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Body System - Uni-Body, Subframe & Mounting System: Removal & Installation Ford Explorer V

Frames, Subframes & Crossmembers 17 illustrations ~1280 words

Removal

Note. Suspension fasteners are critical parts that affect performance of vital components and systems. Failure of these fasteners may result in major service expense. Use the same or equivalent parts if replacement is necessary. Do not use a replacement part of lesser quality or substitute design. Tighten fasteners as specified.

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Scheme 1: Removal
Scheme 1: Removal

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  1. NOTE: Use a steering wheel holding device (such as Hunter® 28-75-1 or equivalent). Using a suitable holding device, hold the steering wheel in the straight-ahead position.
  2. Remove the wheels and tires. REFER to «WHEEL AND TIRE»(ref-517542) .
  3. Vehicles equipped with 3.5L, remove the 3 retainers and the underbody air duct.
  4. Vehicles equipped with 2.0L GTDI, remove the 4 retainers and the underbody shield.
  5. NOTE: RH shown, LH similar. Remove the 2 RH and 2 LH lower pin-type retainers from the engine splash shields and position the shields aside.
  6. Vehicles equipped with a 3.5L, remove the engine exhaust Y-pipe. REFER to «EXHAUST Y-PIPE»(ref-517548-S08700774252012121200000) .
  7. Remove and discard the 4 stabilizer bar bracket-to-front subframe bolts.
  8. NOTE: The hex-holding feature can be used to prevent turning of the stud while removing the outer tie-rod end nuts. NOTE: RH shown, LH similar. Remove and discard both outer tie-rod end nuts. Separate both outer tie-rod ends from the wheel knuckles.
  9. NOTE: Use care when releasing the lower arm and knuckle into the resting position or damage to the ball joint seal or CV boot may occur. NOTE: Use the hex-holding feature to prevent the stud from turning while removing the lower ball joint nuts. NOTE: RH shown, LH similar. Remove and discard both lower ball joint nuts. Separate both lower ball joints from the wheel knuckles.
  10. Remove the flap heat shield bolt and position the flap heat shield to access the EPAS electrical connectors.
  11. Remove the bolt and disconnect the 2 EPAS electrical connectors and the wiring retainer.
  12. NOTE: Do not allow the steering column to rotate while the steering column shaft is disconnected from the steering gear or damage to the clockspring may occur. If there is evidence that the steering column has rotated, the clockspring must be removed and recentered. REFER to «CLOCKSPRING»(ref-517622-S11035099822012121200000) . Remove and discard the steering column shaft bolt and disconnect the steering column shaft from the steering gear.
  13. NOTE: FWD shown, AWD Similar. Remove the roll restrictor-to-subframe bolt.
  14. Unlatch the cooler hose retainer latch. Pry up on the oil cooler hose retainer to release the retainer and remove it from the subframe.
  15. Using a wax pencil (or equivalent) apply witness marks to the vehicle and subframe to aid in installation.
  16. Position the 300-OTC1585AE under the subframe assembly.
  17. NOTE: RH shown, LH similar. Remove and discard the 4 front subframe bracket bolts.
  18. NOTE: RH shown, LH similar. Remove and discard the 2 front subframe rearward bolts and remove the front subframe brackets.
  19. NOTE: RH shown, LH similar. Remove and discard the 2 front subframe forward bolts.
  20. Lower the front subframe assembly from the vehicle.

Installation

Note. Suspension fasteners are critical parts that affect performance of vital components and systems. Failure of these fasteners may result in major service expense. Use the same or equivalent parts if replacement is necessary. Do not use a replacement part of lesser quality or substitute design. Tighten fasteners as specified.

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  1. Using the 300-OTC1585AE , raise and align the subframe assembly to the witness marks made during removal.
  2. NOTE: RH shown, LH similar. Install the 2 new front subframe forward bolts. Tighten to 200 Nm (148 lb-ft).
  3. NOTE: RH shown, LH similar. Position the front subframe brackets and install the 4 new front subframe bracket bolts finger-tight.
  4. NOTE: RH shown, LH similar. Install the 2 new front subframe rearward bolts. Tighten to 200 Nm (148 lb-ft).
  5. NOTE: RH shown, LH similar. Tighten the 4 new front subframe bracket bolts. Tighten to 55 Nm (41 lb-ft).
  6. Install the cooler hose retainer on the subframe.
  7. NOTE: FWD shown, AWD similar. Install the roll restrictor-to-subframe bolt. Tighten to 90 Nm (66 lb-ft).
  8. NOTE: Do not allow the steering column to rotate while the steering column shaft is disconnected from the steering gear or damage to the clockspring may occur. If there is evidence that the steering column has rotated, the clockspring must be removed and recentered. REFER to «CLOCKSPRING»(ref-517622-S11035099822012121200000) . Install the steering intermediate shaft onto the steering gear and install a new bolt. Tighten to 20 Nm (177 lb-in).
  9. Connect the 2 EPAS electrical connectors and attach the wiring retainer and install the bolt. Tighten to 9 Nm (80 lb-in).
  10. Position the flap heat shield and install the flap heat shield bolt. Tighten to 11 Nm (97 lb-in).
  11. NOTE: RH shown, LH similar. Position both ball joints into the wheel knuckles. Install 2 new ball joint nuts. Tighten to 200 Nm (148 lb-ft).
  12. NOTE: The hex-holding feature can be used to prevent turning of the stud while installing the outer tie-rod nuts. NOTE: RH shown, LH similar. Position both outer tie-rod ends to the wheel knuckles and install 2 new outer tie-rod end nuts. Tighten to 150 Nm (111 lb-ft).
  13. Install the 4 new stabilizer bar bracket-to-front subframe bolts. Tighten to 55 Nm (41 lb-ft).
  14. Vehicles equipped with 3.5L, install the engine exhaust Y-pipe. REFER to «EXHAUST Y-PIPE»(ref-517548-S08700774252012121200000) .
  15. NOTE: RH shown, LH similar. Position the RH and LH engine splash shields and install the 4 lower pin-type retainers.
  16. Vehicles equipped with 2.0L GTDI, install the underbody shield and the 4 retainers.
  17. Vehicles equipped with 3.5L, install the underbody air duct and the 3 retainers.
  18. Install the wheels and tires. REFER to «WHEEL AND TIRE»(ref-517542) .
  1. Position the subframe to the vehicle and loosely install the 2 new rear subframe rearward bolts.
  2. Position the 2 rear subframe assembly brackets and loosely install the 2 new rear subframe forward bolts.
  3. Align the subframe to the alignment marks made during removal.
  4. Tighten the 2 new rear subframe rearward bolts. Tighten to 200 Nm (148 lb-ft).
  5. Tighten the 2 new rear subframe forward bolts. Tighten to 200 Nm (148 lb-ft).
  6. Install the 4 new rear subframe assembly bracket bolts. Tighten to 55 Nm (41 lb-ft).
  7. Position the 2 rear brake calipers and install the 4 rear brake caliper bolts. Tighten to 33 Nm (24 lb-ft).
  8. Connect the parking brake cables to the brake calipers.
  9. NOTE: LH shown, RH similar. Position the LH and RH wheel opening parking brake cable brackets and install the wheel opening parking brake cable bracket bolts. Tighten to 15 Nm (133 lb-in).
  10. Position the rear parking brake cable bracket and install the rear parking brake cable bracket bolt. Tighten to 15 Nm (133 lb-in).
  11. Connect the RH parking brake cable to the front parking brake cable and the frame cable bracket.
  12. Adjust the parking brake cable tension. REFER to «PARKING BRAKE CABLE TENSION RELEASE»(ref-517552-S28590964862012121200000) .
  13. Connect the subframe assembly main electrical connector.
  14. Install the 2 new rear shock absorber lower bolts. Tighten to 175 Nm (129 lb-ft).
  15. Using a suitable jackstand, support the lower control arm.
  16. Position the sway bar and install the 2 new sway bar link upper nuts. Tighten to 150 Nm (111 lb-ft).
  17. Remove the jackstand from the lower control arm.
  18. NOTE: If equipped, align the driveshaft using the index-mark made during removal. If equipped, position the driveshaft and install the 6 new driveshaft bolts. Tighten to 25 Nm (18 lb-ft).
  19. Install the muffler and tail pipe. REFER to «MUFFLER AND TAILPIPE»(ref-517548-S34111686962012121200000) - 2.0L GTDI, or 3.5L Ti-VCT.
  20. Install the rear wheels. REFER to «WHEEL AND TIRE»(ref-517542) .

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