1991 1999 ford explorer chilton User Manual
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Make sure the transmission is in P(A/T) or in gear on a manual, then FIRMLY set the parking brake and block the drive wheels. 1. Check under the vehicle to see if there is sufficient clearance for you to access the filler plug on the side of the differential housing. If not you will have to raise and support the vehicle using jackstands at four points to make sure it is completely level. Failure to support the vehicle level will prevent from properly checking or filling the drive axle fluid. 2. Thoroughly clean the area surrounding the fill plug. This will prevent any dirt from entering the housing and contaminating the gear oil. 3. To check the rear drive axle fluid level, loosen the fill plug ...... then remove it. Fluid should trickle out of the hole HOW TO USE THIS BOOK LEVEL CHECK 127
If necessary, add the proper grade of lubricant until fluid trickles out Remove the fill plug and make sure that the gear oil is up to the bottom of the fill hole. If a slight amount of lubricant does not drip out of the hole when the plug is removed, additional lubricant should be added. Use hypoid gear lubricant SAE 80 or 90. 4. If the differential is a Traction-Lok limited-slip unit, be sure to use 4 oz. of Ford Friction Modifier C8AZ-19B546-A or equivalent special limited-slip additive with the lubricant. Once you are finished, install the fill plug, then (if raised) remove the jackstands and lower the vehicle. 5. DRAIN & REFILL Drain and refill the drive axle housings every 100,000 miles (160,000 km) or any time the vehicle is driven in high water (up to the axle). Although some fluid can be removed using a suction gun, the best method is to remove the axle housing cover (if equipped) to ensure that all of any present contaminants are removed. As with any fluid change, the oil should be at normal operating temperature to assure the best flow and removal of fluid/contaminants. Most front and some rear drive axle assemblies do not have a removable cover for fluid draining. However, these units may have a drain plug instead. Drain plug equipped drive axles can be serviced in the same manner as the manual transmission and/or transfer case. If no drain plug is found, you will need to use a suction gun through the fill hole to remove the fluid. The procedure below is for housing cover equipped axles. Drive the vehicle until the lubricant reaches normal operating temperature. 1. If necessary for access, raise and support the vehicle safely using jackstands, but be sure that the vehicle is level so you can properly refill the axle when you are finished. 2. If a suction gun is used to drain the fluid, remove the fill plug and insert the suction tube into the fill hole until it rests at the lowest most point inside the housing. Operate the suction gun as per the manufacturers directions. When the fluid is completely removed, skip to the differential filling procedure. HOW TO USE THIS BOOK 128 DRAIN & REFILL
Remove the fill plug, then clean the area around the axle housing cover to prevent dirt from entering it Use a wire brush to clean the area around the differential. This will help prevent dirt from contaminating the differential housing while the cover is removed. 3. Position a drain pan under the drive axle. 4. Loosen and remove all but two of the cover retaining bolts. Dont lose the axle identification tagLoosen and remove all but 2 of the housing covers upper or side retaining bolts. The remaining 2 bolts should then be loosened to within a few turns of complete removal. Use a small prytool to carefully break the gasket seal at the base of the cover and allow the lubricant to drain. Be VERY careful not to force or damage the cover and gasket mating surface. 5. HOW TO USE THIS BOOK DRAIN & REFILL 129
With the remaining bolts loose, carefully pry out on the cover (to break the seal) and allow the fluid to drain Once most of the fluid has drained, remove the remaining bolts and pull the cover from the housing Once most of the fluid has drained, remove the final retaining bolts and separate the cover from the housing. 6. HOW TO USE THIS BOOK 130 DRAIN & REFILL
To fill the differential: Carefully clean the gasket mating surfaces of the cover and axle housing of any remaining gasket or sealer. A putty knife is a good tool to use for this. You may want to cover the differential gears using a rag or piece of plastic to prevent contaminating them with dirt or pieces of the old gasket. 7. Remove any old gasket material from the sealing surfaces then clean them of any residual oil Install the housing cover using a new gasket and sealant. Tighten the retaining bolts using a crisscross pattern. 8. Make sure the vehicle is level before attempting to add fluid to the drive axle, otherwise an incorrect fluid level will result. Refill the drive axle housing using the proper grade and quantity of lubricant. Install the filler plug, operate the vehicle and check for any leaks. 9. Cooling System CAUTION Never remove the radiator cap under any conditions while the engine is running! Failure to follow these instructions could result in damage to the cooling system and/or personal injury. To avoid having scalding hot coolant or steam blow out of the radiator, use extreme care when removing the radiator cap from a hot radiator. Wait until the engine has cooled, then wrap a thick cloth around the radiator cap and turn it slowly to the first stop. Step back while the pressure is released from the cooling system. When you are sure the pressure has been released, press down on the radiator cap (with the cloth still in position), turn and remove the cap. HOW TO USE THIS BOOK Cooling System 131
Cut-away view of a typical cooling system flow Click to enlarge FLUID RECOMMENDATIONS The recommended coolant for all vehicles covered by this manual is a 50/50 mixture of ethylene glycol and water for year-round use. Choose an aluminum compatible, good quality antifreeze with water pump lubricants, rust inhibitors and other corrosion inhibitors along with acid neutralizers. INSPECTION Any time you have the hood open, glance at the coolant recovery tank to make sure it is properly filled. Top of the cooling system using the recovery tank and its markings as a guideline. If you top off the system, make a note of it to check again soon. A coolant level that consistently drops is usually a sign of a small, hard to detect leak, though in the worst case it could be a sign of an internal engine leak (blown head gasket/cracked block? ... check the engine oil for coolant contamination). In most cases, you will be able to trace the leak to a loose fitting or damaged hose (and you might solve a problem before it leaves you stranded). Evaporating ethylene glycol antifreeze will leave small, white (salt like) deposits, which can be helpful in tracing a leak. HOW TO USE THIS BOOK 132 FLUID RECOMMENDATIONS
Common cooling system components found on all models (not shown is the water pump)-3.0L equipped ranger shown, other models are similar Click to enlarge To add coolant, remove the lid from the coolant recovery tank ... HOW TO USE THIS BOOK INSPECTION 133
... then add enough coolant to attain the proper level as indicated on the tank. Use a funnel to avoid spills At least annually or every 12,000 miles (19,000 km), all hoses, fittings and cooling system connections should be inspected for damage, wear or leaks. Hose clamps should be checked for tightness, and soft or cracked hoses should be replaced. Damp spots, or accumulations of rust or dye near hoses or fittings indicate possible leakage. These must be corrected before filling the system with fresh coolant. The pressure cap should be examined for signs of deterioration and aging. The fan belt and/or other drive belt(s) should be inspected and adjusted to the proper tension. Refer to the information on drive belts found earlier in this section. Finally, if everything looks good, obtain an antifreeze/coolant testing hydrometer in order to check the freeze and boil-over protection capabilities of the coolant currently in your engine. Old or improperly mixed coolant should be replaced. Checking antifreeze protection with an inexpensive testerCAUTION When draining coolant, keep in mind that cats and dogs are attracted to ethylene glycol antifreeze, and are likely to drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain coolant into a sealable container. Coolant may be reused unless it is HOW TO USE THIS BOOK 134 INSPECTION
contaminated or several years old. At least once every 3 years or 36,000 miles (48,000 km), the engine cooling system should be inspected, flushed and refilled with fresh coolant. If the coolant is left in the system too long, it loses its ability to prevent rust and corrosion. If the coolant has too much water, it wont protect against freezing. If you experience problems with your cooling system, such as overheating or boiling-over, check the simple before expecting the complicated. Make sure the system can fully pressurize (are all the connections tight/is the radiator cap on properly, is the cap seal intact?). Ideally, a pressure tester should be connected to the radiator opening and the system should be pressurized and inspected for leaks. If no obvious problems are found, use a hydrometer antifreeze/coolant tester (available at most automotive supply stores) to check the condition and concentration of the antifreeze in your cooling system. Excessively old coolant or the wrong proportions of water and coolant will hurt the coolants boiling and freezing points. Check the Radiator Cap While you are checking the coolant level, check the radiator cap for a worn or cracked gasket. If the cap doesnt seal properly, fluid will be lost and the engine will overheat. Worn caps should be replaced with new ones. Be sure the rubber gasket on the radiator cap has a tight seal Clean Radiator of Debris Periodically, clean any debris-leaves, paper, insects, etc.- from the radiator fins. Pick the large pieces off by hand. The smaller pieces can be washed away with water pressure from a hose. HOW TO USE THIS BOOK INSPECTION 135
Periodically remove all debris from the radiator fins Carefully straighten any bent radiator fins with a pair of needle-nosed pliers. Be careful; the fins are very soft. Dont wiggle the fins back and forth too much. Straighten them once and try not to move them again. DRAINING, FLUSHING & REFILLING CAUTION When draining coolant, keep in mind that cats and dogs are attracted to ethylene glycol antifreeze, and are likely to drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain coolant into a sealable container. Coolant may be reused unless it is contaminated or several years old. A complete drain and refill of the cooling system at least every 30,000 miles (48,000 km) or 3 years will remove the accumulated rust, scale and other deposits. The recommended coolant for most late model cars is a 50/50 mixture of ethylene glycol and water for year-round use. Choose a good quality antifreeze with water pump lubricants, rust inhibitors and other corrosion inhibitors along with acid neutralizers. Before opening the radiator petcock, spray it with some penetrating lubricant. HOW TO USE THIS BOOK 136 DRAINING, FLUSHING & REFILLING