Ford Explorer, Mazda Navajo, Mercury Mountaineer Repair Manual 1991-2001

This repair manual covers 1991-2001 Ford Explorer, Mazda Navajo and Mercury Mountaineer, all models. The manual also includes Explorer Sport through 2003 and Explorer Sport Trac through 2005.
Book Excerpt: 1991-2001 Ford Explorer, Mazda Navajo, Mercury Mountaineer Repair Manual, incl. Sport and Sport Trac through 2005 4.0L (PUSHROD) V6 ENGINE

FLYWHEEL/DRIVEPLATE | REMOVAL AND INSTALLATION
(Refer to illustrations 17.3 and 17.4)

1. Raise the vehicle and support it securely on jackstands, then refer to Chapter 7 and remove the transmission. Caution: If the vehicle is equipped with Automatic Ride Control (ARC), make sure the air suspension switch is turned to the OFF position before the vehicle is raised to prevent damage to the system components (see Chapter 10).
2. On manual transmission equipped vehicles, remove the pressure plate and clutch disc (see Chapter 8).
3. Apply alignment marks on the flywheel/driveplate and crankshaft to ensure correct alignment during reinstallation (see illustration).
4. Remove the bolts that secure the flywheel/driveplate to the crankshaft (see illustration). If the crankshaft turns, wedge a screwdriver through the starter opening to jam the flywheel. Note: 1997 and later models have eight flywheel bolts, while earlier models have six.
5. Remove the flywheel/driveplate from the crankshaft. Since the flyweehl is fairly heavy, be sure to support it while removing the last bolt.
6. Clean the flywheel to remove grease and oil. Inspect the surface for cracks, rivet grooves, burned areas and score marks. Light scoring can be removed with emery cloth. Check for cracked and broken ring gear teeth. Lay the flywheel on a flat surface and use a straightedge to check for warpage.
7. Clean and inspect the mating surfaces of the flywheel/driveplate and the crankshaft. If the crankshaft rear seal is leaking, replace it before reinstalling the flywheel/driveplate.
8. Position the flywheel/driveplate against the crankshaft. Be sure to align the marks made during removal. Note that some engines have an alignment dowel or staggered bolt holes to ensure correct installation. Before installing the bolts, apply thread locking compound to the threads.

BODY

LIFTGATE PANEL (Refer to illustrations 22.1, 22.2, 22.3 and 22.4)

1. Remove the screws securing the panel to the liftgate assembly (see illustration). Some models use plastic rivets instead of screws. Use a trim tool to pry the plastic rivets out.
2. Carefully pry up the liftgate lock knob bezel and remove the one screw accessible through the lock knob hole (see illustration).
3. Remove the liftgate inside handle screws (see illustration).
4. Use a trim tool to pry out the plastic rivets at the top of the panel, then use a flat blade trim tool all around the panel to release the hidden clips (see illustration). Caution: Don't pull on the panel as this will rip the plastic retainer clips out of the panel.
5. Installation is the reverse of removal.

Subject: 1991, 1992, 1993, 1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005 Ford Explorer, Mazda Navajo, Mercury Mountaineer, Explorer Sport, Explorer Sport Trac service, maintenance, repair. ISBN-10: 1563925915 | ISBN-13: 9781563925917 | Haynes 36024