1991 1999 ford explorer chilton User Manual

ADJUSTMENTS
Measuring the steering gear preload
Preload and Meshload
INSPECTION
Raise and support the front of the vehicle on jackstands.
1. 
Disconnect the pitman arm at the ball stud.
2. 
Lubricate the wormshaft seal with a drop of automatic transmission fluid.
3. 
Remove the horn pad from the steering wheel.
4. 
Turn the steering wheel slowly to one stop.
5. 
Using an inch-pound torque wrench on the steering wheel nut, check the amount of torque needed to
rotate the steering wheel through a 1 1
/2...

Rotate the wormshaft stop-to-stop counting the total number of turns and center the shaft (
1
/2  the
total turns).
8. 
Using the torque wrench and socket, measure the torque required to turn the shaft 90° to either side of
center.
9. 
Turn the sector shaft adjusting screw as needed to bring the meshload torque within the 9-11 inch lbs.
range, or at least 4 inch lbs. higher than the preload torque.
10. 
Hold the adjusting screw while tightening the locknut to 14-25 ft. lbs.
11. 
Install the gear.
12....

Place the pitman arm on the sector shaft and install the attaching washer and nut. Align the 2 blocked
teeth on the Pitman arm with 4 missing teeth on the steering gear sector shaft. Tighten the nut to
12-228 ft. lbs. (230-310 Nm).
9. 
Install the flex coupling to steering gear input shaft attaching bolt and tighten to 50-62 ft. lbs. (68-84
Nm).
10. 
Snap the flex coupling shield to the steering gear input shield.
11. 
Check the system to ensure equal turns from center to each lock position.
12. 
Power...

View of the power steering gear and related parts used on Ranger and 1991-94 Explorer
Click to enlarge
Disconnect the pressure and return lines from the steering gear. Plug the lines and the ports in the gear
to prevent entry of dirt.
1. 
Remove the upper and lower steering gear shaft U-joint shield from the flex coupling. Remove the
bolts that secure the flex coupling to the steering gear and to the column steering shaft assembly.
2. 
Raise the vehicle and remove the pitman arm attaching nut and...

Power Rack and Pinion Steering Gear
REMOVAL & INSTALLATION WARNING
If equipped, always turn off the Automatic Ride Control (ARC) service switch before lifting the vehicle off of
the ground. Failure to do so could damage the ARC system components. Refer to Section 1 for jacking
procedures.
Raise and safely support the front of the vehicle, block the rear wheels and apply the parking brake.
1. 
Start the engine then rotate the steering wheel from lock-to-lock and record the number of rotations.
2. 
Divide...

Exploded view of the power rack and pinion steering gear mounting
Click to enlarge
Unscrew the quick-connect fittings for the power steering pressure and return hoses at the steering
gear housing.
7. 
Plug the ends of the lines and the fitting in the rack to avoid dirt contamination.
8. 
Remove the two nuts securing the power steering cooler and remove the cooler.
9. 
Remove the outer tie rod ends.
10. 
Remove the two nuts, bolts and washer assemblies retaining the steering gear housing to the front...

Position the steering gear to the front crossmember and install the nuts, bolts and washer assemblies.
Tighten to 94-127 ft. lbs. (128-11 Nm).
12. 
Install the power steering cooler and two retaining bolts.
13. 
Connect the power steering lines to the steering gear housing and tighten the fittings to 20-25 ft. lbs.
(27-34 Nm).
14. 
Install the outer tie rod ends.
15. 
Ensure that the steering shaft or gear input shaft has not been rotated, then connect the two.
16. 
Install the intermediate...

Exploded view of the power steering pump used on the 3.0L engine
Click to enlarge
HOW TO USE THIS BOOK
964 REMOVAL & INSTALLATION 

Exploded view of the power steering pump used on the 4.0L engine
Click to enlarge
Disconnect the negative battery cable.
1. 
Remove some power steering fluid from the reservoir by disconnecting the fluid return line hose at
the reservoir. Drain the fluid into a container and discard it.
2. 
Remove the pressure hose from the pump. If equipped, disconnect the power steering pump pressure
switch.
3. 
On the 2.3L, 2.5L and 3.0L engines, loosen the idler pulley assembly pivot and adjusting bolts to
slacken...

Install power steering pump pulley removal tool T69L-10300-B or equivalent. Hold the pump and
rotate the tool counterclockwise to remove the pulley. Do not apply in and out pressure to the pump
shaft, as internal pump damage will occur.
9. 
Remove the power steering retaining bolts. Remove the power steering pump from the vehicle.
10. 
To install: Position the pump on the bracket. Install and tighten the retaining bolts.
11. 
Install the pulley removal tool and install the power steering pump pulley to...