1991 1999 ford explorer chilton User Manual

INSPECTION
Loosen the wheel lug nuts.
1. 
Raise and safely support the vehicle. Remove the wheel.
2. 
Looking through the rear brake caliper pad inspection hole, measure the pad thickness from the rotor
surface to the pads metal backing.
3. 
Minimum pad thickness is  1
/8  in. (3.12mm), however, your local safety inspection laws may
supersede this dimension. Contact the appropriate authorities for specific safety requirements.
4. 
Any pad which is below the minimum allowable thickness will require you...

OVERHAUL
The rear disc brake caliper is overhauled in the same manner as the front disc brake caliper. Refer to those
procedures earlier in this section.
Brake Disc
REMOVAL & INSTALLATION Remove the rear disc brake caliper, but do not disconnect the brake hose.
1. 
If equipped, remove the press-on keeper nuts from the wheel studs.
2. 
Remove the rear brake rotor from the axle flange by pulling it straight outwards.
3. 
If the rotor binds on the rear parking brake shoes, remove the adjuster plug from the...

REAR ANTI-LOCK BRAKE SYSTEM (RABS)
Component Location
RABS component locations for 1991-96 modelsClick to enlarge
The RABS consists of the following components: RABS module-located in the dash under the instrument panel mount on a brace, center of panel area.
1. 
Dual Solenoid Electro-Hydraulic Valve is located 5 in. (127mm) rearward of the No. 1 crossmember
on the inboard side of the LH frame rail.
2. 
Speed Sensor and Exciter Ring-located in the rear differential housing.
3. 
Yellow REAR ANTI-LOCK...

Diode/Resistor Element (1991-96)-located three inches left of the cluster connector takeouts in the
instrument panel wiring harness.
7. 
Diode/Resistor Element (1997)-located in the power distribution box, under the hood.
8. 
Sensor test Connector-located under the hood slightly rearward the washer bottle.
9. 
System Self-Test
RABS trouble code indexClick to enlarge
The RABS module performs system tests and self-tests during startup and normal operation. The valve,
sensor and fluid level circuits are...

obtained only when the yellow light is ON. Before reading the code, drive the vehicle to a level area and place
the shift lever in the PARK or NEUTRAL position. Keep the vehicle ignition ON.
Starting in 1993, all vehicles use the RABS II system. The major difference between the two systems is
the addition of keep alive memory (codes are stored, even if ignition is turned off), and a code 16 can be
set which means the system is operating properly.
TO OBTAIN THE FLASH CODE: Locate the RABS diagnostic...

TESTING
Remove the RABS sensor from the axle housing. Connect a Digital Volt/Ohm Meter (DVOM) across the two sensor terminals and record the reading.
1. 
The reading should be between 0.8 and 1.4 k Ohms.
2. 
If not, replace the sensor.
3. 
REMOVAL & INSTALLATION Thoroughly clean the axle housing around the sensor.
1. 
Disconnect the electrical harness plug from the sensor.
2. 
To remove the rear wheel sensor, first disconnect the electrical harness plug ...... then remove the sensor-to-axle housing...

Pull the sensor up and out of the axle housing
Remove the sensor hold-down bolt.
3. 
Remove the sensor by pulling it straight out of the axle housing.
4. 
Ensure that the axle surface is and that no dirt can enter the housing.
5. 
If a new sensor is being installed, lubricate the O-ring with clean engine oil. Carefully push the
sensor into the housing aligning the mounting flange hole with the threaded hole in the housing.
Torque the hold-down bolt to 30 ft. lbs. If the old sensor is being installed,...

PARKING BRAKE
Cable
ADJUSTMENT
1991-92 models
PRE-TENSION PROCEDURE
Pre-tension adjustmentClick to enlarge
This procedure is to be used when a new Tension Limiter has been installed. Depress the parking brake pedal.
1. 
Grip the Tension Limiter Bracket to prevent it from spinning and tighten the equalizer nut 2 1
/2  in.
(63.5mm) up the rod.
2. 
Check to make sure the cinch strap has slipped less than 1 3
/8  in. (35mm) remaining.
3. 
FINAL ADJUSTMENT
This procedure is to be used to remove the slack...

The Tension Limiter will reset the parking brake tension any time the system is disconnected provided
the distance between the bracket and the cinch strap hook is reduced during adjustment. When the
cinch strap contacts the bracket, the system tension will increase significantly and over tensioning may
result. If all available adjustment travel has been used, the tension limiter must be replaced.
1993-99 Models
Starting in 1993, all models use a self-adjusting parking brake cable assembly. However, in...

CABLE TENSION RESETTING
Exploded view of the parking brake control assembly mounting Click to enlarge
In the event that one of the cables has broken, or the cable tension release procedures were not followed
perform the following procedures:
Remove the parking brake control assembly.
1.  HOW TO USE THIS BOOK
ADJUSTMENT 1051