1991 1999 ford explorer chilton User Manual

To access the fuses, remove the fuse panel cover. Note the spare fuses (A) and provided fuse
puller tool
Remove the fuse panel access cover.
2. 
If equipped, remove the fuse puller tool from the cover.
3. 
Using the provided tool or a pair of pliers, grasp the fuse and pull it from the panel
Grasp the push-in type fuse with the provided tool, or a pair of needle-nose pliers.
4. 
Look through the side of the fuse body to determine if the fuse element is blown.
5. 
To install: Check the amperage rating of...

WARNING
If the fuse continues to blow, inspect and test the wire harness and component or components which are
protected by that fuse.
Power Distribution Box
Located under the hood, in the engine compartment. It houses the fuses and relays for most of the under hood
components which are not controlled by a dash mounted switch (such as the alternator, fuel pump, ECM, etc.).
The fuses and relays are replaced in the same manner as the fuse panel inside the vehicle. The power
distribution box cover is hinged...

Turn Signal and Hazard Flasher Locations
Both the turn signal flasher and the hazard warning flasher are mounted on the fuse panel on the truck. To
gain access to the fuse panel, remove the cover from the lower edge of the instrument panel below the steering
column. First remove the two fasteners from the lower edge of the cover. Then pull the cover downward until
the spring clips disengage from the instrument panel.
The turn signal flasher unit is mounted on the front of the fuse panel, and the hazard...

WIRING DIAGRAMS
Sample diagram-how to read and interpret wiring
Common wiring diagram symbols
1991 Ranger 2.3L & 2.9L engine wiring
1991 Ranger 3.0L engine wiring
1991 Ranger 4.0L engine wiring
1991 Ranger body wiring
1991 Explorer 4.0L engine wiring
1991 Explorer body wiring
1992 Ranger 2.3L & 2.9L engine wiring
1992 Ranger 3.0L engine wiring
1992 Ranger 4.0L engine wiring
1992 Ranger body wiring
1992 Explorer 4.0L engine wiring
1992 Explorer body wiring
1993 Ranger 2.3L engine wiring
1993 Ranger 3.0L...

MANUAL TRANSMISSION
Understanding the Manual Transmission
Because of the way an internal combustion engine breathes, it can produce torque (or twisting force) only
within a narrow speed range. Most overhead valve pushrod engines must turn at about 2500 rpm to produce
their peak torque. Often by 4500 rpm, they are producing so little torque that continued increases in engine
speed produce no power increases.
The torque peak on overhead camshaft engines is, generally, much higher, but much narrower.
The...

SHIFTER & LINKAGE ADJUSTMENTS
Both of the 5-speed transmissions are directly controlled with a floor shift mechanism built into the
transmission extension housing. There are no adjustments necessary on these transmissions.
Shift Handle
REMOVAL & INSTALLATION Disconnect the negative battery cable.
1. 
Do not remove the shift knob, unless the shift knob or boot is to be replaced. Otherwise, remove the
shift knob, boot and lever as an assembly.
If necessary, remove the shift lever knob on the Mitsubishi...

Exploded view of the transmission shifter lever assembly
Click to enlarge
To install: Prior to installing the shift lever, lubricate the shift lever ball stud, using C1AZ-19590-B
(ESA-M1C75-B) or equivalent.
6. 
Fit the shift lever into place and install the retaining bolts. Tighten the retaining bolts to specifications.
7. 
Install the rubber boot and retaining screws.
8. 
If the shift lever knob was removed, heat it to 140°-180°F (60°-82°C), using a heat gun. Tap the
knob onto the shift lever, using a...

REMOVAL & INSTALLATION
Location of the transmission switches-Mazda 5-speedClick to enlarge
Location of the transmission switches-Mitsubishi 5-speed Click to enlarge
Disconnect the negative battery cable.
1. 
Raise and support the vehicle safely.
2. 
Place the transmission in any position other than N.
3.  HOW TO USE THIS BOOK
758 REMOVAL & INSTALLATION 

Clean the area around the switch, then remove the switch.
4. 
To install: Install the switch and tighten 8-11 ft. lbs. (11- 16Nm).
5. 
Reconnect the harness connector to the switch.
6. 
Lower the vehicle.
7. 
Reconnect the negative battery cable.
8. 
Extension Housing Seal
REMOVAL & INSTALLATION
Two Wheel Drive Models
Extension housing seal removal
Disconnect the negative battery cable.
1. 
Raise and support the vehicle safely.
2. 
Place a suitable drain pan beneath the extension housing. Clean the area...

Check and adjust the transmission fluid level, using Ford manual transmission lube
D8DZ-19C217-A (ESP-M2C83-C) or equivalent.
8. 
Lower the vehicle.
9. 
Reconnect the negative battery cable.
10. 
Extension housing seal installationClick to enlarge
Four Wheel Drive Models
Refer to the transfer case procedures for the front and/or rear output shaft seals.
Transmission
REMOVAL & INSTALLATION HOW TO USE THIS BOOK
760 REMOVAL & INSTALLATION