1991 1999 ford explorer chilton User Manual
Have a look at the manual 1991 1999 ford explorer chilton User Manual online for free. It’s possible to download the document as PDF or print. UserManuals.tech offer 41 Ford manuals and user’s guides for free. Share the user manual or guide on Facebook, Twitter or Google+.
LIGHTING Headlights REMOVAL & INSTALLATION Examples of various types of automotive light bulbs LIGHTING 717
Exploded view of the front headlight assembly and related components Click to enlarge If equipped, open the headlight access panel by sliding the latch and lifting the panel upwards HOW TO USE THIS BOOK 718 REMOVAL & INSTALLATION
Exploded view of the headlight bulb, retainer and wire harness plug Click to enlarge Open the vehicles hood and secure it in an upright position. 1. If necessary, open the bulb access panel by depressing the latch then lifting. 2. To remove the bulb, grasp the retainer and rotate it counterclockwise to unlock it ... HOW TO USE THIS BOOK REMOVAL & INSTALLATION 719
... then withdraw the bulb from the headlight lens housing Unfasten the locking ring which secures the bulb and wire harness plug assembly, then withdraw the assembly rearward. 3. Disconnect the electrical wire harness plug from the bulb and remove the locking ring as well. 4. Unplug the wire harness from the bulb and either slide the retainer over the plug, or remove it from the bulb To install: Before connecting a light bulb to the wire harness plug, ensure that all electrical contact surfaces are free of corrosion or dirt. 5. Install the locking ring onto the bulb, then line up the replacement headlight bulb with the harness plug. Firmly push the bulb onto the plug until the spring clip latches over the bulbs projection. 6. WARNING Do not touch the glass bulb with your fingers. Oil from your fingers can severely shorten the life of the bulb. If necessary, wipe off any dirt or oil from the bulb with rubbing alcohol before completing installation. Position the headlight bulb and secure it with the locking ring. 7. To ensure that the replacement bulb functions properly, activate the applicable switch to illuminate the bulb which was just replaced. (If this is a combination low and high beam bulb, be sure to check both intensities.) If the replacement light bulb does not illuminate, either it too is faulty or there is a problem in the bulb circuit or switch. Correct if necessary. 8. HOW TO USE THIS BOOK 720 REMOVAL & INSTALLATION
Close the bulb access panel and the vehicles hood. 9. AIMING THE HEADLIGHTS The headlights must be properly aimed to provide the best, safest road illumination. The lights should be checked for proper aim and adjusted as necessary. Certain state and local authorities have requirements for headlight aiming; these should be checked before adjustment is made. CAUTION About once a year, when the headlights are replaced or any time front end work is performed on your vehicle, the headlight should be accurately aimed by a reputable repair shop using the proper equipment. Headlights not properly aimed can make it virtually impossible to see and may blind other drivers on the road, possibly causing an accident. Note that the following procedure is a temporary fix, until you can take your vehicle to a repair shop for a proper adjustment. Headlight adjustment may be temporarily made using a wall, as described below, or on the rear of another vehicle. When adjusted, the lights should not glare in oncoming car or truck windshields, nor should they illuminate the passenger compartment of vehicles driving in front of you. These adjustments are rough and should always be fine-tuned by a repair shop which is equipped with headlight aiming tools. Improper adjustments may be both dangerous and illegal. For most of the vehicles covered by this manual, horizontal and vertical aiming of each sealed beam unit is provided by two adjusting screws which move the retaining ring and adjusting plate against the tension of a coil spring. There is no adjustment for focus; this is done during headlight manufacturing. Because the composite headlight assembly is bolted into position, no adjustment should be necessary or possible. Some applications, however, may be bolted to an adjuster plate or may be retained by adjusting screws. If so, follow this procedure when adjusting the lights, BUT always have the adjustment checked by a reputable shop. Before removing the headlight bulb or disturbing the headlamp in any way, note the current settings in order to ease headlight adjustment upon reassembly. If the high or low beam setting of the old lamp still works, this can be done using the wall of a garage or a building: Park the vehicle on a level surface, with the fuel tank about 1 /2 full and with the vehicle empty of all extra cargo (unless normally carried). The vehicle should be facing a wall which is no less than 6 feet (1.8m) high and 12 feet (3.7m) wide. The front of the vehicle should be about 25 feet from the wall. 1. HOW TO USE THIS BOOK AIMING THE HEADLIGHTS 721
Example of headlight adjustment screw location for composite headlamps Click to enlarge If aiming is to be performed outdoors, it is advisable to wait until dusk in order to properly see the headlight beams on the wall. If done in a garage, darken the area around the wall as much as possible by closing shades or hanging cloth over the windows. 2. Turn the headlights ONand mark the wall at the center of each lights low beam, then switch on the brights and mark the center of each lights high beam. A short length of masking tape which is visible from the front of the vehicle may be used. Although marking all four positions is advisable, marking one position from each light should be sufficient. 3. HOW TO USE THIS BOOK 722 AIMING THE HEADLIGHTS
Low-beam headlight pattern alignment Click to enlarge High-beam headlight pattern alignment Click to enlarge If neither beam on one side is working, and if another like-sized vehicle is available, park the second one in the exact spot where the vehicle was and mark the beams using the same-side light. Then switch the vehicles so the one to be aimed is back in the original spot. It must be parked no closer to or farther away from the wall than the second vehicle. 4. Perform any necessary repairs, but make sure the vehicle is not moved, or is returned to the exact spot from which the lights were marked. Turn the headlights ONand adjust the beams to match the marks on the wall. 5. Have the headlight adjustment checked as soon as possible by a reputable repair shop. 6. Signal and Marker Lights REMOVAL & INSTALLATION Front Marker and Turn Signal 1991-92 RANGER AND 1991-94 EXPLORER MODELS HOW TO USE THIS BOOK Signal and Marker Lights 723
1991-92 Ranger and Explorer (up to 1994) front turn signal and side marker lens assembly Click to enlarge Remove the screws retaining the headlight and trim assembly. On Explorer, remove the grille. 1. Carefully rotate the headlight and trim assembly away from the vehicle, rotating the inboard side away from the vehicle. 2. Remove the side marker, parking and turn signal bulbs and sockets from the headlamp and trim assembly. They can be removed by turning them. 3. If replacing a lens, remove the retaining screws for the lens to be changed and remove it from the headlight door. 4. To install: If removed, install the removed lens assembly 5. Install the bulbs and sockets. 6. Install the headlight and trim assembly. 7. Check the operation of the lights. 8. 1993-99 RANGER AND 1995-99 EXPLORER/MOUNTAINEER MODELS HOW TO USE THIS BOOK 724 REMOVAL & INSTALLATION
1993-99 models front signal and marker lens assembly Click to enlarge Remove the marker/turn signal lens retaining screws or nut. 1. To change a turn signal/marker bulb, first unfasten the lens from the body, the reach behind the lens ... HOW TO USE THIS BOOK REMOVAL & INSTALLATION 725
... and grasp the lamp socket. Twist then pull the socket from the lens Gently pull outward on the lens assembly to disengage the barbed retainers. 2. Twist the lamp socket and remove it from the lens. 3. Pull the bulb from the socket. 4. To remove the bulb from the socket, simply pull it straight out To install: Install the bulb into the lamp socket. 5. Install the lamp socket to the lens and twist it to lock it in position. 6. Position the lens assembly, ensure that the barbed retainers are aligned with their mounting clips, and press the assembly until fully seated. 7. Install the marker/turn signal lens retaining screws or nut. 8. Check the operation of the lights. 9. Rear marker and Rear Lamps HOW TO USE THIS BOOK 726 REMOVAL & INSTALLATION