1991 1999 ford explorer chilton User Manual

							Exploded view of the Mountaineer, 1995-99 Explorer and 1998-99 Ranger stabilizer bar
mounting
Click to enlarge
Raise and safely support the vehicle.
1. 
Remove the nut, washer and bushing (on underside of the lower control arm) linking the stabilizer bar
end to the lower control arm.
2. 
Lift up on the bar and remove the remaining bushings and the spacer and bolt assembly (called the
end link) from the stabilizer bar end.
3. 
Remove the bar mounting bracket-to-frame bolts.
4. 
Remove the stabilizer bar from the vehicle. If necessary, remove the mounting brackets and insulators
from the bar.
5. 
To install: Inspect all of the stabilizer bar mounting and end link bushings. Replace any that are cracked,
squashed, swollen or damaged.
6. 
Position the stabilizer bar mounting brackets to the frame and install the retaining bolts loosely.
7. 
Install the end link assembly to the bar end and the lower control arm. Install the end link retaining
bolt loosely.
8. 
Tighten the mounting bracket bolts to 65-91 ft. lbs. (88-119 Nm).
9. 
The end link assembly must be tightened with the vehicle weight on the front wheels. Lower the vehicle then tighten the end link retaining nut to 10-13 ft. lbs. (13-17 Nm).
10.  HOW TO USE THIS BOOK
REMOVAL & INSTALLATION 875 
						

							
I-Beam Axle
REMOVAL & INSTALLATION
Exploded view of the front I-beam axle assemblyClick to enlarge
Raise and safely support the vehicle. Remove the front wheel spindle. Remove the front spring.
Remove the front stabilizer bar, if equipped.
1. 
Remove the spring lower seat from the radius arm, and then remove the bolt and nut that attaches the
stabilizer bar bracket, if equipped, and the radius arm to the (I-Beam) front axle.
2. 
Remove the axle-to-frame pivot bracket bolt and nut.
3. 
To install: Position the axle to the frame pivot bracket and install the bolt and nut finger tight.
4. 
Position the opposite end of the axle to the radius arm, install the attaching bolt from underneath
through the bracket, the radius arm and the axle. Install the nut and tighten to 188-254 ft. lbs.
(255-345 Nm).
5. 
Install the spring lower seat on the radius arm so that the hole in the seat indexes over the
arm-to-axle bolt.
6. 
Install the front spring.
7.  HOW TO USE THIS BOOK
876 I-Beam Axle 
						

							
Lower the vehicle on its wheels or properly support the vehicle at the front springs before tightening
the axle pivot bolt and nut.
Tighten the axle-to-frame pivot bracket bolt to 111-148 ft. lbs. (150-200 Nm).
8. 
Install the front wheel spindle.
9. 
Upper Control Arm
Only the Mountaineer, 1995-99 Explorer and 1998-99 Ranger models have control arms.
REMOVAL & INSTALLATION HOW TO USE THIS BOOK
REMOVAL & INSTALLATION 877 
						

							Exploded views of the right and left upper control arms
Click to enlarge
After performing this procedure, it will be necessary to have the wheel alignment checked and adjusted
by a professional shop.
Position the steering wheel to the on-center position. Loosen the wheel lug nuts.
1. 
Raise and safely support the vehicle. Position the jack stands under the lower control arms.
2. 
Remove the wheel lug nuts and wheel.
3. 
Before removing the steering knuckle-to-upper ball joint retaining (pinch) bolt, secure the steering
knuckle from tilting. HOW TO USE THIS BOOK
878 REMOVAL & INSTALLATION 
						

							Remove the steering knuckle-to-upper ball joint retaining (pinch) bolt and separate the two
components.
4. 
Make alignment marks on the control arm pivot bolt cam assemblies.
5. 
To remove the left side control arm proceed as follows: Remove the nuts and cam bolts from the control arm pivot points.
1. 
Pull the control arm from the vehicle frame.
2. 
6. 
To remove the right side control arm, proceed as follows: If only the ball joint is to be removed, make alignment marks on the control arm and ball joint
assembly then remove the two retaining nuts and the ball joint. Skip to the installation
procedures.
1. 
Remove the nuts and cam bolts from the control arm pivot points.
2. 
Pull the control arm from the vehicle frame.
3. 
7. 
To install: For right-side control arm, if removed, install the ball joint assembly and retaining nuts to the control
arm and tighten the nuts to 95-128 ft. lbs. (128-173 Nm).
8. 
Install the control arm pivot points into the frame pockets.
9. 
Install the cam bolts and nuts, align the matchmarks and tighten the nuts to 84-113 ft. lbs. (113-153
Nm).
10. 
Connect the upper ball joint shaft to the steering knuckle. Install the retaining (pinch) bolt and tighten
to 30-41 ft. lbs. (40-55 Nm).
11. 
Install the wheel and snug the lug nuts.
12. 
Lower the vehicle and tighten the lug nuts to 100 ft. lbs. (135 Nm).
13. 
Have the alignment checked by a professional repair shop.
14. 
Lower Control Arm
Only the Mountaineer, 1995-99 Explorer and 1998-99 Ranger models have control arms.
REMOVAL & INSTALLATION HOW TO USE THIS BOOK
Lower Control Arm 879 
						

							Exploded view of the lower control arm assembly
Click to enlarge
To remove the lower control arm, the torsion bar must be removed. Anytime the torsion bar is
disturbed, the ride height must be checked and adjusted.
Position the steering wheel to the on-center position. Loosen the wheel lug nuts.
1. 
Raise and safely support the vehicle.
2. 
Remove the wheel lug nuts and wheel.
3. 
Disconnect the stabilizer bar link bolt from the lower control arm.
4. 
Remove the front shock absorber.
5. 
Remove the torsion bar.
6. 
Remove the lower ball joint retaining nut cotter pin and loosen the nut but do not remove it.
7. 
Disconnect the lower ball joint stud from the steering knuckle using a jawed puller, such as Pitman
Arm Puller T64P-3590-F, or equivalent.
8. 
WARNING
Fasten a support, either out of a block of wood or wire wrapped around the frame, and support the weight of
the steering knuckle/brake assembly. Do not allow the steering knuckle/brake assembly to hang from the
upper ball joint as this may damage the joint.
Position a jack under the lower control arm then remove the lower ball joint retaining nut.
9. 
Raise the lower control arm until the lower ball joint stud is free from the steering knuckle.
10. 
Remove the two nuts and bolts retaining the lower arm pivot points to the frame crossmember.
11. 
Remove the lower control arm from the frame pockets. Some careful prying may ease the removal of
the arm.
12. 
To install: Inspect the lower ball joint, boot and pivot bushings. If any inspected components are worn or
damaged, the entire control arm must be replaced.
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880 REMOVAL & INSTALLATION 
						

							
Do not tighten the lower control arm mounting bolts to the final torque until the end of the installation
procedure.
Position the lower control arm pivot points into the frame and crossmember pockets. Install the bolts
and nuts and snug the bolts.
14. 
Position a jack under the lower control arm.
15. 
Install the torsion bar.
16. 
Raise the lower control arm to allow the lower ball joint stud to be inserted into the steering knuckle.
17. 
Lower the control arm assembly and ensure that the lower ball joint stud protrudes through the
steering knuckle bore.
18. 
Install the lower ball joint attaching nut and tighten to 83-113 ft. lbs. (113-153 Nm). Install a new
cotter pin, advancing (tightening) the nut as required. Never loosen the retaining nut in order to install
the cotter pin.
19. 
Install the shock absorber.
20. 
Install the wheel and snug the lug nuts.
21. 
Lower the vehicle and tighten the lug nuts to 100 ft. lbs. (135 Nm).
22. 
The lower control arm-to-frame bolts must be tightened with the weight of the vehicle resting on the
wheels. If clearance permits, allow the vehicle to sit on the ground while tightening the bolts.
If necessary, raise the vehicle again and position either car ramps under the wheels or jackstands on
the lower control arms, as close to the wheels as possible.
23. 
Tighten the control arm-to-frame bolts to 111-148 ft. lbs. (150-200 Nm).
24. 
Lower the vehicle.
25. 
Check and adjust the ride height.
26. 
While it should not be necessary, have the wheel alignment checked by a professional shop.
27. 
Front Wheel Bearings
REMOVAL & INSTALLATION Raise and support the vehicle safely. Remove the tire and wheel assembly from the hub and rotor.
1. 
Remove the caliper from its mounting and position it to the side with mechanics wire in order to
prevent damage to the brake line hose.
2. 
Remove the grease cap from the hub. Remove the cotter pin, retainer, adjusting nut and flatwasher
from the spindle.
3. 
Remove the outer bearing cone and roller assembly from the hub. Remove the hub and rotor from the
spindle.
4.  HOW TO USE THIS BOOK
Front Wheel Bearings 881 
						

							Remove the nut and washer from the spindle ...
... then remove the outer bearingHOW TO USE THIS BOOK
882 REMOVAL & INSTALLATION 
						

							Pull the hub and rotor assembly from the spindle
Using seal removal tool 1175-AC or equivalent remove and discard the grease seal. Remove the
inner bearing cone and roller assembly from the hub.
5. 
Clean the inner and outer bearing assemblies in solvent. Inspect the bearings and the cones for wear
and damage. Replace defective parts, as required.
6. 
Use a small prytool to remove the old sealHOW TO USE THIS BOOK
REMOVAL & INSTALLATION 883 
						

							With the seal removed, the inner bearing may be withdrawn from the hub
If the cups are worn or damaged, remove them with front hub remover tool T81P-1104-C and tool
T77F-1102-A or equivalent.
7. 
Wipe the old grease from the spindle. Check the spindle for excessive wear or damage. Replace
defective parts, as required.
8. 
To install: If the inner and outer cups were removed, use bearing driver handle tool T80-4000-W or equivalent
and replace the cups. Be sure to seat the cups properly in the hub.
9. 
Use a bearing packer tool and properly repack the wheel bearings with the proper grade and type
grease. If a bearing packer is not available work as much of the grease as possible between the rollers
and cages. Also, grease the cone surfaces.
10. 
Thoroughly pack the bearing with fresh, high temperature wheel bearing grease
Position the inner bearing cone and roller assembly in the inner cup. A light film of grease should be
included between the lips of the new grease retainer (seal).
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884 REMOVAL & INSTALLATION