1991 1999 ford explorer chilton User Manual

							Click to enlarge
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. 
Loosen the inner wheel bearing locknut using 4 prong spindle nut spanner wrench, tool
T86T-1197-A or equivalent. Make sure that the tabs on the tool engage the slots in the locknut and
that the slot in the tool is over the pin on the locknut.
7. 
Tighten the inner locknut to 35 ft. lbs. (6 Nm) to seat the bearings.
8. 
Spin the rotor and back off the inner locknut  1
/4  turn. Install the lockwasher on the spindle. Retighten
the inner locknut to 16 inch lbs. (1.8 Nm). It may be necessary to turn the inner locknut slightly so
that the pin on the locknut aligns with the closest hole in the lockwasher.
9. 
Install the outer wheel bearing locknut using 4 prong spindle nut spanner wrench, tool T86T-1197-A
or equivalent. Tighten locknut to 150 ft. lbs.
10. 
Install the axle shaft spacer.
11. 
Clip the snapring onto the end of the spindle.
12. 
Install the manual hub assembly over the spindle. Install the retainer washers.
13. 
Install the wheel and tire assembly. Install and torque lug nuts to specification.
14. 
Check the end-play of the wheel and tire assembly on the spindle. End-play should be 0.001-0.003
in. (0.025-0.076mm) and the maximum torque to rotate the hub should be 25 inch lbs. (2.8Nm).
15. 
WITH AUTOMATIC LOCKING HUBS
Exploded view of the automatic locking hubs and wheel bearings Click to enlarge
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 automatic locking hub assembly
from the spindle.
3. 
Remove the snapring and spacer from the end of the spindle shaft.
4. 
Pull the locking cam assembly and the two plastic spacers off of the wheel bearing adjusting nut.
5. 
Use a magnet and remove the locking key from under the adjusting nut. If required, rotate the
adjusting nut slightly to relieve pressure against the locking key.
6. 
WARNING
HOW TO USE THIS BOOK
926 ADJUSTMENT 
						

							
To prevent damage to the adjusting nut and spindle threads on vehicles equipped with automatic hubs, look
into the spindle keyway under the adjusting nut and remove the separate locking key before removing the
adjusting nut.
Loosen the wheel bearing locknut using a 2- 3
/8  inch (60.3mm) hex socket, such as Hex Locknut
Wrench T70T-152-B.
7. 
Tighten the inner locknut to 35 ft. lbs. (6 Nm) to seat the bearings.
8. 
Spin the rotor and back off the inner locknut  1
/4  turn (90°). Retighten the locknut to 16 inch lbs. (1.8
Nm).
9. 
Align the closest lug in the bearing adjusting nut with the center of the spindle keyway slot. Advance
the nut to the next if required.
10. 
Install the separate locking key in the spindle keyway under the adjusting nut.
11. 
CAUTION
Extreme care must be taken when aligning the adjusting nut with the center of the spindle keyway slot to
prevent damage to the separate locking key. The wheel and tire assembly may come off while the vehicle is in
motion if the key is damaged.
Install the two plastic thrust spacers and push or press the cam assembly onto the adjusting nut by
lining up the keyway in the cam assembly with the separate locking key.
12. 
WARNING
Do not damage the locking key when installing the cam assembly.
Install the axle shaft spacer.
13. 
Clip the snapring onto the end of the spindle.
14. 
Install the manual hub assembly over the spindle. Install the retainer washers.
15. 
Install the wheel and tire assembly. Install and torque lug nuts to specification.
16. 
Check the endplate of the wheel and tire assembly on the spindle. End-play should be 0.001-0.003
in. (0.025-0.076mm) and the maximum torque to rotate the hub should be 25 inch lbs. (2.8Nm).
17. 
Mountaineer, 1995-99 Explorer and 1998-99 Ranger
The Mountaineer, 1995-99 Explorer and 1998-99 Ranger use non-adjustable wheel bearings. If the endplate
is not within specifications, the wheel bearings must be replaced. End-play should be 0.000-0.003 in.
(0.00-0.08mm).
Wheel Alignment
Please refer to 2-wheel drive front suspension wheel alignment, earlier in this section.
Chilton® Automotive Information Systems. © 2004 Thomson Delmar Learning. HOW TO USE THIS BOOK
ADJUSTMENT 927 
						

							
REAR SUSPENSION
Introduction
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REAR SUSPENSION 929 
						

							Rear suspension-Ranger (top); Explorer & Mountaineer (bottom)
Click to enlarge
Leaf Springs
REMOVAL & INSTALLATION HOW TO USE THIS BOOK
930 Introduction 
						

							Exploded view of the Ranger U-bolt and spring plate assembly-Explorer/Mountaineer similar
Click to enlarge
Exploded view of the spring-to-rear shackle assembly Click to enlarge
HOW TO USE THIS BOOK
REMOVAL & INSTALLATION 931 
						

							View of the spring-to-front bracket mounting
Click to enlarge
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.
Raise the vehicle and install jackstands under the frame. The vehicle must be supported in such a way
that the rear axle hangs free with the tires still touching the ground.
1. 
Remove the nuts from the spring U-bolts and drive the U-bolts from the U-bolt plate.
2. 
Remove the spring to bracket nut and bolt at the front of the spring.
3. 
Remove the shackle upper and lower nuts and bolts at the rear of the spring.
4. 
Remove the spring and shackle assembly from the rear shackle bracket.
5. 
To install: Position the spring in the shackle. Install the upper shackle spring bolt and nut with the bolt head
facing outward.
6. 
Position the front end of the spring in the bracket and install the bolt and nut.
7. 
Position the shackle in the rear bracket and install the nut and bolt.
8. 
Position the spring on top of the axle with the spring tie bolt centered in the hole provided in the seat.
9. 
Lower the vehicle to the floor. Torque the spring U-bolt nuts to 65-75 ft. lbs. Torque the front spring
bolt to 75-115 ft. lbs. Torque the rear shackle nuts and bolts to 75-115 ft. lbs.
10. 
Shock Absorbers
REMOVAL & INSTALLATION HOW TO USE THIS BOOK
932 Shock Absorbers 
						

							
Without Automatic Ride Control (ARC)
Rear shock absorber and related parts-RangerClick to enlarge
HOW TO USE THIS BOOK
REMOVAL & INSTALLATION 933 
						

							Explorer & Mountaineer rear shock absorber
Click to enlarge
Raise the vehicle and position jackstands under the axle or wheel, in order to take the load off of the
shock absorber.
1. 
Remove the shock absorber lower retaining nut and bolt. Swing the lower end free of the mounting
bracket on the axle housing.
2. 
Remove the retaining nut(s) from the upper shock absorber mounting.
3. 
Remove the shock absorber from the vehicle.
4. 
Installation is the reverse of the removal procedure. Torque the lower shock absorber retaining bolt to
39-53 ft. lbs.
5. 
On the Ranger torque the upper shock absorber mounting nut to 39-53 ft. lbs. On the
Explorer/Mountaineer torque the upper shock absorber retaining nuts to 15-21 ft. lbs.
6.  HOW TO USE THIS BOOK
934 REMOVAL & INSTALLATION 
						

							To remove the rear shock absorber, first unbolt the lower shock mounting from the drive axle ...
... then pull the lower shock mount from its bracket
Finally, unbolt the upper shock mount and remove the shock from the vehicle
With Automatic Ride Control (ARC) HOW TO USE THIS BOOK
REMOVAL & INSTALLATION 935 
						

							Assembled view of the ARC suspension rear shock absorber
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.
Place the vehicle in two wheel drive.
1. 
Turn off the ARC control service switch.
2. 
Raise the rear of the vehicle and place the jackstands under the rear axle assembly.
3. 
Pry the rear shock absorber electrical connector retainer from the cross member then disconnect the
plug.
4. 
Disconnect the air line at the shock absorber by pushing in and holding the plastic ring while firmly
pulling outward on the air line.
5. 
Remove the lower shock absorber mounting nut and bolt assembly and swing the shock out of the
bracket.
6. 
Remove the two upper shock attaching nuts from the top of the crossmember then remove the shock.
7. 
Installation is the reverse of the removal procedure. Tighten the upper attaching nuts to 15-21 ft. lbs.
(21-29 Nm) and the lower attaching bolt to 39-53 ft. lbs. (53-72 Nm).
8. 
TESTING Visually check the shock absorbers for the presence of fluid leakage. A thin film of fluid is
acceptable. Anything more than that means that the shock absorber must be replaced.
1. 
Disconnect the lower end of the shock absorber. Compress and extend the shock fully as fast as
possible. If the action is not smooth in both directions, or there is no pressure resistance, replace the
shock absorber. Shock absorbers should be replaced in pairs. In the case of relatively new shock
absorbers, where one has failed, that one, alone, may be replaced.
2.  HOW TO USE THIS BOOK
936 TESTING