1991 1999 ford explorer chilton User Manual

							Use the torsion bar tool to relieve the tension from the bar
Use Torsion Bar Tool T95T-520-A, or equivalent, to raise the adjuster lever.
4. 
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-520-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.  HOW TO USE THIS BOOK
896 RIDE HEIGHT ADJUSTMENT 
						

							Bounce the vehicles front and rear suspensions several times to normalize the vehicle static ride
height.
3. 
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. (110-116mm).
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
Except Mountaineer, 1995-99 Explorer and 1998-99 Ranger HOW TO USE THIS BOOK
Shock Absorbers 897 
						

							Shock absorber and related parts
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
898 REMOVAL & INSTALLATION 
						

							To remove the front shock absorber, remove the lower radius arm shock retaining nut ...
... then pull the lower shock mount from the stud
Next, unbolt the upper shock mount using a second wrench on the mount stud to keep it from spinning ...
HOW TO USE THIS BOOK
REMOVAL & INSTALLATION 899 
						

							... then pull the shock assembly from the upper spring mount
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 25-3 ft. lbs. (3-46 Nm).
7. 
Mountaineer, 1995-99 Explorer and 1998-99 Ranger
WITHOUT AUTOMATIC RIDE CONTROL (ARC) HOW TO USE THIS BOOK
900 REMOVAL & INSTALLATION 
						

							Exploded view of the Mountaineer, 1995-99 Explorer and 1998-99 Ranger front shock
absorber
Click to enlarge
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
6.  HOW TO USE THIS BOOK
REMOVAL & INSTALLATION 901 
						

							loosely.
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. 
WITH AUTOMATIC RIDE CONTROL (ARC)
Exploded view of the ARC suspension shock absorberClick to enlarge
WARNING
Always turn off the Automatic Ride Control (ARC) service switch before lifting the vehicle off of the ground.
Failure to do so could damage the ARC system components. Refer to Section 1 for jacking procedures.
Place the vehicle in two-wheel drive.
1.  HOW TO USE THIS BOOK
902 REMOVAL & INSTALLATION 
						

							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.
2. 
Unplug the vehicle wire harness connector from the shock absorber pig tail plug. Disconnect the pig
tail frame retainers.
3. 
Disconnect the air line from the shock absorber. Push in and hold the plastic ring on the shock. While
holding the ring, pull the air line out firmly.
4. 
If removing the left front shock, disconnect the front height sensor from the upper bracket. Release
the spring clip and pull the sensor from the upper ball stud.
5. 
Remove the upper shock-to-frame attaching nut, washer and insulator assembly.
6. 
Remove the two lower shock-to-control arm attaching nuts.
7. 
Slightly compress the shock absorber by hand and remove it from the vehicle.
8. 
To install: Position the lower washer and insulator on the shock absorber rod and position the shock absorber to
the upper frame bracket mount.
9. 
Position the upper insulator and washer on the shock absorber rod and install the attaching nut
loosely.
10. 
Position the lower shock absorber mounting studs into the control arm and install the attaching nuts
loosely.
11. 
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).
12. 
If removed, connect the front height sensor to the upper bracket.
13. 
Connect the air line to the shock absorber. Push in and hold the plastic ring on the shock. While
holding the ring, push the air line in firmly.
14. 
Plug-in the vehicle wire harness connector to the shock absorber pig tail. Install the pig tail frame
retainers.
15. 
Lower the vehicle, then turn on the ARC service switch. Check the ARC system for normal operation
by switching the 4-wheel drive selector lever and observing vehicle movement.
16. 
TESTING
Please refer to the shock absorber testing procedure found in the 2-wheel drive section.
Ball Joints
INSPECTION HOW TO USE THIS BOOK
TESTING 903 
						

							Checking the ball joints
Click 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
6. 
REMOVAL & INSTALLATION
Except Mountaineer, 1995-99 Explorer and 1998-99 Ranger
The ball joints are arranged such that if the upper ball joint is to be removed, the lower ball joint must
be removed first. Also, when installing the upper ball joint, the lower ball joint must be installed first.
Failure to install the lower ball joint before the upper, 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-461-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 and install 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-461-C, forcing screw, D790T-3010-AE, ball joint installer,
T83T-3050-A and receiver cup T80T-3010-A3 or equivalent tools, to install the lower ball joint.
7. 
Turn the forcing screw clockwise until the lower ball joint is firmly seated. Install the snapring on the
lower ball joint.
8.  HOW TO USE THIS BOOK
904 INSPECTION 
						

							
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.
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 arms.
If the ball joint is defective, the entire control arm must be replaced. Refer to the appropriate control arm
removal & installation procedures later in the section.
Steering Knuckle
REMOVAL & INSTALLATION
Except Mountaineer, 1995-99 Explorer and 1998-99 Ranger Raise the vehicle and support on jackstands.
1. 
Remove the wheel and tire assembly.
2. 
Remove the caliper.
3. 
Remove hub locks and locknuts.
4. 
Remove the hub and rotor. Ensure that the wheel bearings do not fall out.
5. 
Remove the nuts retaining the spindle to the steering knuckle. Tap the spindle with a plastic or
rawhide hammer to jar the spindle from the knuckle. Remove the splash shield.
6. 
Remove the axle shaft for the side of the vehicle you are working on. Refer to Section 7 for axle shaft
removal procedures.
7. 
Remove the cotter pin from the tie rod nut and then remove the nut. Tap on the tie rod stud to free it
from the steering arm.
8. 
Remove the upper ball joint cotter pin and nut. Loosen the lower ball joint nut to the end of the stud.
9. 
Strike the inside of the spindle near the upper and lower ball joints to break the spindle loose from the
ball joint studs.
10. 
Remove the camber adjuster sleeve. If required, use pitman arm puller, T64P-3590-F or equivalent
to remove the adjuster out of the spindle. Remove the lower ball joint nut.
11. 
Remove the steering knuckle from the I-beam end.
12. 
To install: Install the steering knuckle to the I-beam end, engaging both upper and lower ball joints studs in their
respective holes.
13. 
Install the camber adjuster into the support arm. Position the slot in its original position.
14. 
CAUTION
The following torque sequence must be followed exactly when securing the spindle. Excessive spindle turning
effort may result in reduced steering returnability if this procedure is not followed.
Install a new nut on the bottom of the ball joint stud and torque to 90 ft. lbs. (minimum). Tighten to
align the nut to the next slot in the nut with the hole in the ball joint stud. Install a new cotter pin.
15. 
Install the snapring on the upper ball joint stud. Install the upper ball joint pinch bolt and torque the
nut to 48-65 ft. lbs.
16.  HOW TO USE THIS BOOK
REMOVAL & INSTALLATION 905