1991 1999 ford explorer chilton User Manual

Extension housing seal installation
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Transmission Assembly
REMOVAL & INSTALLATION Disconnect the negative battery cable.
1. 
Raise the vehicle and support it safely.
2. 
Position a drain pan under the transmission pan and drain the transmission fluid.
3. 
Remove the converter access cover from the lower right side of the converter housing on the 3.0L
engine. Remove the cover from the bottom of the engine oil pan on the 2.3L and 2.5L engine.
Remove a bolt on the access cover of the 2.9L...

Torque converter nut access hole
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Remove the flywheel to converter attaching nuts. Use a socket and breaker bar on the crankshaft
pulley attaching bolt. Rotate the pulley clockwise as viewed from the front to gain access to each of
the nuts.
5. 
On belt driven overhead cam engines, never rotate the pulley in a counterclockwise direction as viewed
from the front. HOW TO USE THIS BOOK
REMOVAL & INSTALLATION 783 

Remove the Vehicle Speed Sensor (VSS) clamp retaining bolt ...
... then pull the VSS sensor from the transfer case (4WD) or extension housing (2WD)
Remove the speedometer cable and/or vehicle speed sensor from the transfer case (4WD) or extension
housing (2WD).
6. 
On 2WD vehicles, scribe a mark indexing the driveshaft to the rear axle flange. Remove the
driveshaft.
7.  HOW TO USE THIS BOOK
784 REMOVAL & INSTALLATION 

On 4WD vehicles, remove the transfer case.
8. 
Speedometer cable connectionClick to enlarge
Disconnect the shift rod or cable at the transmission manual lever and retainer bracket.
9. 
Disconnect the downshift cable from the downshift lever. Depress the tab on the retainer and remove
the kickdown cable from the bracket.
10. 
Disconnect all of the transmission wire harness plugs.
11. 
Remove the starter mounting bolts and the ground cable. Remove the starter.
12. 
If equipped, remove the vacuum line from...

the transmission-to-engine bolts are tightened as if to force the transmission to mate to the engine.
Proper installation of the converter requires full engagement of the converter hub in the pump gear. To
accomplish this, the converter must be pushed and at the same time rotated through what feels like 2 notches
or bumps. When fully installed, rotation of the converter will usually result in a clicking noise heard, caused
by the converter surface touching the housing to case bolts.
Lightly lubricate...

Handles which thread onto the converter-to-flywheel studs can be use to ease the installation
process
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Check dimension A to ensure that the converter is fully seated into the transmission and pump
This should not be a concern, but an indication of proper converter installation since, when the converter is
attached to the engine flywheel, it will be pulled slightly forward away from the bolt heads. Besides the
clicking sound, the converter should rotate freely with no binding.
For...

ADJUSTMENTS
Shift/Manual Linkage
SHIFT SELECT LEVER
Exploded views of the shift cable assembly and mountingClick to enlarge
Before performing the linkage adjustment, confirm that the shift indicator is properly adjusted. Turn the vehicle OFF, block the rear wheels and engage the parking brake.
1. 
From inside the vehicle, place the gear shift lever in the overdrive position (shown as a circle with the
letter D in the middle). On 1991 vehicles, hang an 8 lb. (3.6Kg) weight on the lever. On 1992-99...

Unlock the cable adjuster body by pushing down on the two tangs and releasing the lock tab.
5. 
Move the shift cable back and forth the full adjustment length four or five times to remove any
accumulated dirt. Ensure that the adjuster body moves freely.
6. 
Move the transmission manual control lever all the way rearward (counterclockwise) to its last
position, then move it forward three detent positions. The transmission is now set in the overdrive
position.
7. 
Holding the cable end fitting, push it...

On 1991 vehicles, the pointer is adjusted by loosening the cable lock screw
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On 1991 vehicles, loosen the indicator cable end screw, then move the cable end to properly position
the pointer until it is centered on the overdrive graphic. Tighten the cable end screw.
10. 
On 1992 and later vehicles, there are two styles of thumb wheel adjusters. One style is mounted to the indicator assembly ...
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HOW TO USE THIS BOOK
790 ADJUSTMENTS 

... the other style is mounted to the underside of the column
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On 1992-99 vehicles, turn the adjuster thumb wheel to properly position the pointer until it is
centered on the overdrive graphic.
11. 
If removed, install the ignition switch lock cylinder.
12. 
Install the upper and lower steering column shrouds and the steering wheel.
13. 
Remove the weight from the lever.
14. 
Operate the shift select lever in all positions and ensure that the indicator pointer aligns with all of the...