1991 1999 ford explorer chilton User Manual
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The camber adjuster will seat itself into the knuckle at a predetermined position during the tightening sequence. Do not attempt to adjust this position. Install the axle shaft or shafts that were removed. 17. Install the splash shield and spindle onto the steering knuckle. Install and tighten the spindle nuts to 40-50 ft. lbs. 18. Install the rotor on the spindle and push the outer wheel bearing inwards to seat it.. 19. Install the locknuts and adjust the wheel bearings. Install the remainder of the locking hub assemblies. 20. Mountaineer, 1995-99 Explorer and 1998-99 Ranger WARNING Do not perform this procedure unless a new wheel hub nut and washer assembly is available. Once removed, these parts must never be reused during assembly. Position the steering wheel to the on-center position. 1. 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. Loosen the wheel lug nuts then raise and safely support the front of the vehicle. 2. Remove the wheels. 3. Remove the front disc brake caliper, bracket and rotor. Also remove the rotor splash shield. 4. If equipped, unbolt the front wheel ABS sensor and wire harness from the steering knuckle. 5. Remove the front wheel hub nut and washer. 6. WARNING Never reuse the wheel hub nut and washer. This nut is a torque prevailing design and cannot be reused. Remove the cotter pin and nut retaining the tie rod end to the steering knuckle. 7. Disconnect the tie rod end from the steering knuckle using a jawed puller, such as Pitman Arm Puller T64P-3590-F, or equivalent. 8. Unload the torsion bar. Follow the torsion bar removal procedures, but do not remove the bar. 9. Support the lower control arm with a jack. Remove the cotter pin and loosen the nut retaining the lower ball joint to the steering knuckle. 10. Disconnect the lower ball joint from the steering knuckle using a jawed puller, such as Pitman Arm Puller T64P-3590-F, or equivalent. 11. Remove the lower ball joint retaining nut and slowly raise the lower control arm until the ball joint stud is disengaged from the steering knuckle. 12. The hub shaft is a slip fit into the wheel hub and bearing; a press is not normally required. Ensure that the wheel hub shaft can be pushed inwards. If not, assemble a press to the front wheel studs and press the wheel hub shaft inwards slightly to break it loose. 13. Remove the upper ball joint retaining bolt and nut from the steering knuckle then disconnect the joint from the knuckle. 14. Remove the steering knuckle/spindle assembly from the vehicle. 15. To install: Inspect the upper and lower ball joints and seals for damage and replace as needed. 16. Position the steering knuckle onto the upper ball joint, while aligning the axle shaft with the wheel 17. HOW TO USE THIS BOOK 906 REMOVAL & INSTALLATION
hub, and install the retaining bolt and nut. Tighten the bolt to 30-41 ft. lbs. (40-55 Nm). Install the lower ball joint stud into the steering knuckle until the stud protrudes through the knuckle. 18. Install the retaining nut to the lower ball joint stud and tighten to 84-113 ft. lbs. (113-153 Nm). Install the cotter pin, advancing (tightening) the nut as needed. Never loosen the ball joint nut in order to install the cotter pin. 19. Connect the tie rod end to the steering knuckle and install the retaining nut. Tighten to 57-77 ft. lbs. (77-104 Nm) and install the cotter pin, advancing (tightening) the nut as needed. Never loosen the ball joint nut in order to install the cotter pin. 20. If removed, install the ABS sensor to the wheel hub. 21. Install the hub washer and nut then tighten to 157-213 ft. lbs. (212-288 Nm). 22. Install the front disc brake splash shield, rotor, bracket and caliper. 23. Install the wheel and snug all of the lug nuts. 24. Reload the torsion bar pressure. Refer to the torsion bar installation procedures. Check and, if necessary, set the vehicle ride height. 25. Lower the vehicle and tighten the wheel lug nuts to 100 ft. lbs. (135 Nm). 26. Radius Arm Radius arms are not used on Mountaineer, 1995-99 Explorer and 1998-99 Ranger models. REMOVAL & INSTALLATION Radius rod and related partsClick to enlarge Raise the front of the vehicle, place jackstands under the frame. Place a jack under the axle. 1. WARNING HOW TO USE THIS BOOK Radius Arm 907
The axle must be supported on the jack throughout spring removal and installation, and must not be permitted to hang by the brake hose. If the length of the brake hose is not sufficient to provide adequate clearance for removal and installation of the spring, the disc brake caliper must be removed from the spindle. After removal, the caliper must be placed on the frame or otherwise supported to prevent suspending the caliper from the caliper hose. These precautions are absolutely necessary to prevent serious damage to the tube portion of the caliper hose assembly. Disconnect the lower stud. Remove the front spring from the vehicle. 2. Remove the spring lower seat and stud from the radius arm. Remove the bolts that attach the radius arm to the axle and front bracket. 3. Remove the nut, rear washer and insulator from the rear side of the radius arm rear bracket. 4. Remove the radius arm from the vehicle. Remove the inner insulator and retainer from the radius arm stud. 5. To install: Position the front end of the radius arm from bracket to axle. Install the retaining bolts and stud in the bracket finger tight. 6. Install the retainer and inner insulator on the radius arm stud and insert the stud through the radius arm rear bracket. 7. Install the rear washer, insulator and nut on the arm stud at the rear side of the arm rear bracket. Tighten the nut to 80-120 ft. lbs. 8. Tighten the stud to 190-230 ft. lbs. Tighten the front bracket to axle bolts to 37-50 ft. lbs. and the lower bolt and washer to 190-230 ft. lbs. 9. Install the spring lower seat and spring insulator on the radius arm so that the hole in the seat goes over the arm to axle bolt. Tighten the axle pivot bolt to 120-150 ft. lbs. 10. Install the front spring. Connect the lower stud of the radius arm and torque the retaining nut to 39-53 ft. lbs. on 1991-94 vehicles. 11. Stabilizer Bar REMOVAL & INSTALLATION Ranger As required, raise and support the vehicle safely. 1. Remove the nuts and bolts retaining the stabilizer bar to the end links. 2. Remove the retainers and the stabilizer bar and bushings from the vehicle. 3. To install: Position the stabilizer bar to the axles and brackets. 4. Install the retainer and the end link bolts. 5. Torque the retainer bolts to 35-50 ft. lbs. (47-67 Nm) on 1991-94 models and 22-30 ft. lbs. (30-40 Nm) on 1995-99 models. Torque the end link nuts to 30-41 ft. lbs. (40-55 Nm). 6. HOW TO USE THIS BOOK 908 REMOVAL & INSTALLATION
To remove the stabilizer bar, first unbolt the stabilizer bar end-to-radius arm links ... ... then remove the bar retainer strap bolts followed by the bar and its bushings If necessary, remove the end link-to-radius arm mounting bolts to remove the end links 1991-94 Explorer As required, raise and support the vehicle safely. 1. Remove the nuts and washer and disconnect the stabilizer link assembly from the front I-beam axle. 2. Remove the mounting bolts and remove the stabilizer bar retainers from the stabilizer bar assembly. 3. HOW TO USE THIS BOOK REMOVAL & INSTALLATION 909
Remove the stabilizer bar from the vehicle. 4. To install: Place stabilizer bar in position on the frame mounting brackets. 5. Install retainers and tighten retainer bolt to 35-50 ft. lbs. (47-67 Nm). If removed, install the stabilizer bar link assembly to the stabilizer bar. Install the nut and washer and tighten to 30-41 ft. lbs. (40-55 Nm). 6. Position the stabilizer bar link in the I-beam mounting bracket. Install the bolt and tighten to 30-41 ft. lbs. (40-55 Nm). 7. Mountaineer, 1995-99 Explorer and 1998-99 Ranger Raise and safely support the vehicle. 1. Remove the nut, washer and bushing (on underside of the lower control arm) linking the stabilizer bar end to the lower control arm. 2. Lift up on the bar and remove the remaining bushings and the spacer and bolt assembly (called the end link) from the stabilizer bar end. 3. Remove the bar mounting bracket-to-frame bolts. 4. Remove the stabilizer bar from the vehicle. If necessary, remove the mounting brackets and insulators from the bar. 5. To install: Inspect all of the stabilizer bar mounting and end link bushings. Replace any that are cracked, squashed, swollen or damaged. 6. Position the stabilizer bar mounting brackets to the frame and install the retaining bolts loosely. 7. Install the end link assembly to the bar end and the lower control arm. Install the end link retaining bolt loosely. 8. Tighten the mounting bracket bolts to 65-91 ft. lbs. (88-119 Nm). 9. The end link assembly must be tightened with the vehicle weight on the front wheels. Lower the vehicle then tighten the end link retaining nut to 10-13 ft. lbs. (13-17 Nm). 10. I-Beam Axle The I-beam axle is part of the front drive axle assembly. Refer to Section 7 for front drive axle housing removal and installation procedures. Upper Control Arm Only the Mountaineer, 1995-99 Explorer and 1998-99 Ranger models have control arms. REMOVAL & INSTALLATION HOW TO USE THIS BOOK 910 REMOVAL & INSTALLATION
Exploded view of the left and right upper control arms Click to enlarge After performing this procedure, it will be necessary to have the wheel alignment checked and adjusted by a professional shop. Position the steering wheel to the on-center position. Loosen the wheel lug nuts. 1. Raise and safely support the vehicle. Position the jack stands under the lower control arms. 2. Remove the wheel lug nuts and wheel. 3. Before removing the steering knuckle-to-upper ball joint retaining (pinch) bolt, secure the steering knuckle from tilting. HOW TO USE THIS BOOK REMOVAL & INSTALLATION 911
Remove the steering knuckle-to-upper ball joint retaining (pinch) bolt and separate the two components. 4. Make alignment marks on the control arm pivot bolt cam assemblies. 5. To remove the left side control arm proceed as follows: Remove the nuts and cam bolts from the control arm pivot points. 1. Pull the control arm from the vehicle frame. 2. 6. To remove the right side control arm, proceed as follows: If only the ball joint is to be removed, make alignment marks on the control arm and ball joint assembly then remove the two retaining nuts and the ball joint. Skip to the installation procedures. 1. Remove the nuts and cam bolts from the control arm pivot points. 2. Pull the control arm from the vehicle frame. 3. 7. To install: For right-side control arm, if removed, install the ball joint assembly and retaining nuts to the control arm and tighten the nuts to 95-128 ft. lbs. (128-173 Nm). 8. Install the control arm pivot points into the frame pockets. 9. Install the cam bolts and nuts, align the matchmarks and tighten the nuts to 84-113 ft. lbs. (113-153 Nm). 10. Connect the upper ball joint shaft to the steering knuckle. Install the retaining (pinch) bolt and tighten to 30-41 ft. lbs. (40-55 Nm). 11. Install the wheel and snug the lug nuts. 12. Lower the vehicle and tighten the lug nuts to 100 ft. lbs. (135 Nm). 13. Have the alignment checked by a professional repair shop. 14. Lower Control Arm Only the Mountaineer, 1995-99 Explorer and 1998-99 Ranger models have control arms. REMOVAL & INSTALLATION HOW TO USE THIS BOOK 912 Lower Control Arm
Exploded view of the lower control arm Click to enlarge To remove the lower control arm, the torsion bar must be removed. Anytime the torsion bar is disturbed, the ride height must be checked and adjusted. Position the steering wheel to the on-center position. Loosen the wheel lug nuts. 1. Raise and safely support the vehicle. 2. Remove the wheel lug nuts and wheel. 3. Disconnect the stabilizer bar link bolt from the lower control arm. 4. Remove the front shock absorber. 5. Remove the torsion bar. 6. Remove the lower ball joint retaining nut cotter pin and loosen the nut but do not remove it. 7. Disconnect the lower ball joint stud from the steering knuckle using a jawed puller, such as Pitman Arm Puller T64P-3590-F, or equivalent. 8. WARNING Fasten a support, either out of a block of wood or wire wrapped around the frame, and support the weight of the steering knuckle/brake assembly. Do not allow the steering knuckle/brake assembly to hang from the upper ball joint as this may damage the joint. Position a jack under the lower control arm then remove the lower ball joint retaining nut. 9. Raise the lower control arm until the lower ball joint stud is free from the steering knuckle. 10. Remove the two nuts and bolts retaining the lower arm pivot points to the frame crossmember. 11. Remove the lower control arm from the frame pockets. Some careful prying may ease the removal of the arm. 12. To install: Inspect the lower ball joint, boot and pivot bushings. If any inspected components are worn or damaged, the entire control arm must be replaced. 13. HOW TO USE THIS BOOK REMOVAL & INSTALLATION 913
Do not tighten the lower control arm mounting bolts to the final torque until the end of the installation procedure. Position the lower control arm pivot points into the frame and crossmember pockets. Install the bolts and nuts and snug the bolts. 14. Position a jack under the lower control arm. 15. Install the torsion bar. 16. Raise the lower control arm to allow the lower ball joint stud to be inserted into the steering knuckle. 17. Lower the control arm assembly and ensure that the lower ball joint stud protrudes through the steering knuckle bore. 18. Install the lower ball joint attaching nut and tighten to 83-113 ft. lbs. (113-153 Nm). Install a new cotter pin, advancing (tightening) the nut as required. Never loosen the retaining nut in order to install the cotter pin. 19. Install the shock absorber. 20. Install the wheel and snug the lug nuts. 21. Lower the vehicle and tighten the lug nuts to 100 ft. lbs. (135 Nm). 22. The lower control arm-to-frame bolts must be tightened with the weight of the vehicle resting on the wheels. If clearance permits, allow the vehicle to sit on the ground while tightening the bolts. If necessary, raise the vehicle again and position either car ramps under the wheels or jackstands on the lower control arms, as close to the wheels as possible. 23. Tighten the control arm-to-frame bolts to 111-148 ft. lbs. (150-200 Nm). 24. Lower the vehicle. 25. Check and adjust the ride height. 26. While it should not be necessary, have the wheel alignment checked by a professional shop. 27. Front Wheel Bearings REMOVAL & INSTALLATION Except Mountaineer, 1995-99 Explorer and 1998-99 Ranger HOW TO USE THIS BOOK 914 Front Wheel Bearings
Inspect the bearings for abnormal wear and/or damage WITH MANUAL LOCKING HUBS Raise the vehicle and install jackstands. 1. Remove the wheel and tire assembly. 2. Remove the retainer washers from the lug nut studs and remove the manual locking hub assembly from the spindle. 3. Remove the snapring and spacer from the end of the spindle shaft. 4. Remove the outer wheel bearing locknut from the spindle using 4 prong spindle nut spanner wrench, T86T-1197-A or equivalent. Make sure the tabs on the tool engage the slots in the locknut. 5. Remove the locknut washer from the spindle. 6. Remove the inner wheel bearing locknut from the spindle using 4 prong spindle nut spanner wrench, T86T-1197-A or equivalent. Make sure the tabs on the tool engage the slots in the locknut. 7. Remove the outer bearing cone and roller assembly from the hub. Remove the hub and rotor from the spindle. 8. Using seal removal tool 1175-AC or equivalent remove and discard the grease seal. Remove the inner bearing cone and roller assembly from the hub. 9. Clean the inner and outer bearing assemblies in solvent. Inspect the bearings and the cones for wear and damage. Replace defective parts, as required. 10. If the cups are worn or damaged, remove them with front hub remover tool T81P-1104-C and tool T77F-1102-A or equivalent. 11. Wipe the old grease from the spindle. Check the spindle for excessive wear or damage. Replace defective parts, as required. 12. HOW TO USE THIS BOOK REMOVAL & INSTALLATION 915