1991 1999 ford explorer chilton User Manual

When fluid is seeping out of the shock absorber, its time to replace it
Ball Joints
INSPECTION
Checking the ball jointsClick to enlarge
Check and adjust the front wheel bearings. Raise and support the vehicle.
1. 
Have a helper grasp the lower edge of the tire and move the wheel assembly in and out.
2. 
While the wheel is being moved, observe the lower spindle arm and the lower part of the axle jaw.
3. 
A 1
/32  in. (0.8mm) or greater movement between the lower part of the axle jaw and the lower spindle...

REMOVAL & INSTALLATION
Except Mountaineer, 1995-99 Explorer and 1998-99 Ranger
2WD ball joint removal-except Mountaineer, 1995-99 Explorer and 1998-99 Ranger Click to enlarge
HOW TO USE THIS BOOK
866 REMOVAL & INSTALLATION 

2WD ball joint installation-except Mountaineer, 1995-99 Explorer and 1998-99 Ranger
Click to enlarge
The ball joints are arranged such that if the upper ball joint is to be removed, the lower ball joint must
be removed first. Conversely, the upper ball joint must be installed first, before the lower ball joint.
Failure to install the upper ball joint before the lower, will result in a lack of clearance for the
installation tool.
Remove the steering knuckle.
1. 
Place knuckle in vise and remove snapring...

If the ball joint cannot be installed to the proper depth, realignment of the receiver cup and ball joint
installer will be necessary.
Repeat the previous steps for the upper ball joint. Install the snapring on the lower ball joint.
9. 
Install the steering knuckle.
10. 
Mountaineer, 1995-99 Explorer and 1998-99 Ranger
The ball joints on the Mountaineer, 1995-99 Explorer and 1998-99 Ranger are integral with the control arm.
If the ball joint is defective, the entire control arm must be replaced. Refer...

Remove the axle clamp bolt from the axle. Remove the camber adjuster from the upper ball joint stud
and axle beam.
10. 
Strike the area inside the top of the axle to pop the lower ball joint loose from the axle beam.
11. 
WARNING
Do not use a ball joint fork to separate the ball joint from the spindle, as this will damage the seal and the ball
joint socket!
Remove the spindle and the ball joint assembly from the axle.
12. 
To install:
A 3 step sequence for tightening ball joint stud nuts must be followed...

Exploded view of the Mountaineer, 295-99 Explorer and 298-99 Ranger steering knuckle
Click to enlarge
The steering knuckle and spindle are an integral assembly. Position the steering wheel to the on-center position.
1. 
Loosen the wheel lug nuts then raise and safely support the front of the vehicle.
2. 
Remove the wheels.
3. 
Remove the front disc brake caliper, bracket and rotor. Also remove the rotor splash shield.
4. 
Remove the cotter pin and nut retaining the tie rod end to the steering knuckle.
5....

Puller T64P-3590-F, or equivalent.
Remove the lower ball joint retaining nut and slowly raise the lower control arm until the ball joint
stud is disengaged from the steering knuckle.
11. 
Remove the upper ball joint retaining bolt and nut from the steering knuckle then disconnect the joint
from the knuckle.
12. 
Remove the steering knuckle/spindle assembly from the vehicle.
13. 
To install: Inspect the upper and lower ball joints and seals for damage and replace as needed.
14. 
Position the steering...

Radius rod and related components
Click to enlarge
Raise the front of the vehicle, place jackstands under the frame. Place a jack under the axle.
1. 
WARNING
The axle must be supported on the jack throughout spring removal and installation, and must not be permitted
to hang by the brake hose. If the length of the brake hose is not sufficient to provide adequate clearance for
removal and installation of the spring, the disc brake caliper must be removed from the spindle. After
removal, the caliper must be...

To install:
Position the front end of the radius arm to the axle. Install the attaching bolt from underneath, and
install the nut finger tight.
7. 
Install the retainer and inner insulator on the radius arm stud and insert the stud through the radius
arm rear bracket.
8. 
Install the rear washer, insulator and nut on the arm stud at the rear side of the arm rear bracket.
Tighten the nut to 82-113 ft. lbs. (113-153 Nm).
9. 
Tighten the nut on the radius arm-to-axle bolt to 188-254 ft. lbs. (255-345 Nm)....

Exploded view of the 1991-94 Explorer stabilizer bar and related parts-Ranger similar
Click to enlarge
As required, raise and support the vehicle safely.
1. 
Remove the nuts and washer and disconnect the stabilizer link assembly from the front I-beam axle.
2. 
Remove the mounting bolts and remove the stabilizer bar retainers from the stabilizer bar assembly.
3. 
Remove the stabilizer bar from the vehicle.
4. 
To install: Place stabilizer bar in position on the frame mounting brackets.
5. 
Install...