1991 1999 ford explorer chilton User Manual
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To drain the cooling system, open the radiator petcock (arrow) and allow the coolant to drain into a container HOW TO USE THIS BOOK DRAINING, FLUSHING & REFILLING 137
A length of hose (A) can be fitted to the petcock (B) to help direct the flow of the coolant and avoid spills Click to enlarge Drain the existing antifreeze and coolant. Open the radiator and engine drains (petcocks) or disconnect the bottom radiator hose at the radiator outlet. The engine block drain plugs can also be temporarily removed to drain coolant, but they are often hard to get at and it is not really necessary for this procedure. 1. Close the petcock or reconnect the hose (and install any block drain plugs which may have been removed), then fill the system with water. 2. Add a can of quality radiator flush. 3. Idle the engine until the upper radiator hose gets hot. 4. Drain the system again. 5. Repeat this process until the drained water is clear and free of scale. 6. HOW TO USE THIS BOOK 138 DRAINING, FLUSHING & REFILLING
Close all petcocks and connect any loose hoses. 7. If equipped with a coolant recovery system, flush the reservoir with water and leave empty. 8. To refill the system with coolant, remove the radiator cap. NEVER remove the cap if the system is HOT Use a funnel to avoid spills and fill the radiator with a 50/50 mixture of water/antifreeze Determine the capacity of the coolant system, then properly refill the cooling system with a 50/50 mixture of fresh coolant and water, as follows: Fill the radiator with coolant until it reaches the radiator filler neck seat. 1. Start the engine and allow it to idle until the thermostat opens (the upper radiator hose will become hot). 2. Turn the engine OFFand refill the radiator until the coolant level is at the filler neck seat. 3. Fill the engine coolant overflow tank with coolant to the FULL HOT mark, then install the radiator cap. 4. 9. If available, install a pressure tester and check for leaks. If a pressure tester is not available, run the engine until normal operating temperature is reached (allowing the system to naturally pressurize), then check for leaks. 10. HOW TO USE THIS BOOK DRAINING, FLUSHING & REFILLING 139
The system should be pressure checked whenever leakage is suspected and cant be seen CAUTION If you are checking for leaks with the system at normal operating temperature, BE EXTREMELY CAREFUL not to touch any moving or hot engine parts. Once the temperature has been reached, shut the engine OFF, and check for leaks around the hose fittings and connections which were removed earlier. Check the level of protection with an antifreeze/coolant hydrometer. 11. Brake Master Cylinder FLUID RECOMMENDATIONS WARNING BRAKE FLUID EATS PAINT. Take great care not to splash or spill brake fluid on painted surfaces. Should you spill a small amount on the cars finish, dont panic, just flush the area with plenty of water. When adding fluid to the system ONLY use fresh DOT 3 brake fluid from a sealed container. DOT 3 brake fluid will absorb moisture when it is exposed to the atmosphere, which will lower its boiling point. A container that has been opened once, closed and placed on a shelf will allow enough moisture to enter over time to contaminate the fluid within. If your brake fluid is contaminated with water, you could boil the brake fluid under hard braking and loose all/some of the brake system. Dont take the risk, buy fresh brake fluid whenever you must add to the system. LEVEL CHECK Brake fluid level and condition is a safety related item and it should be checked ANY TIME the hood is opened. Your vehicle should not use brake fluid rapidly (unless there is a leak in the system), but the level should drop slowly in relation to brake pad wear. HOW TO USE THIS BOOK 140 Brake Master Cylinder
The brake master cylinder fluid level should be maintained at the MAX mark on the reservoir The master cylinder reservoir is located under the hood, on the left side firewall. All vehicles covered by this manual should be equipped with a see-through plastic reservoir. This makes checking the level easy and helps reduce the risk of fluid contamination (since you dont have to expose the fluid by opening the cap to check the level). Fluid should be kept near the FULL line or between the MIN and MAX lines, depending on how the reservoir is marked. If fluid must be added, thoroughly clean the fill cap area then remove the cap ...... and add only fresh, clean DOT 3 brake fluid until the proper level is attained HOW TO USE THIS BOOK LEVEL CHECK 141
If it becomes necessary to add fluid to the system, take a moment to clean the area around the cap and reservoir. Use a clean rag to wipe away dust and dirt which could enter the reservoir after the cover is removed. If the level of the brake fluid is less than half the volume of the reservoir (and the brake pads are not approaching a replacement point), it is advised that you check the brake system for leaks. Leaks in the hydraulic system often occur at the wheel cylinders. Clutch Master Cylinder FLUID RECOMMENDATIONS The hydraulic clutch control system consists of a fluid reservoir, a master cylinder, a slave cylinder and connecting tubing. It uses heavy duty brake fluid meeting DOT 3 specification. LEVEL CHECK Clutch master cylinder reservoir locationClick to enlarge The clutch master cylinder reservoir is located under the hood, on the left side firewall. The fluid in the reservoir will slowly increase or rise as the clutch wears. As long as the fluid level is visible at or above the step in the reservoir body, top-off is not necessary and should not be done to prevent overflow as well as possible contamination of the fluid while it is exposed. Before removing the clutch master cylinder reservoir cap, make sure the vehicle is resting on level ground and clean all dirt away from the top of the reservoir. Power Steering Pump Reservoir FLUID RECOMMENDATIONS 1991-95 Models The 1991-95 Ranger/Explorer vehicles use either Type F Automatic Transmission Fluid (ATF) or Ford Premium Power Steering Fluid meeting Ford specification ESW-M2C33-F. Ensure that the fluid added to the power steering pump reservoir is new and clean. HOW TO USE THIS BOOK 142 Clutch Master Cylinder
1996-99 Models The 1996-99 models utilize Mercon® Automatic Transmission Fluid (ATF). Ensure that the fluid added to the power steering pump reservoir is new and clean. LEVEL CHECK The level of the power steering fluid should be checked in the reservoir periodically, at least once a year. Fluid is checked using the dipstick which is attached to the reservoir cap. Although the dipstick is equipped with range markings so that you can check the fluid hot or cold, it is recommended that you check the fluid at normal operating temperature (HOT). WARNING Extensive driving with a low power steering fluid level can damage the power steering pump. The power steering pump on 1991-95 vehicles requires the use of power steering fluid that meets Fords specification ESW-M2C33-F, or an equivalent Type F ATF. 1996-99 models require Mercon® ATF. Warm the fluid to normal operating temperature by driving for at least one mile, or start the engine and allow it to idle for five minutes. 1. With the engine idling, turn the steering wheel back-and-forth several times from lock-to-lock, then center the wheels and shut the engine OFF. 2. To check power steering fluid level, remove the dipstick attached to the cap and read the level Locate the power steering pump reservoir, then remove the cap/dipstick and note the level as indicated by the markings. To be sure of your reading, put the cap back in position, remove it again and double check the level. 3. HOW TO USE THIS BOOK FLUID RECOMMENDATIONS 143
The level should read between the MAX and MIN marks on the dipstick (HOT marks on opposite side) Add the proper amount and type of fluid to attain a FULL (MAX) reading on the dipstick If the level is below the indicator markings, add fluid to bring it up to the proper level (a funnel is usually very helpful). If you are checking the level after running the engine or driving, make sure you add enough fluid to bring it to the FULL HOT range, but like most automotive fluids, DO NOT overfill. 4. When you are finished, install the dipstick and be sure it is secure. 5. Manual Steering Gear The steering gear is factory-filled with steering gear grease. Changing of this lubricant should not be performed and the housing should not be drained, lubricant is not required for the life of the steering gear. Chassis Greasing Chassis greasing should be performed every 12 months or 12,000 miles (19,000 km) for most trucks. Greasing can be performed with a commercial pressurized grease gun or at home by using a hand-operated grease gun. HOW TO USE THIS BOOK 144 LEVEL CHECK
Wipe the grease fittings clean before greasing in order to prevent the possibility of forcing any dirt into the component. There are far less grease points on the modern automotive chassis than there were on trucks of yesteryear. The tie rod ends on these vehicles should be checked and lubricated periodically, and the front suspension should be checked for grease fittings. A water resistant long life grease that meets Fords ESA-M1C75-B specification should be used for all chassis greasing applications. Body Lubrication Whenever you take care of chassis greasing it is also advised that you walk around the vehicle and give attention to a number of other surfaces which require a variety of lubrication/protection. HOOD/DOOR LATCH & HINGES Wipe clean any exposed surfaces of the door hatches and hinges, hood latch and auxiliary catch. Then, treat the surfaces using a multi-purpose grease spray that meets Fords ESR-M1C159-A specification. LOCK CYLINDERS Should be treated with Ford Lock Lubricant, part no. D8AZ-19587-AA or equivalent. Consult your local parts supplier for equivalent lubricants. DOOR WEATHERSTRIPPING Spray the door weatherstripping using a silicone lubricant to help pressure the rubber. THROTTLE VALVE (TV) & KICKDOWN LINKAGE A water resistant long life grease that meets Fords ESA-M1C75-B specification should be used for all linkages. Wheel Bearings HOW TO USE THIS BOOK Chassis Greasing 145
Exploded view of the front wheel bearings and related components-2WD model shown, 4WD is similar Click to enlarge This procedure only covers the repacking (or greasing) of the wheel bearings. For the removal procedures see the appropriate Section for you vehicle. For 4 wheel drive vehicles, see Section 7. For 2 wheel drive vehicles, see Section 8. REPACKING Packing the wheel bearings with greaseHOW TO USE THIS BOOK 146 Wheel Bearings