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CAUTION: The three-way catalytic converter (5E212) is located beside the transfer case . Be careful when working around the three-way catalytic converter because of the extreme high temperatures generated by the three-way catalytic converter . 1. Raise the vehicle on a hoist and position suitable safety stands under vehicle. 2. Remove skid plate from frame (5005) , if equipped. 3. Remove the damper from the transfer case , if equipped. NOTE: Drain transfer case only if transfer case disassembly is required. 4. Place a drain pan under the transfer case . Remove the drain plug and drain the fluid from the transfer case . CAUTION: Do not pull directly on the wires or pull outwardly on the locking tabs. 5. Remove the wire connector from the feed wire harness at the rear of the transfer case . First squeeze the locking tabs, then pull the connectors apart. Remove the connector for the motor from the mounting bracket. NOTE: For detailed instruction on front and rear driveshaft removal and installation, refer to Section 05-01. 6. Disconnect the front driveshaft from the case yoke (7B214) and wire the driveshaft out of the way. 7. Disconnect the rear driveshaft from the case yoke and wire the driveshaft out of the way. 8. Disconnect the speedometer drive gear (17285) from the transfer case rear case (7005) . 9. Disconnect the transfer case breather tube from the mounting bracket. 10. Support the transfer case with a suitable high lift transmission jack, such as Rotunda Number 077-00019 or equivalent.

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1. Loosen the air cleaner outlet tube clamp at the Mass Air Flow (MAF) sensor and remove tube. 2. Disconnect the MAF sensor electrical connector. 3. Remove the engine air cleaner cover. 1 Unclip the two bail clamps. 2 Remove the engine air cleaner cover. 4. Remove the Air Cleaner element (ACL element). 1998 Ford Truck Explorer 2WD V6-245 4.0L VIN X SFI 5. Remove the lower air cleaner assembly. INSTALLATION 1. Follow the removal procedure in reverse order.

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Removal 1. With the vehicle in NEUTRAL, raise and support the vehicle. 2. NOTE: Drain the transfer case if disassembly is required. Remove the drain plug and drain the transfer case. 3. Remove the skid plate, if equipped. 4. NOTE: To maintain initial driveshaft balance, index-mark the rear driveshaft. Remove the rear driveshaft. For additional information, refer to Section 205-01. 5. Remove the two nuts and the front driveshaft shield. 6. NOTE: To maintain initial driveshaft balance, index-mark the front driveshaft. Remove the front driveshaft. For additional information, refer to Section 205-01. 7. Make preliminary adjustment references. 1. Index-mark the torsion bars to the torsion bar crossmember. 2. Measure and record the torsion bar adjuster bolt length. 8. Remove the bolts. 9. Using the special tools, remove the torsion bar adjustment nuts. Tighten the special tool until the torsion bar adjuster lifts off the adjuster nut. 10. Remove the torsion bar adjusting brackets. 1. Move the torsion bars forward. 2. Remove the torsion bar adjusting brackets. 11. Pull the torsion bar rearward and separate it from the lower control arm. Remove the RH torsion bar only. 12. Remove the six bolts and the torsion bar crossmember.

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Exploded view of transfer case is not available. Note location of transfer case bolts and studs prior to disassembling transfer case. Bolts and studs MUST be installed in same locations as removed. Remove rubber plug from rear case. See Fig. 3 . Spread rear output bearing retaining ring from mainshaft through access hole under rubber plug. Retaining ring must be spread to separate front and rear cases. Remove front speed sensor from front case. See Fig. 4 . Remove 6 input shaft studs from front case. See Fig. 5 . Remove 2 studs securing transfer case shield mounting bracket to transfer case. See Fig. 6 . Fig. 2: Locating Motor/Encoder & Gasket Fig. 3: Locating Rear Speed Sensors & Rubber Plug Fig. 4: Locating Front Speed Sensor Fig. 5: Removing & Installing Input Shaft Studs (6)

repair and service manual covers Ford Explorer, Mazda Navajo, and Mercury Mountaineer, all models from 1991 to 2001. Plus Explorer Sport thru 2003 and Explorer Sport Trac thru 2005.

Table of Contents

Introductory pages
About this manual | Introduction | Vehicle identification numbers | Buying parts | Maintenance techniques, tools and working facilities | Jacking and towing | Booster battery (jump) starting | Automotive chemicals and lubricants | Conversion factors | Fraction/decimal/millimeter equivalents | Safety first! | Troubleshooting

* Tune-up and routine maintenance
* 4.0L (pushrod) V6 engine
* 4.0L SOHC V6 engine
* 5.0L V8 engine
* General engine overhaul procedures
* Cooling heating and air conditioning systems
* Fuel and exhaust systems
* Engine electrical systems
* Emissions control systems
* Manual transmission
* Automatic transmission
* Transfer case
* Clutch and driveaxles
* Brakes
* Suspension and steering systems
* Body
* Chassis electrical system
* Wiring diagrams