1991 1999 ford explorer chilton User Manual
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To access the fuses, remove the fuse panel cover. Note the spare fuses (A) and provided fuse puller tool Remove the fuse panel access cover. 2. If equipped, remove the fuse puller tool from the cover. 3. Using the provided tool or a pair of pliers, grasp the fuse and pull it from the panel Grasp the push-in type fuse with the provided tool, or a pair of needle-nose pliers. 4. Look through the side of the fuse body to determine if the fuse element is blown. 5. To install: Check the amperage rating of the fuse which was removed and obtain a new fuse of the same rating. 6. WARNING Never replace a blown fuse with a new fuse of a higher rating. Severe electrical damage, as well as possible electrical fire could result. Align the fuse with its mounting position and push it into place until fully seated in the panel. 7. Turn the ignition switch on and operate the accessory that was protected by that fuse. 8. HOW TO USE THIS BOOK REPLACEMENT 749
WARNING If the fuse continues to blow, inspect and test the wire harness and component or components which are protected by that fuse. Power Distribution Box Located under the hood, in the engine compartment. It houses the fuses and relays for most of the under hood components which are not controlled by a dash mounted switch (such as the alternator, fuel pump, ECM, etc.). The fuses and relays are replaced in the same manner as the fuse panel inside the vehicle. The power distribution box cover is hinged on one end and utilizes a retaining latch on the other. Simply release the latch and lift the cover up to gain access to the fuses and relays. Fusible Links The fusible link is a short length of special, Hypalon (high temperature) insulated wire, integral with the engine compartment wiring harness and should not be confused with standard wire. It is several wire gauges smaller than the circuit which it protects. Under no circumstances should a fuse link replacement repair be made using a length of standard wire cut from bulk stock or from another wiring harness. The fusible links are located near the starter solenoid and shares the terminal with the battery-to-starter solenoid cable. Circuit Breakers The Ranger, Explorer and Mountaineer models use circuit breakers for components which have a high start-up amperage pull (such as power windows). All breakers will automatically reset if they have been tripped. The circuit breakers are replaceable (should one go bad or not reset) and can be found on the fuse panel. Circuit breakers can be replaced as if it were a fuse, simply grasp hold of it and pull it from the panel REPLACEMENT The circuit breakers are replaced in the same manner as a fuse. Simply pull the breaker from the fuse panel to remove. HOW TO USE THIS BOOK 750 REPLACEMENT
Turn Signal and Hazard Flasher Locations Both the turn signal flasher and the hazard warning flasher are mounted on the fuse panel on the truck. To gain access to the fuse panel, remove the cover from the lower edge of the instrument panel below the steering column. First remove the two fasteners from the lower edge of the cover. Then pull the cover downward until the spring clips disengage from the instrument panel. The turn signal flasher unit is mounted on the front of the fuse panel, and the hazard warning flasher is mounted on the rear of the fuse panel. Chilton® Automotive Information Systems. © 2004 Thomson Delmar Learning. HOW TO USE THIS BOOK Turn Signal and Hazard Flasher Locations 751
WIRING DIAGRAMS Sample diagram-how to read and interpret wiring Common wiring diagram symbols 1991 Ranger 2.3L & 2.9L engine wiring 1991 Ranger 3.0L engine wiring 1991 Ranger 4.0L engine wiring 1991 Ranger body wiring 1991 Explorer 4.0L engine wiring 1991 Explorer body wiring 1992 Ranger 2.3L & 2.9L engine wiring 1992 Ranger 3.0L engine wiring 1992 Ranger 4.0L engine wiring 1992 Ranger body wiring 1992 Explorer 4.0L engine wiring 1992 Explorer body wiring 1993 Ranger 2.3L engine wiring 1993 Ranger 3.0L engine wiring 1993 Ranger 4.0L engine wiring 1993 Ranger body wiring 1993 Explorer 4.0L engine wiring; except California 1993 Explorer body wiring; except California 1993 Explorer 4.0L engine wiring; California 1993 Explorer body wiring; California 1994 Ranger 2.3L engine wiring; except California 1994 Ranger 2.3L engine wiring; California 1994 Ranger 3.0L engine wiring 1994 Ranger 4.0L engine wiring; except California 1994 Ranger 4.0L California engine wiring 1994 Ranger body wiring 1994 Explorer 4.0L engine wiring 1994 Explorer body wiring 1995-99 Ranger 2.3L and 2.5L engine wiring 1995-99 Ranger 3.0L & 4.0L engine wiring 1995 Explorer 4.0L engine wiring 1996-99 Explorer/Mountaineer 4.0L engine (VIN X) wiring 1997 Explorer 4.0L SOHC engine (VIN E) wiring 1996-99 Explorer/Mountaineer 5.0L engine wiring 1995-99 Ranger, Explorer & Mountaineer body wiring 1995-99 Ranger body wiring 1995-99 Explorer & Mountaineer body wiring WIRING DIAGRAMS 753
MANUAL TRANSMISSION Understanding the Manual Transmission Because of the way an internal combustion engine breathes, it can produce torque (or twisting force) only within a narrow speed range. Most overhead valve pushrod engines must turn at about 2500 rpm to produce their peak torque. Often by 4500 rpm, they are producing so little torque that continued increases in engine speed produce no power increases. The torque peak on overhead camshaft engines is, generally, much higher, but much narrower. The manual transmission and clutch are employed to vary the relationship between engine RPM and the speed of the wheels so that adequate power can be produced under all circumstances. The clutch allows engine torque to be applied to the transmission input shaft gradually, due to mechanical slippage. The vehicle can, consequently, be started smoothly from a full stop. The transmission changes the ratio between the rotating speeds of the engine and the wheels by the use of gears. 4-speed or 5-speed transmissions are most common. The lower gears allow full engine power to be applied to the rear wheels during acceleration at low speeds. The clutch driveplate is a thin disc, the center of which is splined to the transmission input shaft. Both sides of the disc are covered with a layer of material which is similar to brake lining and which is capable of allowing slippage without roughness or excessive noise. The clutch cover is bolted to the engine flywheel and incorporates a diaphragm spring which provides the pressure to engage the clutch. The cover also houses the pressure plate. When the clutch pedal is released, the driven disc is sandwiched between the pressure plate and the smooth surface of the flywheel, thus forcing the disc to turn at the same speed as the engine crankshaft. The transmission contains a mainshaft which passes all the way through the transmission, from the clutch to the driveshaft. This shaft is separated at one point, so that front and rear portions can turn at different speeds. Power is transmitted by a countershaft in the lower gears and reverse. The gears of the countershaft mesh with gears on the mainshaft, allowing power to be carried from one to the other. Countershaft gears are often integral with that shaft, while several of the mainshaft gears can either rotate independently of the shaft or be locked to it. Shifting from one gear to the next causes one of the gears to be freed from rotating with the shaft and locks another to it. Gears are locked and unlocked by internal dog clutches which slide between the center of the gear and the shaft. The forward gears usually employ synchronizers; friction members which smoothly bring gear and shaft to the same speed before the toothed dog clutches are engaged. Identification The Ranger and Explorer trucks had two manual transmission available, depending on the engine. The Mazda M5OD 5-speed overdrive transmission came equipped on both the 4x2 and 4x4 versions. The Mitsubishi 5-speed overdrive transmission only came on the 2.9L equipped 4x4 Ranger vehicles from 1991-92. Adjustments MANUAL TRANSMISSION 755
SHIFTER & LINKAGE ADJUSTMENTS Both of the 5-speed transmissions are directly controlled with a floor shift mechanism built into the transmission extension housing. There are no adjustments necessary on these transmissions. Shift Handle REMOVAL & INSTALLATION Disconnect the negative battery cable. 1. Do not remove the shift knob, unless the shift knob or boot is to be replaced. Otherwise, remove the shift knob, boot and lever as an assembly. If necessary, remove the shift lever knob on the Mitsubishi 5-speed transmission as follows:Remove the plastic shift pattern insert from the shift knob. 1. Heat the shift lever knob to 140-180°F (60-82°C), using a heat gun. 2. Position a block of wood beneath the shift lever knob and carefully hammer the knob from the lever. Be careful not to damage the finish on the shift lever. 3. 2. Place the gearshift lever in Nposition. 3. Remove the shifter boot retainer screws and slide the boot up the lever. 4. Remove the shift lever-to-extension housing/transfer case adapter housing retaining bolts. Pull the gearshift lever straight up and away from the gearshift lever retainer. 5. HOW TO USE THIS BOOK 756 SHIFTER & LINKAGE ADJUSTMENTS
Exploded view of the transmission shifter lever assembly Click to enlarge To install: Prior to installing the shift lever, lubricate the shift lever ball stud, using C1AZ-19590-B (ESA-M1C75-B) or equivalent. 6. Fit the shift lever into place and install the retaining bolts. Tighten the retaining bolts to specifications. 7. Install the rubber boot and retaining screws. 8. If the shift lever knob was removed, heat it to 140°-180°F (60°-82°C), using a heat gun. Tap the knob onto the shift lever, using a 7 /16 in. (11mm will work) socket and mallet. 9. Place the shift lever in Nposition. Then, align the shift pattern plastic insert with the vehicle centerline and install it to the shift lever knob. 10. Neutral Sensing Switch All manual transmission vehicles are equipped with a neutral sensing switch. The neutral sensing switch signals the vehicle on-board computer, which allows the vehicle to start only when the transmission is in N. HOW TO USE THIS BOOK REMOVAL & INSTALLATION 757
REMOVAL & INSTALLATION Location of the transmission switches-Mazda 5-speedClick to enlarge Location of the transmission switches-Mitsubishi 5-speed Click to enlarge Disconnect the negative battery cable. 1. Raise and support the vehicle safely. 2. Place the transmission in any position other than N. 3. HOW TO USE THIS BOOK 758 REMOVAL & INSTALLATION
Clean the area around the switch, then remove the switch. 4. To install: Install the switch and tighten 8-11 ft. lbs. (11- 16Nm). 5. Reconnect the harness connector to the switch. 6. Lower the vehicle. 7. Reconnect the negative battery cable. 8. Extension Housing Seal REMOVAL & INSTALLATION Two Wheel Drive Models Extension housing seal removal Disconnect the negative battery cable. 1. Raise and support the vehicle safely. 2. Place a suitable drain pan beneath the extension housing. Clean the area around the extension housing seal. 3. Matchmark the driveshaft to the rear axle flange. Disconnect the driveshaft and pull it rearward from the unit. 4. Remove the extension housing seal using tool T71P-77218-A or equivalent, remove the extension housing seal. 5. To install: Lubricate the inside diameter of the oil seal and install the seal into the extension housing using tool T71P-77022-A. Check to ensure that the oil seal drain hole faces downward. 6. Install the driveshaft to the extension housing. Connect the driveshaft to the rear axle flange. Make sure the marks made during removal are in alignment. Fit the attaching washer, lockwasher and nuts. 7. HOW TO USE THIS BOOK Extension Housing Seal 759
Check and adjust the transmission fluid level, using Ford manual transmission lube D8DZ-19C217-A (ESP-M2C83-C) or equivalent. 8. Lower the vehicle. 9. Reconnect the negative battery cable. 10. Extension housing seal installationClick to enlarge Four Wheel Drive Models Refer to the transfer case procedures for the front and/or rear output shaft seals. Transmission REMOVAL & INSTALLATION HOW TO USE THIS BOOK 760 REMOVAL & INSTALLATION