1991 1999 ford explorer chilton User Manual

							As necessary, remove all under dash panels in order to gain access to the ignition switch.
3. 
As necessary, lower the steering column to gain working clearance.
4. 
Disconnect the ignition switch electrical connectors.
5. 
Remove the ignition switch retaining screws from the studs. Disengage the ignition switch from
switch rod. Remove the switch from the vehicle.
6. 
To install: Position the lock cylinder in the LOCKposition.
7. 
To set the switch, position a wire in the opening in the outer surface of the switch through its positions
until the wire drops down into the slot.
8. 
The slot is in the bottom of the switch where the rod must be inserted to allow full movement through
the switch positions.
Position the ignition switch on the column studs and over the actuating rod. Torque the retaining nuts
to 40-64 inch lbs. (4.5-7.2 Nm).
9. 
Remove the wire from the slot in the housing. Continue the installation in the reverse order of the
removal procedure.
10. 
Ignition Lock Cylinder Assembly
REMOVAL & INSTALLATION Disconnect the negative battery cable. Remove the steering wheel.
1. 
On vehicles equipped with tilt wheel, remove the tilt lever.
2. 
On vehicles equipped with tilt wheel, remove the steering column collar by pressing on the collar
from the top and bottom while removing the collar.
3. 
Remove the instrument panel trim cover retaining screws. Remove the trim cover.
4. 
Remove the 2 screws from the bottom of the steering column shroud. Remove the bottom half of the
shroud by pulling the shroud down and toward the rear of the vehicle.
5.  HOW TO USE THIS BOOK
REMOVAL & INSTALLATION 947 
						

							Push the lock cylinder retaining pin then pull the cylinder from the column
Click to enlarge
Turn the lock cylinder with the ignition key in it to the ONposition. On vehicles equipped with
automatic transmission be sure that the selector lever is in the Pposition.
6. 
Push up on the lock cylinder retaining pin with a  1
/8  in. (3mm) diameter wire pin or small punch. Pull
the lock cylinder from the column housing. Disconnect the lock cylinder wiring plug from the horn
brush wiring connector.
7. 
To install: Prior to installation of the lock cylinder, lubricate the cylinder cavity, including the drive gear, with
Lubriplate® or equivalent.
8. 
To install the lock cylinder, turn the lock cylinder to the ONposition, depress the retaining pin. Insert
the lock cylinder housing into its housing in the flange casting. Be sure that the tab at the end of the
cylinder aligns with the slot in the ignition drive gear.
9. 
Turn the key to the OFFposition. This action will permit the cylinder retaining pin to extend into the
cylinder casting housing hole.
10. 
Using the ignition key rotate the lock cylinder to ensure correct mechanical operation in all positions.
Connect the key warning wire plug.
11. 
Install the steering column lower shroud. Install the steering wheel.
12. 
Check for proper vehicle operation in Pand N. Also be sure that the start circuit cannot be actuated in
Dor R.
13. 
Steering Column
REMOVAL & INSTALLATION HOW TO USE THIS BOOK
948 REMOVAL & INSTALLATION 
						

							Exploded view of the typical steering column assemblies and related components
Click to enlarge
CAUTION
Whenever working on a vehicle equipped with an air bag, always refer to Section 6 for disarming procedures.
Follow the procedures outlined or severe injury, or even death may occur.
Disconnect the negative battery cable. If equipped with an airbag, refer to Section 6 to disable the
system.
1. 
Set the parking brake. If equipped with automatic transmission position the selector lever in N.
2. 
Remove the bolt that holds the intermediate shaft to the steering column shaft.
3. 
Using the proper tool, compress the intermediate shaft until it is clear of the steering column shaft.
4. 
Remove the nuts from the studs and remove the shift cable bracket from the steering column bracket,
if the vehicle is equipped with automatic transmission.
5. 
If the vehicle is equipped with automatic transmission disconnect the shift cable from the column
lever. Remove the steering wheel.
6. 
If the vehicle is equipped with tilt wheel, be sure that the steering wheel is in the fall up position before
removing it.
On vehicles equipped with tilt wheel, remove the tilt lever.
7. 
On vehicles equipped with tilt wheel, remove the steering column collar by pressing on the collar
from the top and bottom while removing the collar.
8. 
Remove the instrument panel trim cover retaining screws. Remove the trim cover.
9.  HOW TO USE THIS BOOK
REMOVAL & INSTALLATION 949 
						

							Remove the 2 screws from the bottom of the steering column shroud. Remove the bottom half of the
shroud by pulling the shroud down and toward the rear of the vehicle.
10. 
If the vehicle is equipped with automatic transmission, move the shift lever as required to aid in
removal of the shroud. Lift the top half of the shroud from the column.
11. 
If the vehicle is equipped with automatic transmission, disconnect the selector indicator actuation
cable by removing the screw from the column casting and the plastic plug at the end of the cable.
12. 
To remove the plastic plug from the shift lever socket casting push on the nose of the plug until the
head clears the casting and pull the plug from the casting.
13. 
Remove the plastic clip that retains the combination switch wiring to the steering column bracket.
14. 
Remove the 2 screws form the multi function switch. Remove the switch from the column and leave
the wiring connectors attached to the switch. Position the switch and the wiring out of the way.
15. 
Disconnect the key warning buzzer wire from the horn brush wire. Remove the screw that holds the
horn brush connector to the column. Remove the connector.
16. 
Remove the 5 screws that hold the toe plate to the dash panel. Loosen the toe plate clamp bolt.
17. 
Support the steering column assembly. Remove the bolts that hold the breakaway bracket to the pedal
support bracket.
18. 
Pry apart the locking tabs and disconnect the ignition switch wiring harness. Carefully remove the
steering from the vehicle.
19. 
If the vehicle is equipped with automatic transmission, remove the shift cable bracket from the
column.
20. 
To install: If the vehicle is equipped with automatic transmission, install the shift cable bracket from the column.
Torque the cable bracket bolts to 13-22 ft. lbs. (17-31 Nm).
21. 
Position the steering column in the hole in the vehicle floor.
22. 
Connect the ignition switch wiring harness to the column connector. Install the column breakaway
bolts, but do not tighten.
23. 
Install and torque the toe plate bolts to 5-8 ft. lbs. Torque the toe plate clamp bolt to 62-97 inch lbs.
(7-11 Nm)
24. 
Torque the steering column breakaway bolts to 19-27 ft. lbs. (25-36 Nm).
25. 
Continue the installation in the reverse order of the removal procedure. Torque the steering column
shaft to the intermediate shaft U-joint pinch bolt to 25-34 ft. lbs. (34-46 Nm).
26. 
Steering Linkage HOW TO USE THIS BOOK
950 Steering Linkage 
						

							
2WD steering linkage assemblies, 4WD models similar-except Mountaineer, 1995-99 Explorer and 1998-99 Ranger
Click to enlarge
REMOVAL & INSTALLATION
Except Mountaineer, 1995-99 Explorer and 1998-99 Ranger
PITMAN ARM
As required, raise and safely support the vehicle using jackstands.
1. 
Remove the cotter pin and nut from the drag link ball stud at the pitman arm.
2. 
Remove the drag link ball stud from the pitman arm using pitman arm removal tool T64P-3590-F or
equivalent.
3. 
Remove the pitman arm retaining nut and washer. Remove the pitman arm from the steering gear
sector shaft using tool T64P-3590-F or equivalent.
4. 
To install: Installation is the reverse of the removal procedure. Torque the pitman arm attaching washer and nut
to 170-228 ft. lbs. (230-310 Nm). Torque the drag link ball stud nut to 51-73 ft. lbs. (70-100 Nm)
and install a new cotter pin.
5. 
Check and adjust front end alignment, as required.
6. 
TIE ROD
Raise and support the vehicle using jackstands. Be sure that the front wheels are in the straight ahead
position.
1. 
Remove the nut and cotter pin from the ball stud on the drag link. Remove the ball stud from the drag
link using pitman arm removal tool T64P-3590-F or equivalent.
2.  HOW TO USE THIS BOOK
REMOVAL & INSTALLATION 951 
						

							Loosen the bolts on the tie rod adjusting sleeve. Be sure to count and record the number of turns it
takes to remove the tie rod from the tie rod adjusting sleeve. Remove the tie rod from the vehicle.
3. 
To remove the tie rod end, first remove the cotter pin and discard it. A new pin will be used for installation
Loosen and remove the tie rod end retaining nut ... HOW TO USE THIS BOOK
952 REMOVAL & INSTALLATION 
						

							... then, using a jawed puller, loosen the tie rod stud-to-steering knuckle connection
Loosen the tie rod sleeve clamp bolts ...HOW TO USE THIS BOOK
REMOVAL & INSTALLATION 953 
						

							... and before unthreading the tie rod from the sleeve, make an installation mark on the threads
Lift the tie rod end out of the steering knuckle bore ...
... and unthread the tie rod end from the adjusting sleeve
To install:
Install the tie rod in the tie rod sleeve in the same number of turns it took to remove it. Torque the tie
rod adjusting sleeve nuts to 30-42 ft. lbs. (40-57 Nm).
4. 
Be sure that the adjusting sleeve clamps are pointed down ±45°. Tighten the tie rod ball stud to drag
link retaining bolt to 51-73 ft. lbs. (70-100 Nm). Install a new cotter pin.
5.  HOW TO USE THIS BOOK
954 REMOVAL & INSTALLATION 
						

							Check and adjust front end alignment, as required.
6. 
DRAG LINK
Raise and support the vehicle using jackstands. Be sure that the front wheels are in the straight ahead
position.
1. 
Remove the nuts and cotter pins from the ball stud at the pitman arm and steering tie rod. Remove the
ball studs from the linkage using pitman arm removal tool T64P-3590-F or equivalent.
2. 
Loosen the bolts on the drag link adjusting sleeve. Be sure to count and record the number of turns it
takes to remove the drag link.
3. 
To install: Install the drag link in the same number of turns it took to remove it. Tighten the adjusting sleeve nuts
to 30-42 ft. lbs. (40-57 Nm). Be sure that the adjusting sleeve clamps are pointed down ±45°.
4. 
Position the drag link ball stud in the pitman arm. Position the steering tie rod ball stud in the drag
link. With the vehicle wheels in the straight ahead position install and torque the nuts to 51-73 ft. lbs.
(70-100 Nm). Install a new cotter pin.
5. 
Check and adjust front end alignment, as required.
6. 
Mountaineer, 1995-99 Explorer and 1998-99 Ranger 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.
OUTER TIE ROD END
Position the front wheels in the straight ahead position.
1. 
Raise and safely support the vehicle, as necessary.
2. 
Remove and discard the outer tie rod end retaining nut cotter pin.
3. 
Remove the nut and install a puller to separate the tie rod end from the steering knuckle.
4. 
Hold the tie rod end with a wrench and loosen the jam nut.
5. 
Mark the exact position of the outer tie rod on the inner tie rod threads. Grip the tie rod end with a
pair of pliers and unscrew the outer end from the inner tie rod.
6. 
To install: Ensure that the inner tie rod threads are clean.
7. 
Thread the outer tie rod end onto the inner tie rod to the same location as marked earlier.
8. 
Install the out tie rod end stud into the steering knuckle then install and tighten the attaching nut to
57-77 ft. lbs. (77-104 Nm). Install new cotter pins, advancing (tightening) the nut as required.
NEVER loosen the nut to install the cotter pin.
9. 
Tighten the jam nut, while holding the outer tie rod, to 50-2 ft. lbs. (2-92 Nm).
10. 
Have the toe alignment checked and adjusted by a professional shop.
11. 
INNER TIE ROD END HOW TO USE THIS BOOK
REMOVAL & INSTALLATION 955 
						

							Cutaway view of the Mountaineer, 1995-99 Explorer and 1998-99 Ranger inner tie rod
assembly
Click to enlarge
Unlock the steering column, engage the parking brake then raise and safely support the vehicle.
1. 
Clean away and loose dirt or oil from the steering rack housing.
2. 
Loosen the jam nut but keep it flush with the outer tie rod end.
3. 
Remove the outer tie rod end, then remove the jam nut from the inner tie rod end.
4. 
Remove the steering rack housing from the vehicle.
5. 
Clean the areas around the boots where they attach to the steering rack housing.
6. 
Remove the clamps from the boots (both the small outer and large inner clamps) then remove the
boots from the housing, separating the vent tube while doing so. Note the location of the vent tube
ends at the boots.
7. 
Turn the input shaft as required to expose the flat at the outer end of the rack teeth. Ensure that
enough of the flat is exposed to engage an adjustable wrench to it.
8. 
WARNING
The torque required to break the inner tie rod loose could exceed 100 ft. lbs. (136 Nm). If this force is reacted
against the pinion teeth, sufficient damage may be incurred to affect the smoothness of operation.
Use a large wrench on the inner tie rod socket flats and an adjustable wrench on the rack teeth flats
and remove the tie rod.
9. 
To install: Install the inner tie rod end to the rack and using the two wrenches as per removal, tighten the tie rod
end to 81-95 ft. lbs. (110-130 Nm).
10. 
Apply 1 cu. in. (1639 cu. mm) of wheel bearing grease evenly around the large end of a new boot and
half as much grease to the small end. Install the new boots, working the vent tube onto its fittings, and
align them to their original positions.
11. 
Install new inner (large) clamps and reinstall the outer clamps.
12. 
Install the locknuts and outer tie rod ends.
13. 
Install the steering rack housing back into the vehicle.
14. 
Lower the vehicle. Have the front wheel alignment checked and adjusted by a professional shop.
15. 
Manual Steering Gear HOW TO USE THIS BOOK
956 Manual Steering Gear