up and down motion would multiply
until the vehicle was alternately trying to leap off the ground and to pound itself into the pavement.
Countrary to popular rumor, the shocks do not affect the ride height of the vehicle. This is controlled by other
suspension components such as springs and tires. Worn shock absorbers can affect handling; if the front of the
vehicle is rising or falling excessively, the footprint of the tires changes on the pavement and steering is
affected.
The simplest test of the shock absorber is simply push down on one corner of the unladen vehicle and release
it. Observe the motion of the body as it is released. In most cases, it will come up beyond it original rest
position, dip back below it and settle quickly to rest. This shows that the damper is controlling the spring
action. Any tendency to excessive pitch (up-and-down) motion or failure to return to rest within 2-3 cycles
is a sign of poor function within the shock absorber. Oil-filled shocks may have a light film of oil around the
seal, resulting from normal breathing and air exchange. This should NOT be taken as a sign of failure, but any
sign of thick or running oil definitely indicates failure. Gas filled shocks may also show some film at the
shaft; if the gas has leaked out, the shock will have almost no resistance to motion. HOW TO USE THIS BOOK
864 TESTING