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

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WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. In the USA or Canada on Ford/Motorcraft products call: 1-800-959-3673. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in personal injury. CAUTION: Do not spill brake fluid onto painted or plastic surfaces. If spilled, wipe up immediately before damage to the plastic or painted surfaces occurs. 1. Remove the wheel and tire assembly. For additional information, refer to Section 204-00. 2. Remove the parts in the order indicated in the following illustration and table. To remove individual parts, only carry out the listed steps: 3. To install, reverse the removal procedure. 4. If the hydraulic system was opened, bleed the brake system. For additional information, refer to Brake System Bleeding in this section. Item 2: Brake Caliper Removal Note 1. CAUTION: Do not allow the brake caliper to hang by the flexible brake hose. Support the caliper to the vehicle. Item 11: Brake Disc Removal Note 1. If removing the brake disc, only remove the caliper bracket bolts and position the caliper and bracket aside. Item 10: Spindle Nut Installation Note 1. Tighten the spindle nut to the specified torque. Rotate the hub counter-clockwise 5 rotations and then recheck the torque. Item 3: Brake Disc Pads Installation Note 1. CAUTION: Install a new lining if worn to or past the specified thickness above the metal backing plate or if the pad is damaged. Install new pads in complete axle sets. If replacing the brake pads, use a suitable suction device, remove the brake fluid in the master cylinder reservoir until it is half filled. 2. If replacing the brake pads, use a suitable tool to push the brake caliper pistons into the caliper bore. 3. One brake disc pad kit contains the pads required for both the RH and LH side. Item 1: Caliper Bolt Installation Note 1. Tighten the bottom caliper bolt and then the top caliper bolt. Item 11: Brake Disc Inspection Note 1. NOTE: If machining is necessary use a hub-mount brake lathe to machine the front brake disc. For additional information, refer to section Section 100-04. Measure the front brake disc, and resurface as necessary. Install a new front brake disc if beyond specification.

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Manual Locking Hubs, Ranger 1. Raise the vehicle and install safety stands. 2. Remove the lug nuts (1012) and wheel and tire assembly. Refer to Section 04-04. 3. Remove the retainer washers from the wheel hub bolt nut studs and the manual locking hub assembly from the front wheel spindle (3105). 4. Remove the snap ring from the end of the shaft of the front wheel spindle. Manual Locking Hub, Exploded View, Ranger 5. Remove the axle shaft spacers. 6. Remove the outer wheel bearing locknut from the front wheel spindlej using Hub Locknut Wrench Prong T83T-1197-B. Engage tool tabs into locknut slots. 7. Remove locknut washer from front wheel spindle. 8. Loosen the inner wheel bearing locknut. Engage tool tab in locknut slots. Make sure tool is centered over the locknut pin. 9. Tighten the inner locknut to 47 Nm (35 lb-ft) while turning the rotor in the opposite direction to seat wheel bearings. 10. NOTE: If necessary, tighten inner locknut slightly to align the locknut pin with lockwasher hole. Spin the rotor and back off the inner locknut one-quarter turn. Retighten the inner locknut to 1.8 Nm (16 lb-in). 11. Install the lockwasher on the front wheel spindle. 12. Install the outer wheel bearing locknut using locknut wrench. Tighten locknut to 203 Nm (150 lb-ft). 13. Check the end play of the wheel and tire assembly on the front wheel spindle. Final end play should be 0.00-0.08mm (0.000-0.003 inch). The maximum torque to rotate the hub is 2.8 Nm (25 lb-in). 14. Install the axle shaft spacer. 15. Clip the snap ring onto the end of the shaft of the front wheel spindle. 16. Install the manual hub assembly over the front wheel spindle. Install the retainer washers. 17. Install the wheel and tire assembly. Install and tighten lug nuts to 135 Nm (100 lb-ft). Automatic Locking Hubs, Ranger 1. Raise the vehicle and install safety stands. 2. Remove the lug nuts and the wheel and tire assembly. Refer to Section 04-04. 3. Remove the retainer washers from the wheel hub bolt nut studs. Remove the automatic locking hub assembly from the front wheel spindle. Automatic Locking Hub, Exploded View, Ranger

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1. Loosen the strut tower nuts by at least five turns. See Fig. 4 . Loosen the wheel hub retaining nut. Raise and support vehicle. Remove front wheel, brake caliper and rotor. Remove ABS wheel speed sensor (if equipped). Remove tie rod end cotter pin and nut. Using Tie Rod End Separator (211-001), remove tie rod end. See Fig. 13 . 2. Remove lower control arm nut and pinch bolt. See Fig. 15 . Separate lower control arm from steering knuckle. Remove wheel hub retaining nut. Using a suitable puller, separate wheel hub from halfshaft. See Fig. 6 . Remove strut assembly-to-steering knuckle bolt. See Fig. 3 . Remove steering knuckle. Disassembly & Reassembly 1. Using Bearing Pulling Attachment (205-D064), press wheel hub from wheel knuckle. See Fig. 7 . Remove retainer ring from wheel knuckle. See Fig. 8 . Using a suitable drift, remove front wheel bearing from wheel knuckle. See Fig. 9 . CAUTION: Avoid any impact on the wheel speed sensor ring. Make sure the wheel speed sensor ring is clean. Avoid any contact between the wheel speed sensor ring and a magnetic surface. Make sure the wheel bearing is installed into the wheel knuckle with the wheel speed sensor ring, colored black, at the wheel speed sensor end of the wheel knuckle. 2. To reassemble, reverse disassembly procedure.

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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).

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1. Raise and support the vehicle. Refer to Vehicle Lifting. 2. Remove the tire and wheel. 3. Remove the brake rotor (2). Refer to Brake Rotor Replacement – Front. 4. Important: The wheel speed sensor mounts to the hub/bearing assembly. Thoroughly clean around this area in order to prevent any dirt or contaminants from entering the sealed wheel bearing. Failure to do this may lead to premature wheel bearing failure. Remove the Wheel Speed Sensor (WSS) mounting bolt. 5. NOTICE: Carefully remove the sensor by pulling it straight out of the bore. DO NOT use a screwdriver, or other device to pry the sensor out of the bore. Prying will cause the sensor body to break off in the bore. Remove the wheel speed sensor (5) from the hub/bearing assembly (4). Remove the WSS cable mounting clip from the knuckle. Remove the WSS cable mounting clip from the upper control arm. Remove the WSS cable mounting clip from the frame attachment point. Remove the WSS cable electrical connector. 6. 7. 8. 9. Installation Procedure 1. Plug the WSS bore to prevent debris from falling into the hub. 2. Using a wire brush or equivalent, clean the WSS mounting surface on the hub to remove any rust or corrosion. 3. Apply a thin layer of wheel bearing lubricant, GM P/N 01051344 to the hub surface and the sensor O-ring prior to the sensor installation.