1991 1999 ford explorer chilton User Manual

Using the correct size wrench will help prevent the possibility of rounding off a nut
NEVER work under a vehicle unless it is supported using safety stands (jackstands)
Dos Do keep a fire extinguisher and first aid kit handy.
· 
Do wear safety glasses or goggles when cutting, drilling, grinding or prying, even if you have 20-20
vision. If you wear glasses for the sake of vision, wear safety goggles over your regular glasses.
· 
Do shield your eyes whenever you work around the battery. Batteries contain...

cracked sockets, slipping ratchets, or faulty droplight sockets can cause accidents.
Likewise, keep your tools clean; a greasy wrench can slip off a bolt head, ruining the bolt and often
harming your knuckles in the process.
· 
Do use the proper size and type of tool for the job at hand. Do select a wrench or socket that fits the
nut or bolt. The wrench or socket should sit straight, not cocked.
· 
Do, when possible, pull on a wrench handle rather than push on it, and adjust your stance to prevent a...

FASTENERS, MEASUREMENTS AND CONVERSIONS
Bolts, Nuts and Other Threaded Retainers
Although there are a great variety of fasteners found in the modern car or truck, the most commonly used
retainer is the threaded fastener (nuts, bolts, screws, studs, etc.). Most threaded retainers may be reused,
provided that they are not damaged in use or during the repair. Some retainers (such as stretch bolts or torque
prevailing nuts) are designed to deform when tightened or in use and should not be reinstalled....

Threaded retainer sizes are determined using these measurements
Click to enlarge
If you must replace a fastener, whether due to design or damage, you must ALWAYS be sure to use the
proper replacement. In all cases, a retainer of the same design, material and strength should be used. Markings
on the heads of most bolts will help determine the proper strength of the fastener. The same material, thread
and pitch must be selected to assure proper installation and safe operation of the vehicle afterwards....

When tightening a threaded fastener, torque is applied in three distinct areas, the head, the bearing surface and
the clamp load. About 50 percent of the measured torque is used in overcoming bearing friction. This is the
friction between the bearing surface of the bolt head, screw head or nut face and the base material or washer
(the surface on which the fastener is rotating). Approximately 40 percent of the applied torque is used in
overcoming thread friction. This leaves only about 10 percent of the...

Torque wrenches with pivoting heads must be grasped and used properly to prevent an incorrect
reading
Click to enlarge
Some torque wrenches (usually of the click type) may be equipped with a pivot head which can allow it to be
used in areas of limited access. BUT, it must be used properly. To hold a pivot head wrench, grasp the handle
lightly, and as you pull on the handle, it should be floated on the pivot point. If the handle comes in contact
with the yoke extension during the process of pulling, there...

seating torque and standard torque wrench are usually used first to remove any compliance from the joint. The
fastener is then tightened the specified additional portion of a turn measured in degrees. A torque angle gauge
(mechanical protractor) is used for these applications.
Standard and Metric Measurements
Throughout this manual, specifications are given to help you determine the condition of various components
on your vehicle, or to assist you in their installation. Some of the most common...

SERIAL NUMBER IDENTIFICATION
Vehicle Identification Number (VIN)
A 17 digit combination of numbers and letters forms the vehicle identification number (VIN). The VIN is
stamped on a metal tab that is riveted to the instrument panel close to the windshield. The VIN plate is visible
by looking through the windshield on the drivers side. The VIN number is also found on the Safety
Compliance Certification Label which is described below.
A sample breakdown of the VIN numberClick to enlarge
VIN plate...

The 3rd digit identifies the type of vehicle.
· 
C = Basic (stripped) chassis
D = Incomplete vehicle
M = Multi-purpose vehicle
T = Truck (complete vehicle) The 4th digit identifies the gross vehicle weight rating (GVWR Class) and brake system. For
incomplete vehicles, the 4th digit determines the brake system only. All brake systems are hydraulic.
· 
A = up to 3,000 lbs.
B = 3,001-4,000 lbs.
C = 4,001-5,000 lbs.
D = 5,001-6,000 lbs.
E = 6,001-7,000 lbs.
F = 7,001-8,000 lbs.
G = 8,001-8,500 lbs.
H =...

N = 1992
P = 1993
R = 1994
S = 1995
T = 1996
V = 1997
W = 1998
X = 1999 The 11th digit identifies the assembly plant.
· 
C = Ontario, Canada
H = Lorain, OH
K = Claycomo, MO
L = Wayne, MI
N = Norfolk, VA
P = St. Paul, MN
T = Edison, NJ
U = Louisville, KY
Z = Hazlewood, MO Digits twelve through seventeen make up the sequential serial and warranty number. Digit twelve
uses the letter A until the production or sequence of 99,999 units (digits thirteen through seventeen) is
reached. Letter A then becomes B...