1991 1999 ford explorer chilton User Manual

Before removing the transmission fluid pan, insure that the area is clean of dirt and debris
Place a large drain pan under the transmission.
2. 
Loosen all of the pan attaching bolts to within a few turns of complete removal
Loosen all of the pan attaching bolts to within a few turns of complete removal, then carefully break
the gasket seal allowing most of the fluid to drain over the edge of the pan.
3. 
CAUTION
DO NOT force the pan while breaking the gasket seal. DO NOT allow the pan flange to become...

Once the pan is removed, discard the old gasket and insure that the mating surfaces are clean
Inspect this magnet inside of the pan for any large pieces of debris. A light gray coating is normal
HOW TO USE THIS BOOK
118 DRAIN, PAN/FILTER SERVICE & REFILL 

Clean the pan thoroughly with a safe solvent and allow it to air dry
Clean the transmission oil pan thoroughly using a safe solvent, then allow it to air dry. DO NOT use a
cloth to dry the pan which might leave behind bits of lint. Discard the old pan gasket.
5.  HOW TO USE THIS BOOK
DRAIN, PAN/FILTER SERVICE & REFILL 119 

The transmission filter is secured by a mounting bolt (arrow). Some models may use two bolts
Click to enlarge
HOW TO USE THIS BOOK
120 DRAIN, PAN/FILTER SERVICE & REFILL 

Remove the filter mounting bolt ...
... then pull the filter free from the transmission
If necessary, remove the Automatic Transmission Fluid (ATF) filter mounting bolts, then remove the
filter by pulling it down and off of the valve body. Make sure any gaskets or seals are removed with
the old filter. The transmission usually has one round seal and a rectangular gasket.
6. 
Install the new oil filter screen making sure all gaskets or seals are in place, then secure using the
retaining screws, if...

Install a new pan gasket
Place a new gasket on the fluid pan, then install the pan to the transmission. Tighten the attaching
bolts to 71-119 inch lbs. (8-13 Nm).
8. 
Fill the transmission with the proper amount of ATF
Add three quarts (six quarts if the torque converter was drained) of fluid to the transmission through
the filler tube.
9. 
Remove the jackstands and carefully lower the vehicle.
10. 
Start the engine and move the gear selector through all gears in the shift pattern. Allow the engine to...

even shoot, out of the other cooler line.
Transfer Case
FLUID RECOMMENDATION
Use Mercon® automatic transmission fluid when refilling or adding fluid to the transfer case.
LEVEL CHECK Position the vehicle on level ground.
1. 
The transfer case fill/level check plug is the upper most plug, located on the rear of the case HOW TO USE THIS BOOK
Transfer Case 123 

Remove the plug using a 
3
/8  in. drive ratchet
Remove the transfer case fill plug (the upper plug) located on the rear of the transfer case. The fluid
level should be up to the fill hole.
2.  HOW TO USE THIS BOOK
124 LEVEL CHECK 

Once the plug is removed, fluid should trickle out of the hole. If not, add Mercon ATF fluid until
it does
If lubricant doesnt run out when the plug is removed, add lubricant until it does run out.
3. 
Replace the fill plug.
4. 
DRAIN & REFILL
The manufacturer recommends that the transfer case fluid should be changed every 60,000 miles (96,000km).
However, if the truck is driven in deep water (as high as the transfer case housing) it is a good idea to replace
the fluid. Little harm can come from a fluid...

LEVEL CHECK
The fluid level in the drive axles should be checked at each oil change. Like the manual transmission which is
available, the rear axle does not have a dipstick to check fluid level. Instead, a filler plug is located in the side
of the housing (or in the side of the cover), at a level just barely above the level to which fluid should fill the
housing. To check the fluid level:
To check the front drive axle fluid level, loosen the fill plug ...... then remove it. Fluid should trickle out of...