25813_U01.
qxd 3/31/05 2:19 PM Page 1
FORD, LINCOLN AND MERCURY
Aviator • Explorer • Explorer Sport • Explorer Sport-Trac • Mountaineer
DISC BRAKES .................1-153
DRIVE TRAIN ...................1-89
DRUM BRAKES ...............1-168
ENGINE REPAIR ................1-19
FRONT SUSPENSION ........1-125
FUEL SYSTEM ..................1-79
REAR SUSPENSION ..........1-145
SPECIFICATIONS AND
MAINTENANCE CHARTS .......1-3
Engine and Vehicle Identification ....1-3
General Engine Specifications .........1-3
Engine Tune-Up Specifications........1-4
Firing Order .....................................1-4
Accessory Drive Belt Routing ..........1-4
Capacities ........................................1-6
Valve Specifications.........................1-7
Crankshaft and Connecting Rod
Specifications .................................1-8
Piston and Ring Specifications........1-9
Torque Specifications ....................1-10
Wheel Alignment ...........................1-11
Tire, Wheel and Ball Joint
Specifications ...............................1-12
Brake Specifications ......................1-14
Scheduled Maintenance
Intervals........................................1-15
STEERING .....................1-115
A Exhaust Manifold...........................1-49
Air Bag.........................................1-115
Arming The System ................1-116
Disarming The System............1-115
Precautions.............................1-115
Alternator .......................................1-19
Removal & Installation..............1-19
Anchor Plate (Adapter, Support
Bracket) ......................................1-163
Removal & Installation............1-163
Automatic Transmission ................1-90
Removal & Installation..............1-90
B P
Brake Caliper ...............................1-153
Removal & Installation............1-153
Brake Disc (Rotor) .......................1-163
Removal & Installation............1-163
Brake Drums................................1-168
Removal & Installation............1-168
BVC • 58-25813 • FORD CARS • MJS/BK/KJE • 2/28/05
Brake Shoes.................................1-168
Removal & Installation............1-168
C
Camshaft and Valve Lifters ............1-53
Removal & Installation..............1-53
Clutch ..........................................1-100
Adjustment..............................1-100
Removal & Installation............1-100
Coil Spring Front Suspension .....1-126
Removal & Installation............1-126
Coil Spring Rear Suspension ......1-148
Removal & Installation............1-148
CV-Joints.....................................1-108
Overhaul .................................1-108
Cylinder Head................................1-30
Removal & Installation..............1-30
D Knuckle/Spindle ..........................1-151
Disc Brake Pads...........................1-162
Removal & Installation............1-162
Driver’s Air Bag Module, Steering
Wheel, and Clockspring .............1-116
Removal & Installation............1-116
Driveshafts...................................1-103
Removal & Installation............1-103
E Suspension.................................1-139
Engine Assembly ...........................1-22
Removal & Installation..............1-22
Removal & Installation..............1-49
F Suspension.................................1-151
Front Axle Tube Bearing...............1-111
Removal & Installation............1-111
Front Cover and Seal.....................1-62
Removal & Installation..............1-62
Front Wheel Bearings ..................1-143
Adjustment..............................1-143
Removal & Installation............1-143
Fuel Filter ......................................1-81
Removal & Installation..............1-81
Fuel Injectors.................................1-85
Removal & Installation..............1-85
Fuel Line Couplings ......................1-80
Removal & Installation..............1-80
Fuel Pump .....................................1-81
Removal & Installation..............1-81
Fuel System Pressure ....................1-79
Release .....................................1-79
Fuel System Service
1
Precautions...................................1-79
H
Halfshaft.......................................1-106
Removal & Installation............1-106
Heater Core....................................1-26
Removal & Installation..............1-26
Hydraulic Clutch System .............1-100
Bleeding..................................1-100
Removal & Installation............1-101
I
Ignition Timing ..............................1-22
Adjustment................................1-22
Intake Manifold..............................1-44
Removal & Installation..............1-44
K
Removal & Installation............1-151
L
Leaf Springs ................................1-148
Removal & Installation............1-148
Lower Ball Joint...........................1-131
Removal & Installation............1-131
Lower Control Arm Front
Lower Control Arm Bushing
Replacement.........................1-139
Removal & Installation............1-139
Lower Control Arm Rear
Removal & Installation............1-151
M
Manual Transmission
Assembly......................................1-89
Removal & Installation..............1-89
O
Oil Pan...........................................1-56
Removal & Installation..............1-56
Oil Pump .......................................1-59
Removal & Installation..............1-59
Parking Brake Shoes....................1-164
Removal & Installation............1-164
Pinion Seal ..................................1-113 —
Removal & Installation............1-113
Piston and Ring .............................1-78
Positioning ...............................1-78
—
25813_U01.qxd 3/31/05 2:19 PM Page 2

FORD, LINCOLN AND MERCURY

1-2 AVIATOR • EXPLORER • EXPLORER SPORT • EXPLORER SPORT-TRAC • MOUNTAINEER

Power Rack and Pinion Steering Removal & Installation............1-125 Transfer Case Assembly...............1-102
Gear............................................1-120 Shock Absorber Rear Removal & Installation............1-102
Removal & Installation............1-120 Suspension.................................1-145 U
R Removal & Installation............1-145 Upper Ball Joint...........................1-130
Rear Axle Shaft, Bearing and Spindle/Knuckle ..........................1-139 Removal & Installation............1-130
Seal ............................................1-111 Removal & Installation............1-139 Upper Control Arm Front
Removal & Installation............1-111 Stabilizer Bar Front Suspension.................................1-132
Rear Axle Stub Shaft Bearing and Suspension.................................1-127 Removal & Installation............1-132
Seal ............................................1-114 Removal & Installation............1-127 Upper Control Arm Bushing
Removal & Installation............1-114 Stabilizer Bar Rear Suspension....1-149 Replacement.........................1-139
Rear Main Seal ..............................1-60 Removal & Installation............1-149 Upper Control Arm Rear
Removal & Installation..............1-60 T Suspension.................................1-150
Rear Wheel Bearings....................1-152 Timing Chain, Sprockets, Front Removal & Installation............1-150
Removal & Installation............1-152 Cover and Seal .............................1-72 W
Roller Followers.............................1-41 Removal & Installation..............1-72 Water Pump ...................................1-25
Removal & Installation..............1-41 Toe Link .......................................1-152 Removal & Installation..............1-25
S Removal & Installation............1-152 Wheel Cylinder ............................1-170
Shock Absorber Front Torsion Bar ..................................1-129 Removal & Installation............1-170
Suspension.................................1-125 Removal & Installation............1-129

BVC • 58-25813 • FORD CARS • MJS/BK/KJE • 2/29/05

25813_U01.qxd 3/31/05 2:19 PM Page 3

FORD, LINCOLN AND MERCURY

AVIATOR • EXPLORER • EXPLORER SPORT • EXPLORER SPORT-TRAC • MOUNTAINEER 1-3
SPECIFICATIONS AND MAINTENANCE CHARTS

06017-EXPL-C01

06017-EXPL-C02
—

—
BVC • 58-25813 • FORD CARS • MJS/BK/KJE • 2/29/05
25813_U01.qxd 3/31/05 2:19 PM Page 4

FORD, LINCOLN AND MERCURY

1-4 AVIATOR • EXPLORER • EXPLORER SPORT • EXPLORER SPORT-TRAC • MOUNTAINEER

06017-EXPL-C03

79244G86

Accessory drive belt routing —2002 4.6L VIN W SOHC engine with
67197-EXPL-GDD
A/C
4.0L VIN E SOHC Engine
Firing order: 1–4–2–5–3–6
Distributorless ignition system

BVC • 58-25813 • FORD CARS • MJS/BK/KJE • 2/29/05

25813_U01.qxd 3/31/05 2:19 PM Page 5

FORD, LINCOLN AND MERCURY

AVIATOR • EXPLORER • EXPLORER SPORT • EXPLORER SPORT-TRAC • MOUNTAINEER 1-5

67197-EXPL-GBB
67197-EXPL-GAA

Accessory drive belt routing —2003—05 4.6L VIN W SOHC engine Accessory drive belt routing —4.6L VIN H DOHC engine

67197-EXPL-GCC

Accessory drive belt routing —4.0L VIN E SOHC engine —

—
BVC • 58-25813 • FORD CARS • MJS/BK/KJE • 2/29/05
25813_U01.qxd 3/31/05 2:19 PM Page 6

FORD, LINCOLN AND MERCURY

1-6 AVIATOR • EXPLORER • EXPLORER SPORT • EXPLORER SPORT-TRAC • MOUNTAINEER

06017-EXPL-C04

BVC • 58-25813 • FORD CARS • MJS/BK/KJE • 2/29/05

25813_U01.qxd 3/31/05 2:19 PM Page 7

FORD, LINCOLN AND MERCURY

AVIATOR • EXPLORER • EXPLORER SPORT • EXPLORER SPORT-TRAC • MOUNTAINEER 1-7

06017-EXPL-C05

—
BVC • 58-25813 • FORD CARS • MJS/BK/KJE • 2/29/05
25813_U01.qxd 3/31/05 2:19 PM Page 8

FORD, LINCOLN AND MERCURY

1-8 AVIATOR • EXPLORER • EXPLORER SPORT • EXPLORER SPORT-TRAC • MOUNTAINEER

06017-EXPL-C07

BVC • 58-25813 • FORD CARS • MJS/BK/KJE • 2/29/05