1991 1999 ford explorer chilton User Manual

Exploded view of the typical transmission-to-engine mounting and related components
Click to enlarge
Exploded view of a 2.9L engine crossmember assembly-other models are similar Click to enlarge
Disconnect the negative battery cable.
1. 
Remove the gearshift lever assembly from the control housing.
2. 
Cover the opening in the control housing with a cloth to prevent dirt from falling into the unit.
3. 
Raise the vehicle and support it safely.
4.  HOW TO USE THIS BOOK
REMOVAL & INSTALLATION 761 

On 2WD vehicles, matchmark the driveshaft to the rear axle flange. Position a drain pan under the
tailend of the transmission. Remove the driveshaft-to-rear axle flange fasteners and pull the
driveshaft rearward to disconnect it from the transmission.
5. 
Disconnect the clutch hydraulic line a the clutch housing. Plug the lines.
6. 
Disconnect the speedometer from the transfer case/extension housing.
7. 
Disconnect the starter motor, back-up lamp and, if equipped, neutral sensing switch harness...

CLUTCH
Understanding the Clutch
The purpose of the clutch is to disconnect and connect engine power at the transmission. A vehicle at rest
requires a lot of engine torque to get all that weight moving. An internal combustion engine does not develop
a high starting torque (unlike steam engines) so it must be allowed to operate without any load until it builds
up enough torque to move the vehicle. To a point, torque increases with engine rpm. The clutch allows the
engine to build up torque by physically...

Clutch Interlock Switch
The clutch interlock switch has 3-functions. It is also known as the Clutch Pedal Position (CPP) switch and
provides the 3 following functions:
It requires the clutch pedal to be depressed to the floor in order to start the engine.
· 
If cuts off the speed control system when the clutch pedal is depressed.
· 
It provides a fuel control signal to the EEC system.
· 
REMOVAL & INSTALLATION Disconnect the negative battery cable.
1. 
Disconnect the connector at the switch by flexing...

Fluid level is checked at the master cylinder reservoir. The hydraulic clutch system continually remains in
adjustment, like a hydraulic disc brake system, so not clutch linkage or pedal adjustment is necessary.
REMOVAL & INSTALLATION
Typical hydraulic clutch system used on all modelsClick to enlarge
Disconnect the negative battery cable.
1. 
Disconnect the clutch master cylinder pushrod from the clutch pedal.
2. 
Remove the switch from the master cylinder assembly, if equipped.
3. 
Remove the screw...

flange of the bushing against the pedal blade.
Install the switch.
11. 
Bleed the system.
12. 
Reconnect the negative battery cable.
13. 
Slave Cylinder
REMOVAL & INSTALLATION
Slave cylinder
Click to enlarge
Before performing any service that requires removal of the slave cylinder, the master cylinder and
pushrod must be disconnected from the clutch pedal. If not disconnected, permanent damage to the
master cylinder assembly will occur if the clutch pedal is depressed while the slave cylinder is...

View of the clutch line coupling removal tool
Click to enlarge
Disconnect the negative battery cable.
1. 
Disconnect the coupling at the transmission, using the clutch coupling removal tool T88T-70522-A
or equivalent. Slide the white plastic sleeve toward the slave cylinder while applying a slight tug on
the tube.
2. 
Remove the transmission assembly.
3. 
On the 2.9L (4WD) vehicles, the clutch housing must be removed with the transmission assembly. Remove the slave cylinder-to-transmission retaining...

Reconnect the coupling to the slave cylinder.
9. 
Bleed the system.
10. 
Reconnect the negative battery cable.
11. 
BLEEDING THE SYSTEM
The following procedure is recommended for bleeding a hydraulic system installed on the vehicle. The largest
portion of the filling is carried out by gravity. It is recommended that the original clutch tube with quick
connect be replaced when servicing the hydraulic system because air can be trapped in the quick connect and
prevent complete bleeding of the system. The...

Exploded view of the clutch components for 2.3L, 2.5L, 3.0L & 4.0L engines-other engines are similar
Click to enlarge
Pressure plate bolt torque sequence
Disconnect the negative battery cable.
1.  HOW TO USE THIS BOOK
REMOVAL & INSTALLATION 769 

Disconnect the clutch hydraulic system master cylinder from the clutch pedal and remove.
2. 
Raise the vehicle and support it safely.
3. 
Remove the starter.
4. 
Disconnect the hydraulic coupling at the transmission.
5. 
Clean the area around the hose and slave cylinder to prevent fluid contamination. Remove the transmission from the vehicle.
6. 
Mark the assembled position of the pressure plate and cover the flywheel, to aid during re-assembly.
7. 
Loosen and remove the clutch and pressure plate bolts...