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1991-1999 Ford explorer service-manual 
1991-1999 Ford explorer service-manual
1991-1999 Ford explorer service-manual
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1991-1999 Ford explorer service-manual – PDF DOWNLOAD
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Description
1991-1999 Ford explorer service-manual – PDF DOWNLOAD
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DESCRIPTION:
1991-1999 Ford explorer service-manual – PDF DOWNLOAD
- This Chilton’s Total Car Care manual is intended to help you learn more about the inner workings of your Ranger, Explorer or Mountaineer while saving you money on its upkeep and operation.
- The beginning of the book will likely be referred to the most, since that is where you will find information for maintenance and tune−up. The other sections deal with the more complex systems of your vehicle. Systems (from engine through brakes) are covered to the extent that the average do−it−yourselfer can attempt.
- This book will not explain such things as rebuilding a differential because the expertise required and the special tools necessary make this uneconomical. It will, however, give you detailed instructions to help you change your own brake pads and shoes, replace spark plugs, and perform many more jobs that can save you money and help avoid expensive problems.
- A secondary purpose of this book is a reference for owners who want to understand their vehicle and/or their mechanics better. Where to Begin Before removing any bolts, read through the entire procedure. This will give you the overall view of what tools and supplies will be required. So read ahead and plan ahead.
- Each operation should be approached logically and all procedures thoroughly understood before attempting any work. If repair of a component is not considered practical, we tell you how to remove the part and then how to install the new or rebuilt replacement. In this way, you at least save labor costs. Avoiding Trouble Many procedures in this book require you to “label and disconnect … ” a group of lines, hoses or wires.
- Don’t be think you can remember where everything goes−you won’t. If you hook up vacuum or fuel lines incorrectly, the vehicle may run poorly, if at all. If you hook up electrical wiring incorrectly, you may instantly learn a very expensive lesson. You don’t need to know the proper name for each hose or line. A piece of masking tape on the hose and a piece on its fitting will allow you to assign your own label.
- As long as you remember your own code, the lines can be reconnected by matching your tags. Remember that tape will dissolve in gasoline or solvents; if a part is to be washed or cleaned, use another method of identification. A permanent felt−tipped marker or a metal scribe can be very handy for marking metal parts.
- Remove any tape or paper labels after assembly. Maintenance or Repair? Maintenance includes routine inspections, adjustments, and replacement of parts which show signs of normal wear. Maintenance compensates for wear or deterioration. Repair implies that something has broken or is not working. A need for a repair is often caused by lack of maintenance.
- for example: draining and refilling automatic transmission fluid is maintenance recommended at specific intervals. Failure to do this can shorten the life of the transmission/transaxle, requiring very expensive repairs. While no maintenance program can prevent items from eventually breaking or wearing out, a general rule
TABLE OF CONTENTS:
1991-1999 Ford explorer service-manual – PDF DOWNLOAD
Table of Contents.................................................... 2 HOW TO USE THIS BOOK................................................. 19 Introduction..................................................... 19 Where to Begin................................................... 19 Avoiding Trouble................................................. 19 Maintenance or Repair?........................................... 19 Avoiding the Most Common Mistakes................................ 20 TOOLS AND EQUIPMENT.................................................. 21 Introduction..................................................... 21 Special Tools.................................................... 29 SERVICING YOUR VEHICLE SAFELY........................................ 30 Introduction..................................................... 30 Do's............................................................. 31 Don'ts........................................................... 32 FASTENERS, MEASUREMENTS AND CONVERSIONS.............................. 33 Bolts, Nuts and Other Threaded Retainers......................... 33 Torque........................................................... 34 TORQUE WRENCHES.............................................. 35 TORQUE ANGLE METERS.......................................... 36 Standard and Metric Measurements................................. 37 SERIAL NUMBER IDENTIFICATION......................................... 38 Vehicle Identification Number (VIN).............................. 38 Vehicle Data..................................................... 40 Safety Compliance Certification Label............................ 43 Emission Calibration Label....................................... 44 Engine........................................................... 45 Transmission..................................................... 45 Transfer Case.................................................... 45 Front Drive Axle................................................. 45 Rear Axle........................................................ 45 ROUTINE MAINTENANCE AND TUNE-UP...................................... 47 Introduction..................................................... 47 Air Cleaner (Element)............................................ 54 REMOVAL & INSTALLATION....................................... 54 Fuel Filter...................................................... 57 REMOVAL & INSTALLATION....................................... 57 PCV Valve........................................................ 62 INSPECTION................................................... 62 REMOVAL & INSTALLATION....................................... 63 Evaporative Canister............................................. 63 SERVICING.................................................... 64 Battery.......................................................... 64 PRECAUTIONS.................................................. 64 GENERAL MAINTENANCE.......................................... 65 BATTERY FLUID................................................ 65 CABLES....................................................... 68 CHARGING..................................................... 71 REPLACEMENT.................................................. 71 Belts............................................................ 71 INSPECTION................................................... 71 ADJUSTMENT................................................... 73 REMOVAL & INSTALLATION....................................... 77 Timing Belts..................................................... 82 INSPECTION................................................... 82 CAMSHAFT TIMING INSPECTION................................... 86 Hoses............................................................ 86 INSPECTION................................................... 86 REMOVAL & INSTALLATION....................................... 88 CV-Boots........................................................ 90 INSPECTION................................................... 90 Spark Plugs...................................................... 91 SPARK PLUG HEAT RANGE........................................ 92 REMOVAL & INSTALLATION....................................... 94 INSPECTION & GAPPING......................................... 96 Spark Plug Wires................................................. 99 REMOVAL & INSTALLATION....................................... 99 TESTING...................................................... 100 Distributor Cap and Rotor........................................ 102 REMOVAL & INSTALLATION....................................... 102 INSPECTION................................................... 103 Ignition Timing.................................................. 104 GENERAL INFORMATION.......................................... 104 INSPECTION & ADJUSTMENT...................................... 104 Valve Lash....................................................... 106 Idle Speed and Mixture Adjustments............................... 106 Air Conditioning System.......................................... 107 SYSTEM SERVICE & REPAIR...................................... 107 PREVENTIVE MAINTENANCE....................................... 107 SYSTEM INSPECTION............................................ 108 Windshield Wipers............................................... 108 ELEMENT (REFILL) CARE & REPLACEMENT.......................... 109 Tires and Wheels................................................. 110 TIRE ROTATION................................................ 111 TIRE DESIGN.................................................. 111 TIRE STORAGE................................................. 113 INFLATION & INSPECTION....................................... 113 FLUIDS AND LUBRICANTS................................................ 117 Fluid Disposal................................................... 117 Oil and Fuel Recommendations..................................... 117 ENGINE OIL................................................... 117 FUEL......................................................... 119 OPERATION IN FOREIGN COUNTRIES............................... 119 Engine........................................................... 119 OIL LEVEL CHECK.............................................. 119 OIL & FILTER CHANGE.......................................... 121 Manual Transmission.............................................. 127 FLUID RECOMMENDATION......................................... 127 LEVEL CHECK.................................................. 127 DRAIN & REFILL............................................... 127 Automatic Transmission........................................... 128 FLUID RECOMMENDATION......................................... 128 LEVEL CHECK.................................................. 128 DRAIN, PAN/FILTER SERVICE & REFILL........................... 130 Transfer Case.................................................... 137 FLUID RECOMMENDATION......................................... 137 LEVEL CHECK.................................................. 137 DRAIN & REFILL............................................... 139 Front and Rear Drive Axle........................................ 139 FLUID RECOMMENDATION......................................... 139 LEVEL CHECK.................................................. 140 DRAIN & REFILL............................................... 142 Cooling System................................................... 145 FLUID RECOMMENDATIONS........................................ 146 INSPECTION................................................... 146 DRAINING, FLUSHING & REFILLING............................... 150 Brake Master Cylinder............................................ 154 FLUID RECOMMENDATIONS........................................ 154 LEVEL CHECK.................................................. 154 Clutch Master Cylinder........................................... 156 FLUID RECOMMENDATIONS........................................ 156 LEVEL CHECK.................................................. 156 Power Steering Pump Reservoir.................................... 156 FLUID RECOMMENDATIONS........................................ 156 LEVEL CHECK.................................................. 157 Manual Steering Gear............................................. 158 Chassis Greasing................................................. 158 Body Lubrication................................................. 159 HOOD/DOOR LATCH & HINGES..................................... 159 LOCK CYLINDERS............................................... 159 DOOR WEATHERSTRIPPING........................................ 159 THROTTLE VALVE (TV) & KICKDOWN LINKAGE....................... 159 Wheel Bearings................................................... 159 REPACKING.................................................... 160 TOWING THE VEHICLE................................................... 164 General Recommendations......................................... 164 Trailer Weight.................................................. 164 Hitch (Tongue) Weight........................................... 164 Oil Cooler...................................................... 165 TRANSMISSION................................................. 165 Handling a Trailer.............................................. 165 Towing the Vehicle.............................................. 165 JUMP STARTING A DEAD BATTERY......................................... 167 Introduction..................................................... 167 Jump Starting Precautions........................................ 167 Jump Starting Procedure.......................................... 168 JACKING.............................................................. 170 SPECIFICATION CHARTS................................................. 174 DISTRIBUTOR IGNITION SYSTEM.......................................... 180 General Information.............................................. 180 SYSTEM OPERATION............................................. 181 Diagnosis and Testing............................................ 182 SERVICE PRECAUTIONS.......................................... 182 PRELIMINARY CHECKS........................................... 182 TEST PROCEDURES.............................................. 182 Ignition Coil.................................................... 188 TESTING...................................................... 188 REMOVAL & INSTALLATION....................................... 191 Ignition Control Module (ICM).................................... 191 REMOVAL & INSTALLATION....................................... 191 Distributor...................................................... 193 REMOVAL & INSTALLATION....................................... 193 Camshaft Position (CMP) Sensor................................... 195 DISTRIBUTORLESS IGNITION SYSTEM...................................... 196 General Information.............................................. 196 SYSTEM OPERATION............................................. 196 Diagnosis and Testing............................................ 198 SERVICE PRECAUTIONS.......................................... 198 PRELIMINARY CHECKS........................................... 198 GENERAL SYSTEM TEST.......................................... 198 Ignition Coil Pack(s)............................................ 210 TESTING...................................................... 210 REMOVAL & INSTALLATION....................................... 212 Ignition Control Module (ICM).................................... 218 REMOVAL & INSTALLATION....................................... 218 Camshaft Position (CMP) and Crankshaft Position (CKP) Sensors.... 220 FIRING ORDERS........................................................ 221 CHARGING SYSTEM...................................................... 226 General Information.............................................. 226 Alternator Precautions........................................... 227 Alternator....................................................... 228 TESTING...................................................... 228 REMOVAL & INSTALLATION....................................... 229 Voltage Regulator................................................ 232 REMOVAL & INSTALLATION....................................... 232 STARTING SYSTEM...................................................... 236 General Information.............................................. 236 Starter.......................................................... 238 TESTING...................................................... 238 REMOVAL & INSTALLATION....................................... 239 RELAY REPLACEMENT............................................ 241 SENDING UNITS........................................................ 245 Introduction..................................................... 245 Coolant Temperature Sender....................................... 245 TESTING...................................................... 245 REMOVAL & INSTALLATION....................................... 247 Oil Pressure Sender and Switch................................... 249 TESTING...................................................... 249 REMOVAL & INSTALLATION....................................... 251 Low Oil Level Sensor............................................. 253 TESTING...................................................... 253 REMOVAL & INSTALLATION....................................... 254 SPECIFICATION CHARTS................................................. 256 ENGINE MECHANICAL.................................................... 258 Engine........................................................... 258 REMOVAL & INSTALLATION....................................... 258 Valve Rocker Arm Cover........................................... 265 REMOVAL & INSTALLATION....................................... 265 Rocker Arms...................................................... 276 REMOVAL & INSTALLATION....................................... 276 Rocker Arm Shaft Assembly........................................ 278 REMOVAL & INSTALLATION....................................... 278 DISASSEMBLY & REASSEMBLY..................................... 281 Thermostat....................................................... 281 REMOVAL & INSTALLATION....................................... 281 Intake Manifold.................................................. 287 REMOVAL & INSTALLATION....................................... 287 Exhaust Manifold................................................. 312 REMOVAL & INSTALLATION....................................... 312 Radiator......................................................... 321 REMOVAL & INSTALLATION....................................... 321 Engine Fan....................................................... 325 REMOVAL & INSTALLATION....................................... 325 Water Pump....................................................... 330 REMOVAL & INSTALLATION....................................... 331 Cylinder Head.................................................... 341 REMOVAL & INSTALLATION....................................... 341 Oil Pan.......................................................... 363 REMOVAL & INSTALLATION....................................... 363 Oil Pump......................................................... 371 REMOVAL & INSTALLATION....................................... 372 Crankshaft Damper................................................ 377 REMOVAL & INSTALLATION....................................... 377 Timing Belt and Cover............................................ 379 TROUBLESHOOTING.............................................. 379 REMOVAL & INSTALLATION....................................... 379 Timing Chain Cover & Oil Seal.................................... 382 REMOVAL & INSTALLATION....................................... 382 Timing Chain and Gears........................................... 394 REMOVAL & INSTALLATION....................................... 394 TIMING CHAIN DEFLECTION...................................... 414 Camshaft and Auxiliary Shaft Sprockets and Seals................. 415 REMOVAL & INSTALLATION....................................... 415 Camshafts, Bearings and Lifters.................................. 415 REMOVAL & INSTALLATION....................................... 415 INSPECTION................................................... 428 BEARING REMOVAL & INSTALLATION............................... 431 Auxiliary Shaft.................................................. 434 REMOVAL & INSTALLATION....................................... 434 Rear Main Oil Seal............................................... 436 REMOVAL & INSTALLATION....................................... 436 Flywheel and Ring Gear........................................... 438 REMOVAL & INSTALLATION....................................... 438 EXHAUST SYSTEM....................................................... 443 REPLACEMENT...................................................... 446 ENGINE RECONDITIONING................................................ 449 Determining Engine Condition..................................... 449 COMPRESSION TEST............................................. 449 OIL PRESSURE TEST............................................ 450 Buy or Rebuild?.................................................. 451 Engine Overhaul Tips............................................. 451 TOOLS........................................................ 452 OVERHAUL TIPS................................................ 452 CLEANING..................................................... 453 REPAIRING DAMAGED THREADS.................................... 455 Engine Preparation............................................... 457 Cylinder Head.................................................... 458 DISASSEMBLY.................................................. 459 INSPECTION................................................... 470 REFINISHING & REPAIRING...................................... 474 ASSEMBLY..................................................... 477 Engine Block..................................................... 477 GENERAL INFORMATION.......................................... 478 DISASSEMBLY.................................................. 478 INSPECTION................................................... 481 REFINISHING.................................................. 484 ASSEMBLY..................................................... 486 Engine Start-up and Break-in..................................... 492 STARTING THE ENGINE.......................................... 492 BREAKING IT IN............................................... 493 KEEP IT MAINTAINED........................................... 493 SPECIFICATION CHARTS................................................. 494 EMISSION CONTROLS.................................................... 515 Positive Crankcase Ventilation (PCV) System...................... 515 OPERATION.................................................... 515 TESTING...................................................... 515 REMOVAL & INSTALLATION....................................... 516 Evaporative Emission Control System.............................. 519 OPERATION.................................................... 519 COMPONENT TESTING............................................ 520 REMOVAL & INSTALLATION....................................... 527 Exhaust Gas Recirculation (EGR) System........................... 528 OPERATION.................................................... 528 COMPONENT TESTING............................................ 529 REMOVAL & INSTALLATION....................................... 533 ELECTRONIC ENGINE CONTROLS........................................... 537 Electronic Engine Control (EEC).................................. 537 Powertrain Control Module (PCM).................................. 537 OPERATION.................................................... 537 REMOVAL & INSTALLATION....................................... 538 Heated Oxygen Sensors (HO2S)..................................... 541 OPERATION.................................................... 541 TESTING...................................................... 542 REMOVAL & INSTALLATION....................................... 543 Idle Air Control (IAC) Valve..................................... 544 OPERATION.................................................... 544 TESTING...................................................... 544 REMOVAL & INSTALLATION....................................... 545 Engine Coolant Temperature (ECT) Sensor.......................... 546 OPERATION.................................................... 546 TESTING...................................................... 547 REMOVAL & INSTALLATION....................................... 548 Intake Air Temperature (IAT) Sensor.............................. 549 OPERATION.................................................... 549 TESTING...................................................... 549 REMOVAL & INSTALLATION....................................... 549 Mass Air Flow (MAF) Sensor....................................... 550 OPERATION.................................................... 550 TESTING...................................................... 551 REMOVAL & INSTALLATION....................................... 552 Throttle Position (TP) Sensor.................................... 554 OPERATION.................................................... 554 TESTING...................................................... 555 REMOVAL & INSTALLATION....................................... 556 Camshaft Position (CMP) Sensor................................... 557 OPERATION.................................................... 557 TESTING...................................................... 559 REMOVAL & INSTALLATION....................................... 560 Crankshaft Position (CKP) Sensor................................. 565 OPERATION.................................................... 565 TESTING...................................................... 565 REMOVAL & INSTALLATION....................................... 566 Vehicle Speed Sensor(VSS)........................................ 569 OPERATION.................................................... 570 TESTING...................................................... 570 REMOVAL & INSTALLATION....................................... 570 COMPONENT LOCATIONS.................................................. 571 TROUBLE CODES........................................................ 584 General Description.............................................. 584 FAILURE MODE EFFECTS MANAGEMENT (FMEM)....................... 585 HARDWARE LIMITED OPERATION STRATEGY (HLOS)................... 585 MALFUNCTION INDICATOR LAMP (MIL)............................. 585 Diagnostic Connector............................................. 585 Reading Codes.................................................... 586 EEC-V EQUIPPED ENGINES....................................... 587 EEC-IV EQUIPPED ENGINES...................................... 587 Clearing Codes................................................... 589 CONTINUOUS MEMORY CODES...................................... 589 KEEP ALIVE MEMORY............................................ 589 Diagnostic Trouble Code Charts................................... 589 VACUUM DIAGRAMS...................................................... 600 SPECIFICATION CHARTS................................................. 601 BASIC FUEL SYSTEM DIAGNOSIS.......................................... 602 FUEL LINES AND FITTINGS.............................................. 603 General Information.............................................. 603 Hairpin Clip Fitting............................................. 603 REMOVAL & INSTALLATION....................................... 603 Duckbill Clip Fitting............................................ 605 REMOVAL & INSTALLATION....................................... 605 REMOVAL & INSTALLATION....................................... 607 SEQUENTIAL FUEL INJECTION (SFI) SYSTEM............................... 609 General Information.............................................. 609 FUEL SYSTEM SERVICE PRECAUTIONS.............................. 610 Relieving Fuel System Pressure................................... 610 Inertia Switch................................................... 611 GENERAL INFORMATION.......................................... 611 RESETTING THE SWITCH......................................... 611 Fuel Pump........................................................ 613 REMOVAL & INSTALLATION....................................... 613 TESTING...................................................... 617 Throttle Body Assembly........................................... 620 REMOVAL & INSTALLATION....................................... 620 Fuel Supply Manifold and Injectors............................... 625 REMOVAL & INSTALLATION....................................... 626 TESTING...................................................... 632 Fuel Pressure Regulator.......................................... 633 REMOVAL & INSTALLATION....................................... 633 Pressure Relief Valve............................................ 640 REMOVAL & INSTALLATION....................................... 640 FUEL TANK............................................................ 641 Tank Assembly.................................................... 641 REMOVAL & INSTALLATION....................................... 641 Sending Unit..................................................... 647 REMOVAL & INSTALLATION....................................... 647 UNDERSTANDING AND TROUBLESHOOTING ELECTRICAL SYSTEMS................. 648 Basic Electrical Theory.......................................... 648 HOW DOES ELECTRICITY WORK: THE WATER ANALOGY................. 648 OHM'S LAW.................................................... 649 Electrical Components............................................ 650 POWER SOURCE................................................. 650 GROUND....................................................... 650 PROTECTIVE DEVICES........................................... 650 SWITCHES & RELAYS............................................ 652 LOAD......................................................... 653 WIRING & HARNESSES........................................... 653 CONNECTORS................................................... 654 Test Equipment................................................... 655 JUMPER WIRES................................................. 655 TEST LIGHTS.................................................. 656 MULTIMETERS.................................................. 657 Troubleshooting Electrical Systems............................... 658 Testing.......................................................... 658 OPEN CIRCUITS................................................ 658 SHORT CIRCUITS............................................... 659 VOLTAGE...................................................... 659 VOLTAGE DROP................................................. 660 RESISTANCE................................................... 660 Wire and Connector Repair........................................ 662 BATTERY CABLES....................................................... 663 AIR BAG (SUPPLEMENTAL RESTRAINT) SYSTEM.............................. 664 SERVICE PRECAUTIONS.............................................. 665 DISARMING THE SYSTEM......................................... 665 ARMING THE SYSTEM............................................ 665 HEATING AND AIR CONDITIONING......................................... 666 Blower Motor..................................................... 666 REMOVAL & INSTALLATION....................................... 666 Blower Motor Resistor............................................ 669 REMOVAL & INSTALLATION....................................... 669 Heater Core...................................................... 669 REMOVAL & INSTALLATION....................................... 669 Control Head..................................................... 674 REMOVAL & INSTALLATION....................................... 675 Control Cables................................................... 678 ADJUSTMENT................................................... 678 REMOVAL & INSTALLATION....................................... 678 Air Conditioning Components...................................... 680 REMOVAL & INSTALLATION....................................... 680 CRUISE CONTROL....................................................... 682 Vacuum Controlled Systems........................................ 682 Electronic Systems............................................... 682 ENTERTAINMENT SYSTEMS................................................ 684 Radio Receiver/Tape Player....................................... 684 REMOVAL & INSTALLATION....................................... 684 Speakers......................................................... 686 REMOVAL & INSTALLATION....................................... 686 WINDSHIELD WIPERS.................................................... 690 Wiper Arm And Blade.............................................. 690 REMOVAL & INSTALLATION....................................... 690 Windshield Wiper Motor........................................... 692 REMOVAL & INSTALLATION....................................... 692 Windshield Washer Motor.......................................... 698 REMOVAL & INSTALLATION....................................... 698 INSTRUMENTS AND SWITCHES............................................. 701 Instrument Cluster............................................... 701 REMOVAL & INSTALLATION....................................... 701 Fuel, Oil Pressure, Voltage and Coolant Temperature Gauges....... 705 REMOVAL & INSTALLATION....................................... 705 Rear Wiper Switch................................................ 707 REMOVAL & INSTALLATION....................................... 707 Headlight Switch................................................. 707 REMOVAL & INSTALLATION....................................... 708 Back-up Light Switch............................................. 709 Manual Transmissions......................................... 709 LIGHTING............................................................. 711 Headlights....................................................... 711 REMOVAL & INSTALLATION....................................... 711 AIMING THE HEADLIGHTS........................................ 715 Signal and Marker Lights......................................... 717 REMOVAL & INSTALLATION....................................... 717 Fog/Driving Lights............................................... 728 REMOVAL & INSTALLATION....................................... 728 TRAILER WIRING....................................................... 732 CIRCUIT PROTECTION................................................... 733 Fuses............................................................ 733 REPLACEMENT.................................................. 740 Fusible Links.................................................... 742 Circuit Breakers................................................. 742 REPLACEMENT.................................................. 742 Turn Signal and Hazard Flasher Locations......................... 743 WIRING DIAGRAMS...................................................... 744 MANUAL TRANSMISSION.................................................. 745 Understanding the Manual Transmission............................ 745 Identification................................................... 745 Adjustments...................................................... 745 SHIFTER & LINKAGE ADJUSTMENTS................................ 746 Shift Handle..................................................... 746 REMOVAL & INSTALLATION....................................... 746 Neutral Sensing Switch........................................... 747 REMOVAL & INSTALLATION....................................... 748 Extension Housing Seal........................................... 749 REMOVAL & INSTALLATION....................................... 749 Transmission..................................................... 750 REMOVAL & INSTALLATION....................................... 750 CLUTCH............................................................... 753 Understanding the Clutch......................................... 753 Clutch Interlock Switch.......................................... 754 REMOVAL & INSTALLATION....................................... 754 Master Cylinder and Reservoir.................................... 754 REMOVAL & INSTALLATION....................................... 755 Slave Cylinder................................................... 756 REMOVAL & INSTALLATION....................................... 756 BLEEDING THE SYSTEM.......................................... 758 Driven Disc and Pressure Plate................................... 758 REMOVAL & INSTALLATION....................................... 758 AUTOMATIC TRANSMISSION............................................... 764 Understanding the Automatic Transmission......................... 764 Identification................................................... 764 Neutral Start Switch/Back-up Switch.............................. 764 REMOVAL & INSTALLATION....................................... 764 ADJUSTMENT................................................... 768 Vacuum Diaphragm................................................. 768 REMOVAL & INSTALLATION....................................... 768 Extension Housing Seal........................................... 769 REMOVAL & INSTALLATION....................................... 769 Transmission Assembly............................................ 771 REMOVAL & INSTALLATION....................................... 771 ADJUSTMENTS.................................................. 777 KICKDOWN CABLE............................................... 780 TRANSFER CASE........................................................ 782 Identification................................................... 782 Rear Output Shaft Seal........................................... 783 REMOVAL & INSTALLATION....................................... 783 Front Output Shaft Seal.......................................... 784 REMOVAL & INSTALLATION....................................... 784 Transfer Case Assembly........................................... 786 REMOVAL & INSTALLATION....................................... 786 ADJUSTMENTS.................................................. 788 DRIVELINE............................................................ 790 General Description.............................................. 790 Single Cardan Type Front Driveshaft.............................. 790 REMOVAL & INSTALLATION....................................... 790 DUST SLINGER/BOOT REPLACEMENT................................ 792 Double Cardan Type Front and Rear Driveshaft..................... 792 REMOVAL & INSTALLATION....................................... 792 DISASSEMBLY & ASSEMBLY....................................... 793 Single Cardan Type Rear Driveshaft............................... 795 REMOVAL & INSTALLATION....................................... 795 DISASSEMBLY & ASSEMBLY....................................... 798 Constant Velocity (CV) Type Rear Driveshaft...................... 799 REMOVAL & INSTALLATION....................................... 800 DISASSEMBLY & ASSEMBLY....................................... 800 Center Bearing................................................... 803 REMOVAL & INSTALLATION....................................... 803 FRONT DRIVE AXLE..................................................... 805 General Information.............................................. 805 Manual Locking Hubs.............................................. 805 REMOVAL & INSTALLATION....................................... 805 Automatic Locking Hubs........................................... 807 REMOVAL & INSTALLATION....................................... 807 Vacuum Disconnect Axle Lock...................................... 809 REMOVAL & INSTALLATION....................................... 809 Spindles and Spindle Bearings.................................... 811 REMOVAL & INSTALLATION....................................... 811 Axle Shafts and Seals............................................ 812 REMOVAL & INSTALLATION....................................... 812 Axle Housing..................................................... 818 REMOVAL & INSTALLATION....................................... 818 REAR AXLE............................................................ 824 Determining Axle Ratio........................................... 824 Axle Shaft, Bearing and Seal..................................... 824 REMOVAL & INSTALLATION....................................... 824 Pinion Oil Seal.................................................. 830 REMOVAL & INSTALLATION....................................... 830 Axle Housing..................................................... 833 REMOVAL & INSTALLATION....................................... 833 WHEELS............................................................... 836 Front Wheels..................................................... 836 REMOVAL & INSTALLATION....................................... 836 INSPECTION................................................... 837 Front Wheel Lug Studs............................................ 837 REMOVAL & INSTALLATION....................................... 837 INSPECTION................................................... 839 Rear Wheel Lug Studs............................................. 839 REMOVAL & INSTALLATION....................................... 839 2-WHEEL DRIVE FRONT SUSPENSION....................................... 841 Introduction..................................................... 841 Coil Springs..................................................... 842 REMOVAL & INSTALLATION....................................... 842 Torsion Bars..................................................... 844 REMOVAL & INSTALLATION....................................... 844 RIDE HEIGHT ADJUSTMENT....................................... 846 Shock Absorbers.................................................. 847 REMOVAL & INSTALLATION....................................... 847 TESTING...................................................... 850 Ball Joints...................................................... 851 INSPECTION................................................... 851 REMOVAL & INSTALLATION....................................... 852 Knuckle and Spindle.............................................. 854 REMOVAL & INSTALLATION....................................... 854 Radius Arm....................................................... 857 REMOVAL & INSTALLATION....................................... 857 Stabilizer Bar................................................... 859 REMOVAL & INSTALLATION....................................... 859 I-Beam Axle...................................................... 862 REMOVAL & INSTALLATION....................................... 862 Upper Control Arm................................................ 863 REMOVAL & INSTALLATION....................................... 863 Lower Control Arm................................................ 865 REMOVAL & INSTALLATION....................................... 865 Front Wheel Bearings............................................. 867 REMOVAL & INSTALLATION....................................... 867 ADJUSTMENT................................................... 872 Wheel Alignment.................................................. 873 CASTER....................................................... 873 CAMBER....................................................... 874 TOE.......................................................... 874 4-WHEEL DRIVE FRONT SUSPENSION....................................... 876 Introduction..................................................... 876 Coil Springs..................................................... 878 REMOVAL & INSTALLATION....................................... 878 Torsion Bars..................................................... 879 REMOVAL & INSTALLATION....................................... 879 RIDE HEIGHT ADJUSTMENT....................................... 881 Shock Absorbers.................................................. 882 REMOVAL & INSTALLATION....................................... 882 TESTING...................................................... 888 Ball Joints...................................................... 888 INSPECTION................................................... 888 REMOVAL & INSTALLATION....................................... 889 Steering Knuckle................................................. 890 REMOVAL & INSTALLATION....................................... 890 Radius Arm....................................................... 892 REMOVAL & INSTALLATION....................................... 892 Stabilizer Bar................................................... 893 REMOVAL & INSTALLATION....................................... 893 I-Beam Axle...................................................... 895 Upper Control Arm................................................ 895 REMOVAL & INSTALLATION....................................... 895 Lower Control Arm................................................ 897 REMOVAL & INSTALLATION....................................... 897 Front Wheel Bearings............................................. 899 REMOVAL & INSTALLATION....................................... 899 ADJUSTMENT................................................... 910 Wheel Alignment.................................................. 912 REAR SUSPENSION...................................................... 913 Introduction..................................................... 913 Leaf Springs..................................................... 914 REMOVAL & INSTALLATION....................................... 914 Shock Absorbers.................................................. 916 REMOVAL & INSTALLATION....................................... 916 TESTING...................................................... 920 Stabilizer Bar................................................... 921 REMOVAL & INSTALLATION....................................... 921 STEERING............................................................. 923 Steering Wheel................................................... 923 REMOVAL & INSTALLATION....................................... 923 Combination Switch............................................... 929 REMOVAL & INSTALLATION....................................... 929 Ignition Switch.................................................. 930 REMOVAL & INSTALLATION....................................... 930 Ignition Lock Cylinder Assembly.................................. 931 REMOVAL & INSTALLATION....................................... 931 Steering Column.................................................. 932 REMOVAL & INSTALLATION....................................... 932 Steering Linkage................................................. 934 REMOVAL & INSTALLATION....................................... 935 Manual Steering Gear............................................. 940 ADJUSTMENTS.................................................. 941 REMOVAL & INSTALLATION....................................... 942 Power Steering Gear.............................................. 943 ADJUSTMENTS.................................................. 943 REMOVAL & INSTALLATION....................................... 943 Power Rack and Pinion Steering Gear.............................. 945 REMOVAL & INSTALLATION....................................... 945 Power SteeringPump............................................... 947 REMOVAL & INSTALLATION....................................... 947 BLEEDING..................................................... 950 QUICK-CONNECT PRESSURE LINE.................................. 950 SPECIFICATION CHARTS................................................. 952 BRAKE OPERATING SYSTEM............................................... 953 Basic Operating Principles....................................... 953 DISC BRAKES.................................................. 954 DRUM BRAKES.................................................. 955 Brake Light Switch............................................... 955 REMOVAL & INSTALLATION....................................... 955 Master Cylinder.................................................. 956 REMOVAL & INSTALLATION....................................... 956 Power Booster.................................................... 960 REMOVAL & INSTALLATION....................................... 960 Brake Hoses and Lines............................................ 965 REMOVAL & INSTALLATION....................................... 965 Bleeding The Brakes.............................................. 967 FRONT DISC BRAKES.................................................... 970 Introduction..................................................... 970 Brake Pads....................................................... 971 INSPECTION................................................... 971 REMOVAL & INSTALLATION....................................... 971 Calipers......................................................... 986 REMOVAL & INSTALLATION....................................... 987 OVERHAUL..................................................... 989 Brake Rotor (Disc)............................................... 993 REMOVAL & INSTALLATION....................................... 993 INSPECTION................................................... 993 REAR DRUM BRAKES..................................................... 995 Introduction..................................................... 995 Brake Drums...................................................... 997 REMOVAL & INSTALLATION....................................... 997 INSPECTION................................................... 998 Brake Shoes...................................................... 999 REMOVAL & INSTALLATION....................................... 999 ADJUSTMENTS..................................................1009 Wheel Cylinders..................................................1012 REMOVAL & INSTALLATION.......................................1012 OVERHAUL.....................................................1013 REAR DISC BRAKES.....................................................1019 General Information..............................................1019 Brake Pads.......................................................1019 REMOVAL & INSTALLATION.......................................1019 INSPECTION...................................................1021 Brake Caliper....................................................1021 REMOVAL & INSTALLATION.......................................1021 OVERHAUL.....................................................1022 Brake Disc.......................................................1022 REMOVAL & INSTALLATION.......................................1022 INSPECTION...................................................1022 REAR ANTI-LOCK BRAKE SYSTEM (RABS)...................................1023 Component Location...............................................1023 System Self-Test.................................................1024 Computer (RABS) Module...........................................1025 REMOVAL & INSTALLATION.......................................1025 RABS Valve.......................................................1025 REMOVAL & INSTALLATION.......................................1025 RABS Sensor......................................................1025 TESTING......................................................1026 REMOVAL & INSTALLATION.......................................1026 Exciter Ring.....................................................1027 PARKING BRAKE........................................................1028 Cable............................................................1028 ADJUSTMENT...................................................1028 REMOVAL & INSTALLATION.......................................1032 Brake Shoes......................................................1038 REMOVAL & INSTALLATION.......................................1038 ADJUSTMENT...................................................1039 4-WHEEL ANTI-LOCK BRAKE SYSTEM (4WABS)...............................1041 Introduction.....................................................1041 System Self-Test.................................................1041 Hydraulic Control Unit (HCU).....................................1042 PUMP TESTING.................................................1042 REMOVAL & INSTALLATION.......................................1043 Electronic Control Unit..........................................1043 REMOVAL & INSTALLATION.......................................1043 Front Wheel Speed Sensor.........................................1044 TESTING......................................................1044 REMOVAL & INSTALLATION.......................................1044 Rear Speed Sensor................................................1044 TESTING......................................................1044 REMOVAL & INSTALLATION.......................................1044 Front Speed Sensor Ring..........................................1045 REMOVAL & INSTALLATION.......................................1046 Rear Speed Sensor Ring...........................................1046 REMOVAL & INSTALLATION.......................................1046 SPECIFICATION CHARTS.................................................1047 EXTERIOR.............................................................1048 Doors............................................................1048 REMOVAL & INSTALLATION.......................................1048 ADJUSTMENT...................................................1051 Hood.............................................................1052 REMOVAL & INSTALLATION.......................................1052 ALIGNMENT....................................................1054 Liftgate.........................................................1054 REMOVAL & INSTALLATION.......................................1054 ALIGNMENT....................................................1058 Tailgate.........................................................1060 REMOVAL & INSTALLATION.......................................1060 Front and Rear Bumpers...........................................1062 REMOVAL & INSTALLATION.......................................1062 Grille...........................................................1065 REMOVAL & INSTALLATION.......................................1066 Outside Mirrors..................................................1067 REMOVAL & INSTALLATION.......................................1067 Antenna..........................................................1069 REMOVAL & INSTALLATION.......................................1069 Fenders..........................................................1071 REMOVAL & INSTALLATION.......................................1071 Pickup Truck Bed.................................................1073 REMOVAL & INSTALLATION.......................................1073 Chassis and Cab Mount Bushings...................................1074 REMOVAL & INSTALLATION.......................................1074 Spare Tire Carrier...............................................1078 REMOVAL & INSTALLATION.......................................1078 INTERIOR.............................................................1080 Door Panels......................................................1080 REMOVAL & INSTALLATION.......................................1080 Interior Trim Panels.............................................1086 REMOVAL & INSTALLATION.......................................1086 Instrument Panel.................................................1091 REMOVAL & INSTALLATION.......................................1091 Center Console...................................................1094 REMOVAL & INSTALLATION.......................................1094 Headliner........................................................1096 REMOVAL & INSTALLATION.......................................1096 Door Locks.......................................................1098 REMOVAL & INSTALLATION.......................................1098 Door Glass and Regulator.........................................1100 REMOVAL & INSTALLATION.......................................1101 Electric Window Motor............................................1105 REMOVAL & INSTALLATION.......................................1105 Windshield and Fixed Glass.......................................1106 REMOVAL & INSTALLATION.......................................1106 WINDSHIELD CHIP REPAIR.......................................1107 Inside Rear View Mirror..........................................1108 REMOVAL & INSTALLATION.......................................1108 Seats............................................................1108 REMOVAL & INSTALLATION.......................................1109 Seat Belt Systems................................................1112 REMOVAL & INSTALLATION.......................................1112 SPECIFICATION CHARTS.................................................1118
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