1991 1999 ford explorer chilton User Manual

Lock the flywheel in place and remove the retaining bolts ...
Remove the flywheel attaching bolts and remove the flywheel.
3. 
... then remove the flywheel from the crankshaft
To install:
Position the flywheel on the crankshaft flange. Coat the threads of the flywheel attaching bolts with
Loctite® or equivalent and install the bolts. Tighten the bolts in sequence across from each other to
specifications.
4.  HOW TO USE THIS BOOK
434 REMOVAL & INSTALLATION 

Upon installation, apply a thread-locking compound to the flywheel bolts
On a manual shift transmission, install the clutch disc and pressure plate and cover assembly
following the procedures in Section 7.
5. 
Install the transmission following the procedure in Section 7.
6. 
Chilton® Automotive Information Systems. © 2004 Thomson Delmar Learning. HOW TO USE THIS BOOK
REMOVAL & INSTALLATION 435 

EXHAUST SYSTEM
Safety glasses should be worn at all times when working on or near the exhaust system. Older exhaust
systems will almost always be covered with loose rust particles which are more than a nuisance and
could injure your eye.
CAUTION
DO NOT perform exhaust repairs or inspection with the engine or exhaust hot. Allow the system to cool
completely. Exhaust systems are noted for sharp edges, flaking metal and rusted bolts. Gloves and eye
protection are required. A healthy supply of penetrating...

Check the muffler for rotted spot welds and seams
Your vehicle must be raised and supported safely at four points to inspect the exhaust system properly. Start
the inspection at the exhaust manifold where the header pipe is attached and work your way to the back of the
vehicle. On dual exhaust systems, remember to inspect both sides of the vehicle. Check the complete exhaust
system for open seams, holes, loose connections, or other deterioration which could permit exhaust fumes to
seep into the passenger...

Make sure the exhaust does contact the body or suspension
Check for overstretched or torn exhaust hangers HOW TO USE THIS BOOK
EXHAUST SYSTEM 439 

Example of a badly deteriorated exhaust pipe
Inspect flanges for gaskets that have deteriorated and need replacement
Some systems, like this one, use large O-rings (donuts) in between the flanges
REPLACEMENT
There are basically two types of exhaust systems. One is the flange type where the component ends are
attached with bolts and a gasket in-between. The other exhaust system is the slip joint type. These
components slip into one another using clamps to retain them together.
CAUTION
Allow the exhaust...

Nuts and bolts will be extremely difficult to remove when deteriorated with rust
CAUTION
Do NOT perform exhaust repairs or inspection with the engine or exhaust hot. Allow the system to cool.
Exhaust systems are noted for sharp edges, flaking metal and rusted bolts. Gloves and eye protection are
required.
Example of a flange type exhaust system jointHOW TO USE THIS BOOK
REPLACEMENT 441 

Example of a common slip joint type system
Raise and support the vehicle safely, as necessary for access. Remember that some longer exhaust
pipes may be difficult to wrestle out from under the vehicle if it is not supported high enough.
1. 
If you havent already, apply a generous amount of penetrating oil or solvent to any rusted fasteners.
2. 
On flange joints, carefully loosen and remove the retainers at the flange. If bolts or nuts are difficult to
break loose, apply more penetrating liquid and give...

ENGINE RECONDITIONING
Determining Engine Condition
Anything that generates heat and/or friction will eventually burn or wear out (for example, a light bulb
generates heat, therefore its life span is limited). With this in mind, a running engine generates tremendous
amounts of both; friction is encountered by the moving and rotating parts inside the engine and heat is created
by friction and combustion of the fuel. However, the engine has systems designed to help reduce the effects of
heat and friction...

A screw-in type compression gauge is more accurate and easier to use without an assistant
Install a screw-in type compression gauge into the No. 1 spark plug hole until the fitting is snug.
7. 
WARNING
Be careful not to crossthread the spark plug hole.
According to the tool manufacturers instructions, connect a remote starting switch to the starting
circuit.
8. 
With the ignition switch in the OFFposition, use the remote starting switch to crank the engine
through at least five compression strokes...