1991 1999 ford explorer chilton User Manual

LIGHTING
Headlights
REMOVAL & INSTALLATION
Examples of various types of automotive light bulbs
LIGHTING 717 

Exploded view of the front headlight assembly and related components
Click to enlarge
If equipped, open the headlight access panel by sliding the latch and lifting the panel upwards HOW TO USE THIS BOOK
718 REMOVAL & INSTALLATION 

Exploded view of the headlight bulb, retainer and wire harness plug
Click to enlarge
Open the vehicles hood and secure it in an upright position.
1. 
If necessary, open the bulb access panel by depressing the latch then lifting.
2. 
To remove the bulb, grasp the retainer and rotate it counterclockwise to unlock it ... HOW TO USE THIS BOOK
REMOVAL & INSTALLATION 719 

... then withdraw the bulb from the headlight lens housing
Unfasten the locking ring which secures the bulb and wire harness plug assembly, then withdraw the
assembly rearward.
3. 
Disconnect the electrical wire harness plug from the bulb and remove the locking ring as well.
4. 
Unplug the wire harness from the bulb and either slide the retainer over the plug, or remove it from the bulb
To install:
Before connecting a light bulb to the wire harness plug, ensure that all electrical contact surfaces are...

Close the bulb access panel and the vehicles hood.
9. 
AIMING THE HEADLIGHTS
The headlights must be properly aimed to provide the best, safest road illumination. The lights should be
checked for proper aim and adjusted as necessary. Certain state and local authorities have requirements for
headlight aiming; these should be checked before adjustment is made.
CAUTION
About once a year, when the headlights are replaced or any time front end work is performed on your vehicle,
the headlight should be...

Example of headlight adjustment screw location for composite headlamps
Click to enlarge
If aiming is to be performed outdoors, it is advisable to wait until dusk in order to properly see the
headlight beams on the wall. If done in a garage, darken the area around the wall as much as possible
by closing shades or hanging cloth over the windows.
2. 
Turn the headlights ONand mark the wall at the center of each lights low beam, then switch on the
brights and mark the center of each lights high beam. A short...

Low-beam headlight pattern alignment
Click to enlarge
High-beam headlight pattern alignment Click to enlarge
If neither beam on one side is working, and if another like-sized vehicle is available, park the second
one in the exact spot where the vehicle was and mark the beams using the same-side light. Then
switch the vehicles so the one to be aimed is back in the original spot. It must be parked no closer to
or farther away from the wall than the second vehicle.
4. 
Perform any necessary repairs, but...

1991-92 Ranger and Explorer (up to 1994) front turn signal and side marker lens assembly
Click to enlarge
Remove the screws retaining the headlight and trim assembly. On Explorer, remove the grille.
1. 
Carefully rotate the headlight and trim assembly away from the vehicle, rotating the inboard side
away from the vehicle.
2. 
Remove the side marker, parking and turn signal bulbs and sockets from the headlamp and trim
assembly. They can be removed by turning them.
3. 
If replacing a lens, remove the...

1993-99 models front signal and marker lens assembly
Click to enlarge
Remove the marker/turn signal lens retaining screws or nut.
1. 
To change a turn signal/marker bulb, first unfasten the lens from the body, the reach behind the lens ...
HOW TO USE THIS BOOK
REMOVAL & INSTALLATION 725 

... and grasp the lamp socket. Twist then pull the socket from the lens
Gently pull outward on the lens assembly to disengage the barbed retainers.
2. 
Twist the lamp socket and remove it from the lens.
3. 
Pull the bulb from the socket.
4. 
To remove the bulb from the socket, simply pull it straight out
To install:
Install the bulb into the lamp socket.
5. 
Install the lamp socket to the lens and twist it to lock it in position.
6. 
Position the lens assembly, ensure that the barbed retainers are...