Auto Repair Manual Free Download and ReviewsFree download ebook pdf files automotive manual

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1. Remove the battery (10655). For additional information, refer to Battery. 2. Remove the battery junction box (BJB) cover and remove the attachment nut securing the positive cable. 3. Remove the negative cable bolt. 4. Remove the harness clips from the cable in the luggage compartment. 5. Remove the rear seat cushion. 6. Remove the upper RH B-pillar trim panel. For additional information, refer to Section 501-05. 7. NOTE: LH shown, RH similar Remove the lower RH B-pillar trim cover and scuff plate screws . 8. NOTE: LH shown, RH similar Remove the RH front and rear scuff plates. 9. NOTE: LH shown, RH similar Remove the RH A-pillar lower trim panel and position aside the carpet to expose battery cable. 10. Remove the retaining tie straps and detach the cable forward past the rear seatback into the passenger compartment. 11. Remove the cable attachment cover and the nut at the dash through-bolt and remove the cable. 12. In the engine compartment at the dash panel, remove the protective cover and the nut. 13. Remove the bolt at the body.

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ISSUE Some 2002-2005 4×4 Explorer 4dr/Mountaineer and 2003-2005 4×4 Aviator vehicles may exhibit a vibration/drone/boom at 55-75 MPH (89-121 km/h). Electronic vibration analyzer (EVA) readings will fall under 1st order rear driveshaft at 2700-3100 shaft RPM (45-52 Hertz). ACTION If the condition is present in 3rd gear (with overdrive cancelled), and is isolated to the driveline (not felt through the steering wheel), install a premium balanced driveshaft. Refer to the following Service Procedure. SERVICE PROCEDURE NOTE THIS TSB DOES NOT APPLY TO THE SOLID 4X2 DRIVESHAFT, IT ONLY APPLIES TO 4X4 WITH BOOT/SLIP JOINT IN THE MIDDLE OF THE DRIVESHAFT. 1. With the vehicle in NEUTRAL, position it on a hoist. Refer to Workshop Manual Section 100-02. 2. Remove skid plate, if equipped. 3. Remove the driveshaft flange bolts (Figure 1). 5. Using a suitable tool, disconnect the driveshaft flanges and remove the driveshaft (Figure 3). Figure 3 – Article 05-16-4 6. Measure the NEW driveshaft length from u-joint center to u-joint center. Refer to Step 6a or 6b. a. Driveshafts measuring LESS than 1194 ± 1.0 mm must be expanded as follows: (1) Place driveshaft on a suitable workbench and firmly secure either flange in a suitable vice. CAUTION CAREFULLY SECURE THE DRIVESHAFT TO AVOID DAMAGE TO THE FLANGE. (2) Grasp the shaft at the opposing flange with both hands and expand (by pulling) as required to 1194 ± 1.0 mm.

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Draining WARNING: Never remove the pressure relief cap while the engine is operating or when the cooling system is hot. Failure to follow these instructions can result in damage to the cooling system or engine or personal injury. To avoid having scalding hot coolant or steam blow out of the degas bottle when removing the pressure relief cap, wait until the engine has cooled, then wrap a thick cloth around the pressure relief cap and turn it slowly. Step back while the pressure is released from the cooling system. When you are sure all the pressure has been released, (still with a cloth) turn and remove the pressure relief cap. CAUTION: The coolant must be recovered in a suitable, clean container for reuse. If the coolant is contaminated it must be recycled or disposed of correctly. CAUTION: Care must be taken to ensure the accessory drive belt does not become contaminated with engine coolant. CAUTION: Some vehicle cooling systems are filled with Motorcraft Premium Engine Coolant VC-4-A (in Oregon VC-5, in Canada CXC-10) or equivalent meeting Ford specifications ESE-M97B44-A (green color). Others are filled with Motorcraft Premium Gold Engine Coolant VC-7-A or equivalent meeting Ford specification WSS-M97B51-A1 (yellow color). Always refill the cooling system with the same coolant that was drained from the system. Do not mix coolant types. 1. Release the pressure in the cooling system by slowly turning the pressure relief cap one half turn counterclockwise. When the pressure is released, remove the pressure relief cap. 2. NOTE: Less than 80% of coolant can be recovered with the engine in the vehicle. Dirty, rusty or contaminated coolant requires replacement. Place a suitable container below the radiator draincock. If equipped, disconnect the coolant return hose at the oil cooler. Close the radiator draincock when finished. Filling and Bleeding With RADKITPLUS 1. Using the special tool, install the RADKITPLUS and follow the RADKITPLUS manufacturer’s instructions to fill and bleed the cooling system. Filling and Bleeding Without RADKITPLUS CAUTION: Engine coolant provides freeze protection, boil protection, cooling efficiency and corrosion protection to the engine and cooling components. In order to obtain these protections, the engine coolant must be maintained at the correct concentration and fluid level in the degas bottle. When adding engine coolant, use a 50/50 mixture of engine coolant and clean, drinkable water. To maintain the integrity of the coolant and the cooling system:

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Removal & Installation WARNING Do not loosen the axle wheel hub retainer until the wheel and tire are removed from the vehicle. Wheel bearing damage will occur if the wheel bearing is unloaded with the weight of the vehicle applied. NOTE Have an assistant press the brake pedal to keep the axle from turning. 1. Before servicing the vehicle, please familiarize yourself with safety procedures. ? Remove the axle-to-wheel hub retainer nut and washer. ? Remove the parking brake shoes. WARNING Do not use a hammer to separate the outboard CV-joint from the hub. Damage to the threads and internal CV-joint components can result. 2. 3. ? Press the outboard CV-joint until it is loose from the hub. ? Remove and discard the toe link-to-wheel knuckle nut. WARNING Do not damage the boot while separating the toe link from the wheel knuckle. 4. 5. ? Remove the bolt and separate the toe link from the wheel knuckle. ? Remove and discard the upper arm-to-wheel knuckle nut. WARNING Do not damage the boot while separating the ball joint from the wheel knuckle. 6. 7. ? Remove the bolt and separate the upper arm from the wheel knuckle. ? Remove and discard the lower arm-to-wheel knuckle nut. 8. 9. ? Remove the lower arm-to-wheel knuckle bolt. ? Remove the wheel knuckle. ? Using a suitable press, remove and discard the wheel hub. ? Remove and discard the wheel bearing retainer ring. ? Using a suitable press, remove the wheel bearing. 10. 11. 12. 13. 14. Fig. Rear hub/bearing Assembly-Aviator, Explorer and Mountaineer Fig. Pressing out the bearing ? To install: 1. Installation is the reverse of the removal procedure. ? Observe the following torques: 2. Lower arm-to-wheel knuckle nut: 111 ft. lbs. (150 Nm). ? Upper arm-to-wheel knuckle nut: 66 ft. lbs. (90 Nm). ? Toe link-to-wheel knuckle nut: 66 ft. lbs. (90 Nm). ? Axle-to-hub retainer nut: 203 ft. lbs. (275 Nm). ? ? Always install a new: 3. Axle-to-wheel hub retainer nut. ? Toe link-to-wheel knuckle nut. ? Upper arm-to-wheel knuckle nut. ? Lower arm-to-wheel knuckle nut. ? Wheel hub. ? Wheel bearing retainer ring. ? ? 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. ? Remove or disconnect the following: NOTE Do not loosen the axle wheel hub retainer until the wheel and tire are removed from the vehicle. Wheel bearing damage will occur if the wheel bearing is unloaded with the weight of the vehicle applied. 2. NOTE Do not use a hammer to separate the outboard CV joint from the hub. Damage to the threads and internal CV joint components may result.

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ISSUE Some 2002-2005 Explorer 4dr/Mountaineer and 2003-2005 Aviator vehicles may exhibit a noise from the rear wheel hub bearings. Previous service procedures required service replacement of the wheel hub bearing assembly, base part (1109). This new service procedure allows replacement at a lower service level of the wheel bearing, base part (1215) to repair the noise condition. ACTION Replace the rear hub bearing and wheel bearing retainer ring. Refer to the following Service Procedure. SERVICE PROCEDURE NOTE HAVE AN ASSISTANT PRESS THE BRAKE PEDAL TO KEEP THE AXLE FROM TURNING. 1. Remove the axle-to-wheel hub retainer nut and washer (Figure 1). Discard the nut. When reinstalling at end of procedure, tighten to 203 lb-ft (275 N•m).Figure 1 – Article 05-25-8 2. Remove the bolt and disconnect the wheel speed sensor (Figure 2). To install, tighten to 71 lb-in (8 N•m).