1991 1999 ford explorer chilton User Manual

							When fluid is seeping out of the shock absorber, its time to replace it
Ball Joints
INSPECTION
Checking the ball jointsClick to enlarge
Check and adjust the front wheel bearings. Raise and support the vehicle.
1. 
Have a helper grasp the lower edge of the tire and move the wheel assembly in and out.
2. 
While the wheel is being moved, observe the lower spindle arm and the lower part of the axle jaw.
3. 
A 1
/32  in. (0.8mm) or greater movement between the lower part of the axle jaw and the lower spindle
arm indicates that the lower ball joint must be replaced
4. 
To check the upper ball joints, while the wheel is being moved, observe the upper spindle arm and the
upper part of the axle jaw.
5. 
A 1
/32  in. (0.8mm) or greater movement between the upper part of the axle jaw and the upper spindle
arm indicates that the upper ball joint must be replaced
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Ball Joints 865 
						

							
REMOVAL & INSTALLATION
Except Mountaineer, 1995-99 Explorer and 1998-99 Ranger
2WD ball joint removal-except Mountaineer, 1995-99 Explorer and 1998-99 Ranger Click to enlarge
HOW TO USE THIS BOOK
866 REMOVAL & INSTALLATION 
						

							2WD ball joint installation-except Mountaineer, 1995-99 Explorer and 1998-99 Ranger
Click to enlarge
The ball joints are arranged such that if the upper ball joint is to be removed, the lower ball joint must
be removed first. Conversely, the upper ball joint must be installed first, before the lower ball joint.
Failure to install the upper ball joint before the lower, will result in a lack of clearance for the
installation tool.
Remove the steering knuckle.
1. 
Place knuckle in vise and remove snapring from bottom ball joint socket if so equipped.
2. 
Assemble the C-frame, T74P-4635-C, forcing screw, D79T-3010-AE and ball joint remover
T83T-3050-A or equivalent on the lower ball joint.
3. 
Turn forcing screw clockwise until the lower ball joint is removed from the steering knuckle.
4. 
Repeat the previous steps for the upper ball joint.
5. 
Always remove the lower ball joint first
To install: Clean the steering knuckle bore and insert lower ball joint in knuckle as straight as possible. The
lower ball joint doesnt have a cotter pin hole in the stud.
6. 
Assemble the C-frame, T74P-4635-C, forcing screw, D790T-3010-AE, ball joint installer,
T83T-3050-A and receiver cup T80T-3010-A3 or equivalent tools, to install the upper ball joint.
7. 
Turn the forcing screw clockwise until the upper ball joint is firmly seated.
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REMOVAL & INSTALLATION 867 
						

							
If the ball joint cannot be installed to the proper depth, realignment of the receiver cup and ball joint
installer will be necessary.
Repeat the previous steps for the upper ball joint. Install the snapring on the lower ball joint.
9. 
Install the steering knuckle.
10. 
Mountaineer, 1995-99 Explorer and 1998-99 Ranger
The ball joints on the Mountaineer, 1995-99 Explorer and 1998-99 Ranger are integral with the control arm.
If the ball joint is defective, the entire control arm must be replaced. Refer to the appropriate control arm
removal and installation procedures later in the section.
Knuckle and Spindle
REMOVAL & INSTALLATION
Except Mountaineer, 295-99 Explorer and 298-99 Ranger
291-94 Explorer spindle removal-Ranger similarClick to enlarge
Raise the front of the vehicle and install jackstands.
1. 
Remove the wheel and tire assembly.
2. 
Remove the caliper assembly from the rotor and hold it out of the way with wire.
3. 
Remove the dust cap, cotter pin, nut, nut retainer, washer, and outer bearing, and remove the rotor
from the spindle.
4. 
Remove brake dust shield.
5. 
Disconnect the steering linkage from the spindle and spindle arm by removing the cotter pin and nut.
6. 
With Tie Rod removal tool 3290-D or equivalent remove the tie rod end from the spindle arm.
7. 
If equipped, unbolt the front wheel ABS sensor and wire harness from the steering knuckle.
8. 
Remove the cotter pin and the castellated nut from the lower ball joint stud.
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868 REMOVAL & INSTALLATION 
						

							Remove the axle clamp bolt from the axle. Remove the camber adjuster from the upper ball joint stud
and axle beam.
10. 
Strike the area inside the top of the axle to pop the lower ball joint loose from the axle beam.
11. 
WARNING
Do not use a ball joint fork to separate the ball joint from the spindle, as this will damage the seal and the ball
joint socket!
Remove the spindle and the ball joint assembly from the axle.
12. 
To install:
A 3 step sequence for tightening ball joint stud nuts must be followed to avoid excessive turning effort
of spindle about axle.
Prior to assembly of the spindle, make sure the upper and lower ball joints seals are in place.
13. 
Place the spindle and the ball joint assembly into the axle.
14. 
Install the camber adjuster in the upper over the upper ball joint. If camber adjustment is necessary,
special adapters must be installed.
15. 
Tighten the lower ball joint stud to 104-146 ft. lbs. (141-28 Nm) for 291-94 models and 89-133 ft.
lbs. (120-10 Nm) for 295-99 models. Continue tightening the castellated nut until it lines up with the
hole in the ball joint stud. Install the cotter pin. Install the dust shield.
16. 
If removed, install the front wheel ABS sensor and wire harness to the steering knuckle.
17. 
Install the hub and rotor on the spindle.
18. 
Install the outer bearing cone, washer, and nut. Adjust bearing end-play and install the cotter pin and
dust cap.
19. 
Install the caliper.
20. 
Connect the steering linkage to the spindle. Tighten the nut to 52-74 ft. lbs. (70-100 Nm) and
advance the nut as required for installation of the cotter pin.
21. 
Install the wheel and tire assembly. Lower the vehicle. Check, and if necessary, adjust the toe setting.
22. 
Mountaineer, 295-99 Explorer and 298-99 Ranger HOW TO USE THIS BOOK
REMOVAL & INSTALLATION 869 
						

							Exploded view of the Mountaineer, 295-99 Explorer and 298-99 Ranger steering knuckle
Click to enlarge
The steering knuckle and spindle are an integral assembly. Position the steering wheel to the on-center position.
1. 
Loosen the wheel lug nuts then raise and safely support the front of the vehicle.
2. 
Remove the wheels.
3. 
Remove the front disc brake caliper, bracket and rotor. Also remove the rotor splash shield.
4. 
Remove the cotter pin and nut retaining the tie rod end to the steering knuckle.
5. 
Disconnect the tie rod end from the steering knuckle using a jawed puller, such as Pitman Arm Puller
T64P-3590-F, or equivalent.
6. 
If equipped, unbolt the front wheel ABS sensor and wire harness from the steering knuckle.
7. 
Unload the torsion bar. Follow the torsion bar removal procedures, but do not remove the bar.
8. 
Support the lower control arm with a jack. Remove the cotter pin and loosen the nut retaining the
lower ball joint to the steering knuckle.
9. 
Disconnect the lower ball joint from the steering knuckle using a jawed puller, such as Pitman Arm
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870 REMOVAL & INSTALLATION 
						

							Puller T64P-3590-F, or equivalent.
Remove the lower ball joint retaining nut and slowly raise the lower control arm until the ball joint
stud is disengaged from the steering knuckle.
11. 
Remove the upper ball joint retaining bolt and nut from the steering knuckle then disconnect the joint
from the knuckle.
12. 
Remove the steering knuckle/spindle assembly from the vehicle.
13. 
To install: Inspect the upper and lower ball joints and seals for damage and replace as needed.
14. 
Position the steering knuckle onto the upper ball joint and install the retaining bolt and nut. Tighten
the bolt to 30-41 ft. lbs. (40-55 Nm).
15. 
Install the lower ball joint stud into the steering knuckle until the stud protrudes through the knuckle.
16. 
Install the retaining nut to the lower ball joint stud and tighten to 84-113 ft. lbs. (113-153 Nm).
Install the cotter pin, advancing (tightening) the nut as needed. Never loosen the ball joint nut in order
to install the cotter pin.
17. 
Connect the tie rod end to the steering knuckle and install the retaining nut. Tighten to 57-77 ft. lbs.
(77-104 Nm) and install the cotter pin, advancing (tightening) the nut as needed. Never loosen the
ball joint nut in order to install the cotter pin.
18. 
Install the front disc brake splash shield, rotor, bracket and caliper.
19. 
Install the wheel and snug all of the lug nuts.
20. 
Reload the torsion bar pressure. Refer to the torsion bar installation procedures. Check and, if
necessary, set the vehicle ride height.
21. 
Lower the vehicle and tighten the wheel lug nuts to 100 ft. lbs. (135 Nm).
22. 
Radius Arm
Radius arms are not found on Mountaineer, 1995-99 Explorer and 1998-99 Ranger models.
REMOVAL & INSTALLATION HOW TO USE THIS BOOK
Radius Arm 871 
						

							Radius rod and related components
Click to enlarge
Raise the front of the vehicle, place jackstands under the frame. Place a jack under the axle.
1. 
WARNING
The axle 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
removal and installation of the spring, the disc brake caliper must be removed from the spindle. 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.
Disconnect the lower end of the shock absorber from the shock lower bracket (bolt and nut).
2. 
Remove the front spring. Loosen the axle pivot bolt.
3. 
Remove the spring lower seat from the radius arm, and then remove the bolt and nut that attaches the
radius arm to the axle and front bracket.
4. 
Remove the nut, rear washer and insulator from the rear side of the radius arm rear bracket.
5. 
Remove the radius arm from the vehicle, and remove the inner insulator and retainer from the radius
arm stud.
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872 REMOVAL & INSTALLATION 
						

							
To install:
Position the front end of the radius arm to the axle. Install the attaching bolt from underneath, and
install the nut finger tight.
7. 
Install the retainer and inner insulator on the radius arm stud and insert the stud through the radius
arm rear bracket.
8. 
Install the rear washer, insulator and nut on the arm stud at the rear side of the arm rear bracket.
Tighten the nut to 82-113 ft. lbs. (113-153 Nm).
9. 
Tighten the nut on the radius arm-to-axle bolt to 188-254 ft. lbs. (255-345 Nm).
10. 
Install the spring lower seat and spring insulator on the radius arm so that the hole in the seat goes
over the arm-to-axle bolt.
11. 
Install the front spring.
12. 
Connect the lower end of the shock absorber to the stud on the radius arm with the retaining nut and
tighten to specifications.
13. 
Stabilizer Bar
REMOVAL & INSTALLATION
Ranger As required, raise and support the vehicle safely.
1. 
Remove the nuts and bolts retaining the stabilizer bar to the end links.
2. 
Remove the retainers and the stabilizer bar and bushings from the vehicle.
3. 
To install: Position the stabilizer bar to the axles and brackets.
4. 
Install the retainer and the end link bolts.
5. 
Torque the retainer bolts to 35-50 ft. lbs. (47-67 Nm) on 1991-94 models and 2-30 ft. lbs. (30-40
Nm) on 1995-99 models. Torque the end link nuts to 30-41 ft. lbs. (40-55 Nm).
6. 
1991-94 Explorer HOW TO USE THIS BOOK
Stabilizer Bar 873 
						

							Exploded view of the 1991-94 Explorer stabilizer bar and related parts-Ranger similar
Click to enlarge
As required, raise and support the vehicle safely.
1. 
Remove the nuts and washer and disconnect the stabilizer link assembly from the front I-beam axle.
2. 
Remove the mounting bolts and remove the stabilizer bar retainers from the stabilizer bar assembly.
3. 
Remove the stabilizer bar from the vehicle.
4. 
To install: Place stabilizer bar in position on the frame mounting brackets.
5. 
Install retainers and tighten retainer bolt to 35-50 ft. lbs. (47-67 Nm). If removed, install the
stabilizer bar link assembly to the stabilizer bar. Install the nut and washer and tighten to 30-41 ft.
lbs. (40-55 Nm).
6. 
Position the stabilizer bar link in the I-beam mounting bracket. Install the bolt and tighten to 30-41
ft. lbs. (40-55 Nm).
7. 
Mountaineer, 1995-99 Explorer and 1998-99 Ranger HOW TO USE THIS BOOK
874 REMOVAL & INSTALLATION