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Removal (Bronco & F150) 1. Using Torx Bit (T-25), remove 5 bolts from cap assembly. Remove cap assembly. See Fig. 5 . DO NOT drop spring, ball bearing, bearing race or spring retainer. 2. Remove rubber sealing ring and seal bridge retainer. Remove retainer ring by closing ends with needle nose pliers while pulling hub lock from wheel hub. 3. If wheel hub and spindle are to be removed, remove “C” washer from stub shaft groove. Remove splined spacer from axle shaft. Remove wheel bearing lock nuts and lock washer. Exploded View Of Automatic Locking Hub (Bronco & F150) Exploded View Of Automatic Locking Hub (Explorer & Ranger) Removing Manual Locking Hub (Bronco & F150) Exploded View Of Manual Locking Hub (Explorer & Ranger)

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Manual locking hubs engage and disengage front wheels from axle shafts on 4WD vehicles. These hubs are are optional. When hubs are engaged in LOCK position, wheels and axle shafts rotate together. When hubs are disengaged or unlocked in FREE position, front wheels free-wheel on hub bearings. REMOVAL & INSTALLATION MANUAL LOCKING HUB Removal 1) Position locking hub in FREE position. Remove cover-to- body retaining bolts. Remove cover assembly and gasket. 2) Remove snap ring from drive axle. Remove body-to-hub retaining bolts. Remove body and gasket. See Fig. 1. CAUTION: Lubricate sliding surfaces with multipurpose grease, but DO NOT pack hub with grease.

The Ford supplied Sierra 4×4 Supplementary Workshop Manual is a “must have” for any owner of one of these cars. The biggest problem can be actually finding one to purchase. I got lucky and managed to get mine direct from a Ford dealer, brand new for ?8, who was having a clearout. They do appear regularly at autojumbles and it is just a case of keep looking. The manual only covers those items unique to the 4×4 Sierra’s and are to be used in conjunction with the Ford Sierra Workshop Manual. Ford never produced a supplement that covered the 2.9 engine or the later Mark Two model but all the running gear sections are relevant as this never changed during the life of the model

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X1 CHECK THE IGNITION STATES Diagnostic Tool X2 RETRIEVE THE DIAGNOSTIC TROUBLE CODES X3 VERIFY THE INOPERATIVE INDICATOR LAMP Monitor the PID IGN_GEM while turning the ignition switch through the START, RUN, OFF, and ACC positions. Do the PID values agree with the ignition switch positions? Yes GO to X2. No REFER to Section 417-02. Use the recorded results from the continuous and on-demand self-tests. Are any DTCs recorded? Yes If DTC B1342, GO to X17 . No GO to X3. If DTC P1804, GO to X3 . If DTC P1806, GO to X3 . If DTC P1808, GO to X3 . If DTC P1810, GO to X3 . Verify the inoperative indicator. Are the 4×4 HIGH or 4×4 LOW indicators inoperative? Yes GO to X6. No If the 4×4 LOW indicator is inoperative, GO to X12 . If the 4×4 HIGH indicator is inoperative, GO to X7 . If both the 4×4 HIGH and 4×4 LOW indicators are inoperative, GO to X4 . X4 CHECK THE O/D OFF INDICATOR Verify the O/D OFF indicator works. Does the O/D OFF indicator function correctly? Yes GO to X7. No GO to X5. X5 CHECK THE VOLTAGE TO THE INDICATORS Instrument Cluster 220a Measure the voltage between the instrument cluster 220a pin 5, circuit 484 (OG/BK), harness side and ground.

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Fig. 1: Exploded View Of Automatic Locking Hub (Explorer & Ranger) Fig. 2: Exploded View Of Manual Locking Hubs (Explorer & Ranger)
REMOVAL & INSTALLATION AUTOMATIC LOCKING HUBS MANUAL LOCKING HUBS Removal 3. Using magnet, remove locking key from spindle keyway. It may be necessary to rotate adjusting nut slightly to relieve pressure for locking key removal. Loosen adjusting nut with 2 3/8″ Hex Socket (T70T- 4252-B). 4. Tighten adjusting nut to 35 ft. lbs. (47 N.m) while turning hub back and forth to seat bearings. Spin hub and back off adjusting nut 90 degrees. Retighten adjusting nut to 16 INCH lbs. (1.8 N.m). 5. Align nearest hole in adjusting nut with center of spindle keyway slot. If necessary, advance nut to next lug. Install locking key in spindle keyway under adjusting nut. Install 2 thrust washers. Press plastic cam assembly onto adjusting nut while lining up key in fixed cam with spindle keyway.