Instructions
Before removing any parts, park the car on a secure, stable and level surface, loosen (but do not remove) the wheel lug nuts, jack the vehicle up and place the car on four stable jack stands or use a professional vehicle lift. We recommend having two people available for certain steps of the installation.
Front Install Instructions
1. Securely support both front corners of the car.
2. Remove front wheels.
3. Disconnect link on ride height sensor to prevent damage.
4. Disconnect hydraulic suspension line and drain in to pan. Remove line from bulkhead mounting plate
5. Remove the Lower Front shock clevis bolt that attaches the fork of the shock to the lower front control arm.
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The Ford Explorer’s brake system is a relatively robust and trouble-free system. But, that doesn’t mean something can’t go wrong. The Ford Explorer is one of the most common vehicles on our roads. The system is a product of what Ford learned in the late 1990s about brake systems and what it means to customer satisfaction. It is a relatively robust and trouble-free system. But, it does not mean something cannot go wrong. The Explorer’s brake system has large enough rotors and pad surface to safely bring the vehicle to a stop and the rotors can last at least the first two brake jobs depending on the driver. The calipers can last more than 100,000 miles before they might require replacement.
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Disassembly
1. Remove the differential case (4204). For additional information, refer to Differential Case in this section.
2. NOTE: The differential bearings (4221) need not be removed to overhaul the Ford limited slip differential. If bearing removal is required, use the special tool 205-D072 (D97L-4221-A) and special tool 205–D019 (D80L-630–8) for differential case bearings.
NOTE: The anti-lock speed sensor ring cannot be reused once removed. Remove the differential pinion shaft lock bolt and remove the differential pinion shaft (4211). If required, remove the differential ring gear and anti-lock speed sensor ring.
3. Install the special tool in a suitable vise.
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REMOVAL:
1. Disconnect the negative battery cable(s).
2. Remove the torque converter access cover and inspection plate.
3. Remove the transmission pan, drain the fluid and re-install the pan.
4. Remove the fill tube bracket bolt and pull the tube out of the transmission. Retain the fill tube seal. On 4WD models, it will also be necessary to remove the bolt attached to the transfer case vent tube to the converter housing.
5. Rotate the crankshaft with a pry bar from under the vehicle until the converter bolts are accessible.
6. Mark the drive shaft and pinion yokes for assembly alignment. Disconnect and remove the drive shaft. On 4WD models, remove both drive shafts.
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