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1. Drain cooling system. Remove timing belt. Remove right ignition coil. Disconnect coolant hose from coolant inlet housing.
2. Remove retaining bolts and separate coolant inlet housing and "O" ring from water pump. Remove retaining bolts/nuts and water pump. Remove "O" ring from coolant by-pass pipe which fits into rear of water pump.
Installation Ensure sealing surfaces are clean. Install NEW "O" ring on coolant by-pass pipe. Lubricate "O" ring with soapy water solution.
2. Apply a .08-.12" (2.0-3.0 mm) diameter bead of sealant on mounting surface at rear of water pump. Install water pump. Ensuring water pump engages over coolant by-pass pipe. Tighten fasteners to specification. See
3. To install remaining components, reverse removal procedure. Fill and bleed cooling system.
Remove the transaxle and flexplate.
CAUTION Make sure not to damage the crankshaft sealing surface when removing the oil seal.
Insert a flat-bladed pry tool or equivalent through the dust lip at an angle.
Carefully pry the oil seal out of the engine. Pry against the chamfered edge of the crankshaft, do not damage the sealing surface of the crankshaft or an oil leak may occur.
To Install: CAUTION Smooth any burr or rough edge on the crankshaft with 400 grit sandpaper to prevent seal damage during installation. NOTE: When installing seal, no lube on seal is needed.
Place special tool 6926-1 seal guide or equivalent on crankshaft.
Place the seal on the guide. Make sure the seal lip is facing the crankshaft and the guide tool remains on the crankshaft.
Rear crankshaft seal installation (2.4L engine shown, 3.3L & 3.8L engines similar)
CAUTION Do not drive the seal into the block past flush. An oil leak may occur.
Drive the seal into the block using a seal driver or special tool 6926-2 and handle C-4171 until the tool bottoms out against the block and the seal is flush.
Loosen the wheel hub nut. Remove the front road wheel and tire. Remove the tie rod end retaining nut. Using the special tool 204-192 Ball joint Splitter detach the tie rod end. Remove the subframe reinforcement plate retaining bolts. Loosen the subframe rear mount bolt. Loosen the subframe front mount bolt. Remove and discard the wheel hub nut. using spcial tools 204-269Forcing Screw,205-491-01 adapter nuts,205-491 wheel hub puller Detach the wheel knuckle. Remove the lower arm ball joint retaining bolt. Reposition the lower arm. Detach the wheel knuckle. using special tools 307-443 RH Halfshaft splitter ,307-442 RH Halfshaft splitter handle detach the halfshaft. Remove the exhaust muffler inlet pipe. Remove the halfshaft seal. Remove the transfer case Y bracket retaining bolt. To prevent damage to the transfer box internal seal, make sure that the link shaft is not retracted further than 200 mm from the transfer box casing. remove the halfshaft. Attach special tools to the halfshaft. Lever the special tools to displace the halfshaft. Install the transfer case Y bracket retaining bolt. Remove the halfshaft. Use suitable protective covers to protect the barshaft. Remove the halfshaft snap ring. Install a new snap ring to the halfshaft. Install a new halfshaft seal. Remove the special tool. Remove the transfer case Y bracket retaining bolt. Remove the special tool. Make sure the CV joint splines are located fully. Do not use excessive force when engaging the CV joint into the link shaft. Install the halfshaft. Install the transfer case Y bracket retaining bolt. Tighten to 25 Nm. Attach the wheel knuckle. Reposition the lower arm. Attach the wheel knuckle. Install the lower arm ball joint retaining bolt. Tighten to 83 Nm. Install the exhaust muffler inlet pipe. Tighten the subframe front mount retaining bolt. Tighten to 142 Nm. Loosely install the subframe rear mount retaining bolt. Install the subframe reinforcement plate retaining bolts. Tighten to 35 Nm. Tighten to 142 Nm. Install the tie rod end. Tighten to 35 Nm. Loosely install a new wheel hub nut. Install the front road wheel and tire. Tighten the wheel hub nut. Tighten to 330 Nm. Check the subframe alignment.
You probably have the 9 inch differential. If it is a rear wheel seal remove the tire and wheel assembly. Be sure to use a jack stand so you don't have the vehicle fall on you. Remove the 4 retaining bolts that hold the backing plate onto the housing. Pull the axle from the axle tube. It may be stubborn at removal. If it is the pinion seal remove the drive line. Remove the pinion nut that rests inside the yoke. Try to use an impact tool for easy removal. Once the nut is off the yoke willcome off. You may need a puller to help in removal. One the yoke is off remove the pinion shaft seal. Replace with a new seal. install the yoke and the washer and then the pinion nut. Re-torque the pinion nut to 150 foot pounds.
SECTION 205-05: Rear Drive Halfshafts
2002 Explorer/Mountaineer Workshop Manual
REMOVAL AND INSTALLATION
Protector, Differential Seal 205-506
Remover, Front Wheel Hub 205-D070 (D93P-1175-B) or equivalent
Remover, Halfshaft 205-502 Removal and Installation NOTE: This procedure applies to both rear halfshaft assemblies.
CAUTION: Do not loosen the rear axle wheel hub retainer until after the wheel and tire assembly are removed from the vehicle. Wheel bearing damage will occur if the wheel bearing is unloaded with the weight of the vehicle applied. With the vehicle in NEUTRAL, raise and support the vehicle. For additional information, refer to Section 100-02 .
Remove the rear wheel and tire assembly. For additional information, refer to Section 204-04 .
NOTE: Have an assistant press the brake pedal to keep the axle from rotating. Remove and discard the rear axle wheel hub retainer and the washer.
CAUTION: To prevent damage to the brake hose, do not allow the disc brake caliper to hang suspended from the hose. Remove the brake disc.
Remove the two bolts and lift the disc brake caliper and brake pads off the brake disc.
Using mechanics wire, position the disc brake caliper out of the way.
Remove the brake disc.
Remove the bolt retaining the parking brake cable bracket to the frame.
CAUTION: Cover the stabilizer link bolt threads and the nut to prevent boot damage when removing the halfshaft assembly from the vehicle. Using a rubber hose approximately 37.5 mm (1.5 in) long, cover the stabilizer link bolt threads and nut.
WARNING: The bolt that retains the upper ball joint to the knuckle is longer and it has fewer threads than the bolt that retains the toe link to the knuckle. Switching these bolts during installation will prevent the pinch arms on the knuckle from correctly retaining the toe link to the knuckle. This may cause the toe link to separate from the knuckle during vehicle operation. Failure to follow these instructions may result in personal injury. Remove the pinch bolts and disconnect the toe link and upper ball joint from the knuckle.
CAUTION: Support the rear suspension upper arm to prevent boot damage when removing the halfshaft assembly from the vehicle. Using a wood stick, approximately 450 mm (18 in) long and 25 mm (1 in) wide, support the rear suspension upper arm.
CAUTION: 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. CAUTION: Once the outboard CV joint separates from the hub the knuckle will continue to pivot until the brake backing plate presses against the suspension lower arm. To prevent damage to the brake backing plate, immediately after separating the outboard CV joint from the hub, rest the knuckle on a cushioned support that is tall enough to keep the backing plate from pressing against the suspension lower arm. Separate the outboard CV joint from the hub and rest the knuckle on a cushioned support.
Using the special tool, press the outboard CV joint until it is loose in the hub.
Remove the special tool.
Separate the outboard CV joint from the hub.
Rest the knuckle on a cushioned support.
CAUTION: Do not damage the axle shaft oil seal or the machined sealing surface on the inboard CV joint housing. CAUTION: Do not allow the splines on inboard CV joint housing to touch the axle shaft oil seal. NOTE: A circlip retains the inboard CV joint housing to the differential side gear in the axle. Using the special tool, disengage the inboard CV joint housing from the differential side gear.
CAUTION: To prevent damage to the axle shaft oil seal, install the special tool before removing the inboard CV joint housing from the axle. Install the special tool.
Remove the halfshaft assembly from the vehicle.
CAUTION: To prevent damage to the axle shaft oil seal, install the Differential Seal Protector before positioning the inboard CV joint housing in the axle. CAUTION: Always install the halfshaft with a new retainer circlip and a new rear axle wheel hub retainer. CAUTION: Never use power tools to tighten the rear axle wheel hub retainer. To install, reverse the removal procedure.
Removal NOTE: Left-hand dual arm mirror with heat shown, non-heated and aero mirrors similar. All exterior mirrors
Position the exterior mirror glass in the full down position.
Grasp the top and carefully pull the exterior mirror glass away from the mirror housing.
Disconnect the electrical terminals (if equipped) and remove the exterior mirror glass.
Power exterior mirrors
Remove the jack pins from the exterior mirror glass backing plate.
Use pliers to grasp the jack pins at the base to remove.
Installation Power exterior mirrors
Remove the sealing boots from the exterior mirror motor.
Install the jack pins in the sealing boots.
Install the jack pins and sealing boots.
Hold the legs of the jack pins and push the jack pins back into the exterior mirror housing.
Install the sealing boots so the boot shoulder is under the mirror collar and turn each jack pin until the head of the jack pin is aligned with the slots in the sockets on the backing glass plate.
All exterior mirrors
Place the new exterior mirror glass assembly down on a smooth firm surface.
Align the friction pins vertically to the exterior mirror glass backing plate socket and push down to snap the pivot ball into the socket.
CAUTION: Do not over heat the exterior mirror glass backing plate. Heat only until backing plate is warm to the touch. Using the special tool, warm the main pivot sockets in exterior mirror glass backing plate.
Loosely install the glass.
Connect the electrical wiring to the electrical terminals (if equipped).
Position the friction pins in the mirror housing.
Align the jack pin locating tabs to match with the mirror glass back.
Using a flat hand, press on the center of the mirror glass until seated on the center pivot of the mirror housing.
Press the mirror glass toward one of the jack pins until snapped in place.
Repeat for second jack pin.
Power exterior mirrors NOTE: If the jack pins do not engage, they may not be aligned correctly. Remove the exterior mirror glass, align the jack pins to the slots in the sockets and repeat the installation procedure.
NOTE: The jack pin should click while manually adjusting the exterior mirror glass. Tilt the exterior mirror glass to the full outboard position and then press on the outer side of the class until the in/out jack pin snaps into the socket on the exterior mirror backing plate.
NOTE: The jack pin should click while manually adjusting the exterior mirror glass. Tilt the exterior mirror glass to the full down position and then press on the outer side of the class until the up/down jack pin snaps into the socket on the exterior mirror backing plate.