1991 1999 ford explorer chilton User Manual

CV-joint exploded view
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Removing the shroud from the outer bearing race and flange Click to enlarge
HOW TO USE THIS BOOK
812 DISASSEMBLY & ASSEMBLY 

Removing the ball bearings
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Assembling the inner bearing race and cage Click to enlarge
Place the driveshaft on a suitable workbench.
1. 
The CV joint components are matched. Extreme care should be take not to mix or substitute
components.
Remove the clamp retaining the shroud to the outer bearing race and flange assembly.
2. 
Carefully tap the shroud lightly with a blunt tool and remove the shroud. Be careful not to damage the
shroud, dust boot or outer bearing race and flange assembly....

Remove the circlip retaining the inner race assembly to the shaft, using snapring pliers. Discard the
clip and remove the inner race assembly.
7. 
If required, remove the clamp retaining the boot to the shaft and remove the boot.
8. 
Carefully pry the ball bearings from the cage. Be careful not to scratch or damage the cage, race or
ball bearings.
9. 
Rotate the inner race to align with the cage windows and remove the inner race through the wider end
of the cage.
10. 
To assemble: Install the inner...

Cutaway view of the coupling shaft and center support bearing
Click to enlarge
Remove the driveshaft from the vehicle.
1. 
Separate the driveshaft from the coupling shaft maintaining proper orientation.
2. 
Remove the nut retaining the half round yoke to the coupling shaft and remove the yoke.
3. 
Check the center bearing support for wear by rotating the outer area while holding the coupling shaft.
If any wear or roughness is evident, replace the bearing.
4. 
Inspect the rubber insulator for evidence of...

FRONT DRIVE AXLE
General Information
The front drive axle on the Ranger, Explorer and Mountaineer can be either the Dana 28 series, or the Dana 35
series. However, there are two versions of the Dana 35 and while both are an Independent Front Suspension
(IFS) axle, their differences are drastic.
The Mountaineer, 1995-99 Explorer and 1998-99 Rangers use a centrally mounted front differential with
unequal length upper and lower control arms and front axle halfshafts. Also, these axle assemblies do not use...

To remove the manual locking hub, remove the wheel and stud retainers (if equipped), then pull
the hub off
Remove the manual locking hub assembly from the rotor by pulling straight outward.
5. 
Inspect the O-ring seal on the back side of the hub assembly and, if damaged, replace it.
6. 
Installation is the reverse of the removal procedure. Ensure that the rotor mounting face is flat and
free of burrs, dirt or grease, especially where the O-ring seal makes contact.
7. 
Turn the hub assembly over ...
HOW...

... and inspect this rubber O-ring seal for damage. Replace as needed
Automatic Locking Hubs
REMOVAL & INSTALLATION
Except Mountaineer, 1995-99 Explorer and 1998-99 Ranger
OUTER HUB COVER
Exploded view of the automatic locking hubs and related components Click to enlarge
Loosen the front wheel lug nuts.
1. 
Raise and safely support the front of the vehicle.
2. 
Remove the lug nuts and wheel/tire assembly.
3. 
If equipped, remove the lug nut retainer washers from the wheel studs.
4. 
Some gentle tapping...

Exploded view of the locking cam assembly
Click to enlarge
Remove the outer hub cover.
1. 
Remove the snap-ring from the end of the splined axle shaft.
2. 
Remove the axle shaft spacer(s).
3. 
WARNING
Do not pry on the locking cam or thrust spacers during removal. Prying may damage the cam or spacers.
Pull the locking cam assembly and the two thrust spacers (behind cam assembly) from the wheel
bearing adjusting nut.
4. 
Installation is the reverse of the removal procedure. Make sure to install the two...

When installing the outer hub cover, ensure that the legs on the cover seat in the pockets on the
locking cam
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Mountaineer, 1995-99 Explorer and 1998-99 Ranger
While the Mountaineer, 1995-99 Explorer and 1998-99 Rangers technically have automatic locking hubs, the
system is mounted to the axle housing itself and is called a vacuum disconnect axle lock. Refer to the
procedures in this section.
Vacuum Disconnect Axle Lock
The vacuum disconnect axle locking system was used on the...

Exploded view of the vacuum disconnect axle lock assembly on Mountaineer, 1995-99 Explorer and 1998-99 Ranger
Click to enlarge
Raise and safely support the front of the vehicle.
1. 
If possible, support the right side of the vehicle slighly higher than the left. This will minimize the
amount of axle fluid lost when the center disconnect shift motor cover is removed.
Position a drain pan beneath the center disconnect shift motor cover.
2. 
Label and disconnect the vacuum lines at the shift motor.
3....