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1996 Ford Explorer CAR/TRUCK REPAIR PROCEDURES AND DIAGRAMS - WHAT Ford REPAIR SHOPS DON'T WANT YOU TO KNOW
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- Component Locations
- Wiring Diagrams
- Technical Service Bulletins
- Specifications
- A/C & Heater Service
- Brake Service
- Fuel Filter Replacement
- Driveline, U-Joint & CV Axles Replacement
- Starter & Alternator Replacement
- Maintenance Lamp Reset
- Radiator & Hose Replacement
- Serpentine Belt Service
A/C & HEATER SERVICE PROCEDURES FOR 1996 Ford Explorer AUTOMOBILES
Vacuum & Wiring Diagrams -> Light Trucks & Vans -> Air Conditioning & Heater Vacuum Hose Routing
Vehicle: 1996 Ford Explorer 4.0 V6 GAS
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BRAKE SERVICE PROCEDURES FOR 1996 Ford Explorer AUTOMOBILES
Disc Brakes -> Caliper Service -> Aerostar, Explorer & Ranger -> Assemble -> Bronco, E-150 & F-150 -> Cleaning & Inspection -> Disassemble -> E-250-350 -> E-250-350, F-250-350 & F-Super Duty -> F-250-350 & F-Super Duty -> Inspection -> Overhaul -> Replace -> Villager -> Villager & Windstar
Vehicle: 1996 Ford Explorer 5.0 V8 GAS
Replace
Aerostar, Explorer & Ranger
- Remove and discard a portion of brake fluid from master cylinder.
- Raise and support vehicle, then remove wheel and tire assembly.
- Use an eight inch C-clamp to move piston back into its bore as follows:
- Place head of C-clamp against caliper and screw end of C-clamp against outer pad below spring clip.
- Tighten C-clamp until torque buttons just clear caliper (approximately 1/8 inch). Remove C-clamp.
- Clean excess dirt from around pin tabs, then use caliper pin remover tool No. D89T-2196-A or equivalent and light hammer to drive caliper pin from caliper a...
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FUEL FILTER REPLACEMENT PROCEDURES FOR 1996 Ford Explorer AUTOMOBILES
Ford Motor Co. Light Trucks, SUVs & Vans -> Fuel Pressure Relief -> Gasoline Fuel Injected Engines Except Escape, Freestar, Mariner, Monterey, Villager, 2005-06 Aviator, Explorer & Mountaineer, 2005-06 Expedition & Navigator & 2004-06 F150 & Mark LT
Vehicle: 1996 Ford Explorer 4.0 V6 GAS
The fuel system remains under high pressure even when the engine is not running. This residual pressure must be relieved before servicing the fuel system. To avoid injury or fire, release pressure from the fuel system before disconnecting any fuel line.
The fuel system pressure must be relieved prior to disconnecting fuel lines to prevent accidental spray of fuel.
After the battery ...
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DRIVELINE, U-JOINT & CV AXLES REPLACEMENT PROCEDURES FOR 1996 Ford Explorer AUTOMOBILES
DRIVESHAFT, Replace -> Four Wheel Drive (4WD) -> Front -> Rear -> Two Wheel Drive (2WD)
Vehicle: 1996 Ford Explorer 4.0 V6 GAS
Front
The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the rear jack storage area. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations.
- With vehicle in neutral, raise and support vehicle.
- Index-mark front axle pinion flange to front driveshaft.
- Remove transfer case skid plate.
- Index-mark transfer case pinion flange to front ...
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STARTER & ALTERNATOR REPLACEMENT PROCEDURES FOR 1996 Ford Explorer AUTOMOBILES
Alternator, Replace
Vehicle: 1996 Ford Explorer 4.0 V6 GAS
- Disconnect battery ground cable.
- Remove air cleaner assembly, if required.
- Disconnect wire harness connectors from voltage regulator.
- Remove accessory drive belt.
- Remove alter...
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MAINTENANCE LAMP RESET PROCEDURES FOR 1996 Ford Explorer AUTOMOBILES
Ford Motor Co. Trucks -> Fuel Reset ->
Vehicle: 1996 Ford Explorer 5.0 V8 GAS
The FUEL RESET indicator is grounded through the inertia switch whenever vehicle is in a high force situation. The Inertia F...
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RADIATOR & HOSE REPLACEMENT PROCEDURES FOR 1996 Ford Explorer AUTOMOBILES
Heater Hose, Replace -> Bypass -> Inlet -> Outlet
Vehicle: 1996 Ford Explorer 4.0 V6 GAS
Inlet
- Drain cooling system into a suitable container.
- Reposition heater core inlet hose clamp at heater water control valve.
- Remove hose from heater water control valve.
- Reposition heater hose inlet clamp at heater core.
- Remove heater inlet hose from heater core.
- Remove hose from vehicle.
- Reverse procedure to install.
Outlet
- Drain cooling system into a suitable container.
- Reposition heater hose outlet clamp at heater core.
- Disconnect heater outlet hose f...
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SERPENTINE BELT SERVICE PROCEDURES FOR 1996 Ford Explorer AUTOMOBILES
Serpentine Drive Belt, Replace
Vehicle: 1996 Ford Explorer 4.0 V6 GAS
- Raise tensioner by turning counterclockwise, then remove belt.
- Install new be...
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COMPONENT LOCATION DIAGRAMS FOR 1996 Ford Explorer AUTOMOBILES
Component location diagrams for most 1996 Ford Explorer cars and light trucks sold in the U.S. from 1990+.
Power Distribution Box Components Diagram for 1996 Ford Explorer 5.0 V8 GAS Components on diagram: |
I/P Modules & Related Components Diagram for 1996 Ford Explorer 5.0 V8 GAS Components on diagram: |
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WIRING DIAGRAMS FOR 1996 Ford Explorer AUTOMOBILES
OEM drawn wiring diagrams for most 1996 Ford Explorer cars and light trucks sold in the U.S.
1996 Ford Explorer 5.0 V8 GAS Wiring Diagram Components on diagram: |
1996 Ford Explorer 4.0 V6 GAS Wiring Diagram Components on diagram: |
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TECHNICAL SERVICE BULLETINS FOR 1996 Ford Explorer AUTOMOBILES
OEM TSB listings for most 1996 Ford Explorer cars and light trucks sold in the U.S. from 1985+.
Document: RECALL - CERTAIN 1992-2003 MODEL YEAR CARS AND TRUCKS - FUSED JUMPER HARNESS REPLACEMENT FOR VEHICLES SERVICED WITH AN INCOMPATIBLE FUSED JUMPER HARNESS Vehicle: 1996 Ford Explorer 4.0 V6 GAS Auto Systems: |
Document: RECALL - 1992-2004 MULTIPLE VEHICLE LINES - SPEED CONTROL SYSTEM MODIFICATION Vehicle: 1996 Ford Explorer 4.0 V6 GAS |
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COMPONENT/PARTS SPECIFICATIONS FOR 1996 Ford Explorer AUTOMOBILES
BRAKE SPECIFICATIONS: Brake drum, rotor, caliper, and related specifications for most 1996 Ford Explorer cars and light trucks sold in the U.S. and Canada from 1970+.
- Brake caliper mounting bolt torque
- Brake drum runout, machining, & discard specs
- Minimum brake lining thickness.
- Brake rotor runout, parallelism, machining, discard, & finish specs
A/C SYSTEM SPECIFICATIONS: Air conditioning refrigerant capacity and type as well as lubricant capacity for most 1996 Ford Explorer cars and light trucks sold in the U.S. and Canada from 1980+.
- Refrigerant capacity & type, compressor oil viscosity, total system oil capacity & compressor clutch gap
COOLING SYSTEM BLEED: Cooling system bleeder valve identification, bleeder type and bleed procedures for most domestic and imported cars and light trucks sold in the U.S. and Canada from 1986+.
PREVENTIVE MAINTENANCE: Preventive maintenance recommendations and required services for most domestic and imported cars and light trucks sold in the U.S. and Canada from 1980+. Includes severe and routine service schedules
QUICK-LUBE and ILLUSTRATIONS: Fluid recommendations, capacities, drain plug torques, tire data, and severe service recommended preventive maintenance schedules. Information covers most 1996 Ford Explorer cars and light trucks sold in the U.S. and Canada from 1980+. Engine and chassis service images.
- Automatic transmission/transaxles capacities, lubricant recommendations
- Differential/final drive capacities, lube recommendations, grades, & viscosities
- Final drive fill & drain plug torques
- Number of lubrication fittings & plugs
- Power steering, brake, & clutch fluid recommendations
- Manual transmission/transaxle capacities, lube recommendations, grades, & viscosities
- Number of lubrication fittings & plugs
- Power steering, brake, & clutch fluid recommendations
- Engine oil capacities, API grade recommendations, SAE viscosity recommendations, drain plug torque
- Severe service maintenance & interval recommendations
- Tire sizes, wheel nut/bolt torque, pressures & rim sizes
- Transfer case capacities, lube recommendations, grades, & viscosities
TUNE-UP & DRIVEABILITY SPECIFICATIONS: Most tune-up specifications for most 1996 Ford Explorer cars and light trucks sold in the U.S. and Canada from 1980+
- Airflow sensor electrical specifications
- Tensioning specifications for systems with automatic tensioners
- Barometric pressure sensor specs
- Battery group number and cranking performance
- Crankshaft & camshaft position sensor resistance
- Engine compression pressures
- Coolant temperature sensor specs
- Computer advance.
- Diesel fuel temperature sensor resistance.
- Distributor advance specifications
- Ignition pickup coil resistance
- Exhaust gas recirculation temperature sensor resistance
- Engine fastener torque values
- Firing order diagrams
- Fuel system pressures
- Generator (alternator) specs
- Intake air temperature sensor specs
- Ignition coil specifications
- Fuel injector resistance
- Engine idle speeds
- Knock sensor resistance
- Manifold absolute pressure sensor specs
- Mixture control solenoid resistance
- Voltage regulator specs
- Spark plug applications & gaps
- Starter motor electrical specs.
- Tensioning specifications for systems without automatic tensioners
- Throttle body temperature sensor resistance
- Ignition timing in degrees at rpm
- Transmission oil temperature sensor resistance
- Throttle position sensor specs
- Vacuum sensor valve specs
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