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2003 ford explorer xlt suspension diagrams

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2006 Ford Explorer Scheduled Maintenance Guide

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Scheduled Maintenance: 2006 Ford Explorer Driving Condition: Normal Condition Engine Displacement Transmission Fuel Cylinders Drivetrain 4.0 L Automatic Flexible 6 RWD ded Maintenance Mileage: Every 5,000 15 30 45 60 75 90 100 105 120 135 150 Value Package Price: See Dealer See Dealer See Dealer See Dealer See Dealer See Dealer See Dealer See Dealer See Dealer See Dealer See Dealer See Dealer Change engine oil and replace oil filter (Up to 5 quarts of oil. Perform at specified mileage interval or every 6 months, whichever occurs first) – See dealer Perform multi-point inspection – See dealer Rotate and inspect tires; check wheel end play and turning noise – See dealer Inspect automatic transmission fluid level (if equipped with underhood dipstick) – See dealer Inspect brake pads/shoes/rotors/drums, brake lines and hoses, and parking brake system – See dealer Inspect engine cooling system and hoses – See dealer Inspect and lubricate all non-sealed steering linkage,ball joints,suspension joints,half and drive-shafts and u-joints – See dealer Inspect complete exhaust system and heat shields – See dealer Replace engine air filter – See dealer Replace fuel filter – See dealer Inspect 4×2 front wheel bearings; replace grease and grease seals, and adjust bearings – See dealer Change Premium Gold engine coolant – See dealer Inspect accessory drive belt(s) – See dealer Replace PCV valve – See dealer Replace spark plugs – See dealer Replace accessory drive belts (if not replaced within last 100,000 miles) – See dealer Replace rear axle lubricant – See dealer Change automatic transmission/transaxle fluid and filter – See dealer Notes: Prices are shown for illustrative purposes only and may vary based on required fluid quantities and other conditions. Information in this document is current as of January 07, 2010 and could change in the future.

2003 Ford Truck Expedition Suspension – Air Suspension Height Sensor Linkage Loose Service Procedure

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ISSUE Some 2003-2006 Expedition and Navigator vehicles equipped with an air suspension may exhibit an air suspension height sensor linkage arm disengaging from the suspension ball stud or height sensor rotating arm. This concern typically occurs with the rear sensor (Figure 1) but may occur with the front sensors as well. If this occurs, the symptom will typically be the vehicle leaning to one side, the vehicle sitting too low/high, a harsh ride, and/or an inoperative air suspension. In addition, this concern may result in diagnostic trouble code (DTC) C1725 (air suspension front pneumatic failure) or C1726 (air suspension rear pneumatic failure). ACTION When a linkage arm becomes disengaged, do not re-attach the arm and do not replace the sensor unless broken. Instead, install a revised linkage arm on all three (3) sensor assemblies, even if they have not detached from the ball stud. 1. Replace linkage arms on all three (3) sensor assemblies following Workshop Manual (WSM), Section 204-05. 2. Discard the old linkage arms. NOTE IF THE SENSOR ASSEMBLY NEEDS TO BE REPLACED FOR ANY DAMAGE/FAILURE OTHER THAN THE ONE DESCRIBED IN THIS TSB, THE REPLACEMENT ASSEMBLY IS SUPPLIED WITH A NEW STYLE LINKAGE ARM, SO THERE IS NO NEED TO ORDER ADDITIONAL LINKAGES FOR THE SERVICE REPAIR. WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage OPERATION DESCRIPTION TIME 061510A 2003-2006 0.4 Hr. Expedition/Navigator: Replace The Three Linkage Arms, Includes Time To Check Diagnostic Trouble Codes (Do Not Use With 5300A, 5300A7, 5300A8) DEALER CODING CONDITION BASIC PART NO. CODE 5A967

2003-2005 FORD Explorer Sport Trac Alignment – Irregular Front Tire Wear SERVICE PROCEDURE

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ISSUE Some 2003-2005 Explorer Sport Trac vehicles equipped with the Goodyear Wrangler RT/S, P255/70R16 109S AT OWL tire, may exhibit signs of feathering heel-toe wear on the inside or outside edges of the front tires . Tire noise may also be present during regular highway drive or when braking. ACTION Inspect the tires for feathering heel-toe wear. It may be necessary to rotate or replace tires and reset toe. Refer to the following Service Procedure. SERVICE PROCEDURE Zoom Sized for Print 1. Visually inspect the front tire’s inside and outside shoulder ribs (Figure 1) 2. Measure the difference in tread depth of the leading edge compared to trailing edge, of the most-worn lug (figure 2). If the average difference in tread depth between leading and trailing edge is less than 2 mm, rotate the tires . If the average difference is more than 2 mm, replace the front tires. Also inspect the rear tires and replace if necessary. 3. Ensure that the camber and caster readings are within specification

2003 Ford F-Super Duty 250-550/ Excursion Rear Drive Axle/Differential/ Ford 10.50-Inch Ring Gear Installation Manual

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1. Remove the differential case. For additional information, refer to Differential Case in this section. 2. NOTE: The differential bearings need not be removed to overhaul the Ford limited slip differential. If bearing removal is required, for additional information, refer to Differential Case in this section. NOTE: The anti-lock speed sensor ring cannot be reused once removed. Remove the differential pinion shaft lock bolt and remove the differential pinion shaft. ? If required, remove the ring gear and anti-lock speed sensor ring. 3. NOTE: This tool does not have the 1/2-inch drive hole. Install the special tool in a suitable vise. 2003 F-Super Duty 250-550/Excursion Workshop Manual 5. Install the special tool in the bottom side gear bore. ? Apply a small amount of grease to the centering hole of the special tool. 6. Install the nut in the upper differential side gear. Hold the nut in position while installing the hex screw. Tighten the hex-head screw until contact is made with the Step Plat 2003 F-Super Duty 250-550/Excursion Workshop Manual 7. Insert a suitable dowel bar in the hole of the nut. Tighten the forcing screw to force the differential side gear away from the differential pinion gears. The dowel bar is used to keep the nut from turning when the forcing screw is tightened. NOTE: Differential pinion thrust washers cannot be removed independently of the differential pinion gears and so must be removed simultaneously with the differential pinion gears. Insert the special tool in the pinion shaft bore and turn the differential case to “walk” the differential pinion gears and differential pinion thrust washers out to the differential case windows. 9. Remove the differential pinion gears and differential pinion thrust washers. 10. Remove the differential side gears and differential clutch packs and tag them RIGHT and LEFT with the shim

LEAKS FROM REAR HALFSHAFT AXLE SEAL REPAIR MANUAL

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FORD: LINCOLN: 2002-2006 Explorer 2003-2005 Aviator 2003-2006 Expedition 2003-2006 Navigator MERCURY: 2002-2006 Mountaineer This article supersedes TSB 05-15-5 to update the 3. Do not use a damaged seal installation tool vehicle model years, Parts, and Service Procedure. exhibiting nicks, burrs, or sharp edges. NOTE ISSUE THE USE OF SEAL PROTECTOR 1L2W-4N206-AA Some 2003-2006 Expedition/Navigator, 2002-2006 IS NO LONGER REQUIRED. Explorer 4dr/Mountaineer, and 2003-2005 Aviator vehicles equipped with the 8.8? or 9.75? ring gear 4. Do not tap directly on the back of the seal and independent rear suspension (IRS), may exhibit installation tool, always tap on the handle, per leaks at the rear halfshaft axle seals. A new Instruction Sheet. Seal should be driven evenly unitized seal is now available for service. The new into housing bore with only enough force to seal design eliminates the need to use seal seat in the bore. protectors during installation. Removal of the excluder seal (1L2W-1N013-BA) if present is 5. Before installing the halfshaft, verify that the required. inboard excluder seal (1L2W-1N013-BA) is not present on the halfshaft. If the excluder seal is ACTION present, follow the kit Instruction Sheet and Order and install the new seal kit to correct the leak remove the excluder seal. condition. Review the updated instruction sheet NOTE included in the kit and obtain the required tools before beginning repair. OVERFILLING THE AXLE CAN INCREASE POTENTIAL FOR LEAKS. INSTALLATION SERVICE TIPS PART NUMBER PART NAME Refer to the appropriate Workshop Manual, Section 7L1Z-4A109-B Axle Shaft Seal Kit (9.75 Axle) 205-02 for half shaft removal and installation. 7L1Z-4A109-C Axle Shaft Seal Kit (8.8 Axle) NOTE IN THE WORKSHOP MANUAL UNDER THE HALF WARRANTY STATUS: Eligible Under Provisions Of SHAFT REMOVAL/INSTALLATION SECTION New Vehicle Limited THERE ARE ADDITIONAL PARTS CALLED OUT Warranty Coverage THAT ARE REQUIRED TO BE REPLACED. OPERATION DESCRIPTION TIME THESE PARTS ARE NOT INCLUDED IN THE 062205A 2003-2006 0.8 Hr. AXLE SHAFT SEAL KIT LISTED. Expedition/Navigator: Replace Rear Axle (Stub) 1. Use only the proper seal installation tool, Lisle Shaft Seal Includes Time Special Seal Installer (LIS 17850) available To Remove And Install through the Rotunda Technician Tool Program. Halfshaft One Side (Do Not Use With 4139A, 2. Ensure the seal installation tool is clean and 4139A2) free of debris prior to inserting into new seal.