1991 1999 ford explorer chilton User Manual

Check the flywheel surface for flatness and, if necessary, remove it from the engine for truing
To install:
Position the clutch disc on the flywheel so that the Clutch Alignment Shaft Tool T74P-727-K or
equivalent can enter the clutch pilot bearing and align the disc.
10. 
Be sure that the flywheel surface is clean before installing the clutch HOW TO USE THIS BOOK
REMOVAL & INSTALLATION 771 

Typical clutch alignment tool, note how the splines match the transmissions input shaft
Use the clutch alignment tool to align the clutch disc during assembly.
When reinstalling the original pressure plate and cover assembly, align the assembly and flywheel
according to the marks made during the removal operations. Position the pressure plate and cover
assembly on the flywheel, align the pressure plate and disc, and install the retaining bolts that fasten
the assembly to the flywheel. Tighten the bolts...

Be sure to use a torque wrench to tighten all of the bolts
Install the transmission into the vehicle.
1. 
Connect the coupling by pushing the male coupling into the slave cylinder.
2. 
Connect the hydraulic clutch master cylinder pushrod to the clutch pedal.
3. 
Chilton® Automotive Information Systems. © 2004 Thomson Delmar Learning. HOW TO USE THIS BOOK
REMOVAL & INSTALLATION 773 

AUTOMATIC TRANSMISSION
Understanding the Automatic Transmission
The automatic transmission allows engine torque and power to be transmitted to the rear wheels within a
narrow range of engine operating speeds. It will allow the engine to turn fast enough to produce plenty of
power and torque at very low speeds, while keeping it at a sensible rpm at high vehicle speeds (and it does this
job without driver assistance). The transmission uses a light fluid as the medium for the transmission of
power. This...

View of the Park/Neutral Position (PNP) switch used on the A4LD transmission
Click to enlarge
Disconnect the negative battery cable.
1. 
Raise and support the vehicle safely.
2. 
Disconnect the harness connector from the neutral start switch.
3. 
Clean the area around the switch. Remove the switch and O-ring, using a thin wall socket (tool
T74P-77247-A or equivalent).
4. 
To install: Fit a new O-ring to the switch. Install the switch.
5. 
Reconnect the harness connector to the switch.
6. 
Lower the...

Remove the two Transmission Range (TR) sensor retaining bolts
Click to enlarge
Remove the manual control lever retaining nut as well as the lever.
6. 
Remove the two retaining bolts and the sensor.
7. 
To install: Ensure that the transmission shift lever is in the Neutral (N) position.
8. 
Install the TR sensor and loosely install the retaining bolts.
9.  HOW TO USE THIS BOOK
REMOVAL & INSTALLATION 777 

Align the new sensor with the Digital TR Sensor Alignment Tool
Click to enlarge
Align TR sensor slots using the Transmission Range Sensor Alignment Tool T97L-70010-AH, or
equivalent.
10. 
Tighten the retaining bolts to 7-9 ft. lbs. (9-12 Nm).
11. 
Install the manual control lever to the sensor and tighten the retaining bolt HOW TO USE THIS BOOK
778 REMOVAL & INSTALLATION 

Click to enlarge
Install the manual control lever to the sensor and tighten the retaining nut to 22-26 ft. lbs. (30-35
Nm).
12. 
Connect the TR sensor electrical wire harness plug.
13. 
Install the shift control cable to the transmission manual control lever.
14. 
Lower the vehicle and connect the negative battery cable.
15. 
Ensure that the wheels are still blocked and the parking brake is applied.
16. 
Check for proper operation of the switch. The engine should only start in Park (P) or Neutral (N)....

Remove the vacuum diaphragm retaining clamp and bolt, then pull the diaphragm out of the
transmission
Click to enlarge
Disconnect the negative battery cable.
1. 
Raise and support the vehicle safely.
2. 
Disconnect the hose from the vacuum diaphragm.
3. 
Remove the vacuum diaphragm retaining clamp bolt and clamp. Do not pry on the clamp.
4. 
Pull the vacuum diaphragm from the transmission case and remove the vacuum diaphragm control rod
from the transmission case.
5. 
To install: Install the vacuum...

Extension housing seal removal
Disconnect the negative battery cable.
1. 
Raise and support the vehicle safely.
2. 
Matchmark the driveshaft end yoke and rear axle companion flange to assure proper positioning
during assembly. Remove the driveshaft.
3. 
Remove the oil seal from the extension housing, using seal remover T71P-7657-A or equivalent.
4. 
To install:
Before install the replacement seal, inspect the sealing surface of the universal joint yoke for scores. If scoring
is found, replace the yoke....