1991 1999 ford explorer chilton User Manual

Inspect the nylon bushings on the shift fork and if worn, replace them.
9. 
To assemble the shift motor and fork to the cover, proceed as follows: Lightly lubricate the O-ring on the motor shaft and slide it into the cover until it is fully
seated.
1. 
Install the motor shaft-to-cover snapring.
2. 
Install the inboard shift fork snapring.
3. 
Install the shift fork in the same position as was removed.
4. 
Install the outboard shift fork snapring.
5. 
10. 
Ensure that the locking collar inside the axle...

Since the rotor is removed, check that the wheel bearings are properly greased and that the rotor
grease seal is in acceptable condition.
Install the rotor on the spindle.
10. 
Install the wheel bearing, locknut, thrust bearing, snapring and locking hubs.
11. 
Install the disc brake calipers. Install the wheel and tire assembly.
12. 
Lower the vehicle. Tighten the lug nuts to specification.
13. 
Mountaineer, 1995-99 Explorer and 1998-99 Ranger
The Mountaineer, 1995-99 Explorer and 1998-99 Ranger models...

Exploded view of the right-hand axle shaft assembly and related components
Click to enlarge
Loosen the front wheel lug nuts.
1. 
Raise and support the vehicle safely. Remove the wheel and tire assembly.
2. 
Remove the disc brake calipers and support the caliper on the vehicles frame rail.
3. 
Remove the hub locks and lock nuts.
4. 
Remove the hub and rotor.
5. 
Remove the nuts retaining the spindle to the steering knuckle. Tap the spindle with a plastic or
rawhide hammer to jar the spindle from the...

Pull the axle shaft assemble out through the hole in the steering knuckle
Remove the left-hand side axle shaft by pulling the assembly out of the carrier and through the hole
in the steering knuckle (spindle mount).
8. 
Remove the right-hand axle shaft by performing the following: Remove and discard the right front axle joint boot clamp from the outer axle assembly.
1. 
Pull the right-hand axle shaft out of the axle joint boot and stub shaft and through the hole in
the steering knuckle (spindle mount)....

Position the rubber boot and clamp onto the outer axle shaft and crimp the clamp securely on the
rubber boot using Keystone Clamp Pliers T63P-9171-A.
3. 
Install the left-hand axle shaft by sliding it through the hole in the steering knuckle and engaging it
into the carrier. Ensure that the shaft is fully seated into the carrier and engage to the splines inside.
12. 
Install the front disc brake rotor shield, spindle and retaining nuts.
13. 
Install the front brake rotors, bearings, locknuts and hubs....

Remove the wheel hub nut (arrow) and discard it. NEVER reuse the wheel hub nut
Remove the upper ball joint-to-steering knuckle retaining bolt
Rotate the knuckle (1) downward and pull the CV-joint (2) out of the wheel hub by compressing the axle shaft (3) inwardHOW TO USE THIS BOOK
828 REMOVAL & INSTALLATION 

Using a CV-joint puller (arrow) to remove the inboard joint from the axle housing
Pull the entire halfshaft from the vehicle
Remove the outboard CV-joint from the wheel hub by slightly rotating the steering knuckle down,
taking care not to overstress the joint or boot, and pulling the CV-joint out from the hub.
9. 
Use a CV joint puller and impact slide hammer to pull the inboard CV-joint from the axle housing.
You can also use a prytool to carefully pry the CV-joint outward to disengage the internal...

Axle Housing
REMOVAL & INSTALLATION
Dana 28
Exploded view of the Dana 28 front drive axle found on Rangers-other models are similar Click to enlarge
Disconnect the negative battery cable.
1. 
Raise and support the vehicle safely. Remove the wheel and tire assembly.
2.  HOW TO USE THIS BOOK
830 Axle Housing 

Before removing the driveshaft from the front axle yoke, mark the yoke and driveshaft so that they can
be reassembled in the same relative position, thus eliminating driveshaft imbalance.
Disconnect the driveshaft from the front axle yoke.
3. 
Remove the disc brake calipers and support the caliper on the vehicles frame rail.
4. 
Remove the cotter pin and nut retaining the steering linkage to the spindle. Disconnect the linkage
from the spindle.
5. 
The axle arm assembly must be supported on the jack...

Dana 35
EXCEPT MOUNTAINEER, 1995-99 Explorer and 1998-99 Ranger
Exploded view of the Dana 35 front drive axle on Rangers-other models are similar Click to enlarge
Disconnect the negative battery cable.
1. 
Raise and support the vehicle safely. Remove the wheel and tire assembly.
2. 
Remove the spindle, shaft and joint assembly.
3. 
Before removing the driveshaft from the front axle yoke, mark the yoke and driveshaft so that they can
be reassembled in the same relative position, thus eliminating...