1991 1999 ford explorer chilton User Manual

							
The camber adjuster will seat itself into the knuckle at a predetermined position during the tightening
sequence. Do not attempt to adjust this position.
Install the axle shaft or shafts that were removed.
17. 
Install the splash shield and spindle onto the steering knuckle. Install and tighten the spindle nuts to
40-50 ft. lbs.
18. 
Install the rotor on the spindle and push the outer wheel bearing inwards to seat it..
19. 
Install the locknuts and adjust the wheel bearings. Install the remainder of the locking hub assemblies.
20. 
Mountaineer, 1995-99 Explorer and 1998-99 Ranger WARNING
Do not perform this procedure unless a new wheel hub nut and washer assembly is available. Once removed,
these parts must never be reused during assembly.
Position the steering wheel to the on-center position.
1. 
WARNING
If equipped, 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.
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. 
If equipped, unbolt the front wheel ABS sensor and wire harness from the steering knuckle.
5. 
Remove the front wheel hub nut and washer.
6. 
WARNING
Never reuse the wheel hub nut and washer. This nut is a torque prevailing design and cannot be reused.
Remove the cotter pin and nut retaining the tie rod end to the steering knuckle.
7. 
Disconnect the tie rod end from the steering knuckle using a jawed puller, such as Pitman Arm Puller
T64P-3590-F, or equivalent.
8. 
Unload the torsion bar. Follow the torsion bar removal procedures, but do not remove the bar.
9. 
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.
10. 
Disconnect the lower ball joint from the steering knuckle using a jawed puller, such as Pitman Arm
Puller T64P-3590-F, or equivalent.
11. 
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.
12. 
The hub shaft is a slip fit into the wheel hub and bearing; a press is not normally required. Ensure that the wheel hub shaft can be pushed inwards. If not, assemble a press to the front wheel
studs and press the wheel hub shaft inwards slightly to break it loose.
13. 
Remove the upper ball joint retaining bolt and nut from the steering knuckle then disconnect the joint
from the knuckle.
14. 
Remove the steering knuckle/spindle assembly from the vehicle.
15. 
To install: Inspect the upper and lower ball joints and seals for damage and replace as needed.
16. 
Position the steering knuckle onto the upper ball joint, while aligning the axle shaft with the wheel
17.  HOW TO USE THIS BOOK
906 REMOVAL & INSTALLATION 
						

							hub, and install the retaining bolt and nut. Tighten the bolt to 30-41 ft. lbs. (40-55 Nm).
Install the lower ball joint stud into the steering knuckle until the stud protrudes through the knuckle.
18. 
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.
19. 
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.
20. 
If removed, install the ABS sensor to the wheel hub.
21. 
Install the hub washer and nut then tighten to 157-213 ft. lbs. (212-288 Nm).
22. 
Install the front disc brake splash shield, rotor, bracket and caliper.
23. 
Install the wheel and snug all of the lug nuts.
24. 
Reload the torsion bar pressure. Refer to the torsion bar installation procedures. Check and, if
necessary, set the vehicle ride height.
25. 
Lower the vehicle and tighten the wheel lug nuts to 100 ft. lbs. (135 Nm).
26. 
Radius Arm
Radius arms are not used on Mountaineer, 1995-99 Explorer and 1998-99 Ranger models.
REMOVAL & INSTALLATION
Radius rod and related partsClick to enlarge
Raise the front of the vehicle, place jackstands under the frame. Place a jack under the axle.
1. 
WARNING
HOW TO USE THIS BOOK
Radius Arm 907 
						

							
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 stud. Remove the front spring from the vehicle.
2. 
Remove the spring lower seat and stud from the radius arm. Remove the bolts that attach the radius
arm to the axle and front bracket.
3. 
Remove the nut, rear washer and insulator from the rear side of the radius arm rear bracket.
4. 
Remove the radius arm from the vehicle. Remove the inner insulator and retainer from the radius arm
stud.
5. 
To install: Position the front end of the radius arm from bracket to axle. Install the retaining bolts and stud in the
bracket finger tight.
6. 
Install the retainer and inner insulator on the radius arm stud and insert the stud through the radius
arm rear bracket.
7. 
Install the rear washer, insulator and nut on the arm stud at the rear side of the arm rear bracket.
Tighten the nut to 80-120 ft. lbs.
8. 
Tighten the stud to 190-230 ft. lbs. Tighten the front bracket to axle bolts to 37-50 ft. lbs. and the
lower bolt and washer to 190-230 ft. lbs.
9. 
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. Tighten the axle pivot bolt to 120-150 ft. lbs.
10. 
Install the front spring. Connect the lower stud of the radius arm and torque the retaining nut to 39-53
ft. lbs. on 1991-94 vehicles.
11. 
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 22-30 ft. lbs. (30-40
Nm) on 1995-99 models. Torque the end link nuts to 30-41 ft. lbs. (40-55 Nm).
6.  HOW TO USE THIS BOOK
908 REMOVAL & INSTALLATION 
						

							To remove the stabilizer bar, first unbolt the stabilizer bar end-to-radius arm links ...
... then remove the bar retainer strap bolts followed by the bar and its bushings
If necessary, remove the end link-to-radius arm mounting bolts to remove the end links
1991-94 Explorer
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.  HOW TO USE THIS BOOK
REMOVAL & INSTALLATION 909 
						

							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 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. 
I-Beam Axle
The I-beam axle is part of the front drive axle assembly. Refer to Section 7 for front drive axle housing
removal and installation procedures.
Upper Control Arm
Only the Mountaineer, 1995-99 Explorer and 1998-99 Ranger models have control arms.
REMOVAL & INSTALLATION HOW TO USE THIS BOOK
910 REMOVAL & INSTALLATION 
						

							Exploded view of the left and right 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
REMOVAL & INSTALLATION 911 
						

							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
912 Lower Control Arm 
						

							Exploded view of the lower control arm
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.
13.  HOW TO USE THIS BOOK
REMOVAL & INSTALLATION 913 
						

							
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
Except Mountaineer, 1995-99 Explorer and 1998-99 Ranger HOW TO USE THIS BOOK
914 Front Wheel Bearings 
						

							Inspect the bearings for abnormal wear and/or damage
WITH MANUAL LOCKING HUBS
Raise the vehicle and install jackstands.
1. 
Remove the wheel and tire assembly.
2. 
Remove the retainer washers from the lug nut studs and remove the manual locking hub assembly
from the spindle.
3. 
Remove the snapring and spacer from the end of the spindle shaft.
4. 
Remove the outer wheel bearing locknut from the spindle using 4 prong spindle nut spanner wrench,
T86T-1197-A or equivalent. Make sure the tabs on the tool engage the slots in the locknut.
5. 
Remove the locknut washer from the spindle.
6. 
Remove the inner wheel bearing locknut from the spindle using 4 prong spindle nut spanner wrench,
T86T-1197-A or equivalent. Make sure the tabs on the tool engage the slots in the locknut.
7. 
Remove the outer bearing cone and roller assembly from the hub. Remove the hub and rotor from the
spindle.
8. 
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.
9. 
Clean the inner and outer bearing assemblies in solvent. Inspect the bearings and the cones for wear
and damage. Replace defective parts, as required.
10. 
If the cups are worn or damaged, remove them with front hub remover tool T81P-1104-C and tool
T77F-1102-A or equivalent.
11. 
Wipe the old grease from the spindle. Check the spindle for excessive wear or damage. Replace
defective parts, as required.
12.  HOW TO USE THIS BOOK
REMOVAL & INSTALLATION 915