FORD EXPLORER 1997 2.G Severe Duty Supplement Manual

Severe service conditions 2
Maintenance recommendations 4
Severe duty equipment 18
Index 28
Table of contents
1

SEVERE SERVICE CONDITIONS
USING THE SEVERE DUTY
SUPPLEMENT
This supplement is intended to aid
the operators of special service or
fleet vehicles used in severe duty
or high mileage operations.
Failure to maintain your special
service vehicle properly may
restrict warranty coverage, reduce
vehicle performance and operation
and adversely affect vehicle safety.
For a detailed list of severe duty
maintenance intervals, refer to the
ªService Guideº.
Information about this guide
The information found in this
guide was in effect at the time of
printing. Ford may change the
contents without notice and
without incurring obligation.
Engine maintenance
Replace engine oil and filter every
three months or 5,000 km (3,000
miles) if your vehicle operates
under any of the following
conditions:
²Short trips of less than 16 km
(10 miles) when outside
temperatures remain below
±18ÉC (0ÉF).
²Operating during hot weather
(above 32ÉC [90ÉF])
²Towing a trailer or carrying a
heavy load.
MAX
Severe service conditions
2

²Continuously driving above
normal highway speeds.
²Driving in stop-and-go traffic.
²Operating in extremely dusty
conditions. If operating under
these conditions, the air cleaner
and emission filters must be
replaced at more frequent
intervals than normal.
²Extensive idling (such as
delivery use).
Automatic transmission
maintenance
The automatic transmission fluid
should be changed every 35,000
km (21,000 miles).
The 5R55E automatic transmission
fluid should be changed every
80,000 km (50,000 miles).
If in addition to the specified
severe duty operating conditions,
your automatic transmission may
need to be checked more
frequently if your driving habits
frequently include any of the
following:
²Using your vehicle as a
snowplow.
²Off road and 4x4 operation.
Rear axle maintenance
1
All rear axle lube quantities must
be replaced every 160,000 km
(100,000 miles)
2or anytime that
the axle has been submerged in
water. Excepting these conditions,
the lube should not require
DON'T ADD IF IN CROSSHATCHED AREA • CHECK WHEN HOT IDLING IN PARK
Severe service conditions
3

checking or changing unless a leak
is suspected or repair required.
1Limited slip axles have synthetic
lubrication and do not require
changing.
2For non-limited slip axles, the
ªService Guideº states 165,000 km
(99,000 miles)
PRIORITY MAINTENANCE
CHECKS
The following list ofPriority
maintenance checksshould be
performed according to the
frequencies indicated. Continue to
read the ªSevere Duty
Supplementº for more detailed
information on these important
maintenance checks.
Refer to the ªService Guideº for
additional information on owner
maintenance checks.
Maintenance checks Frequency
Engine oil recommendationsCheck daily
(when refueling)
Windshield washer fluidCheck daily
(when refueling)
Worn or underinflated tiresCheck daily
(when refueling)
Automatic transmission fluid5,000 km (3,000 miles)
or once per month
Engine coolant level5,000 km (3,000 miles)
or once per month
Power steering fluid level5,000 km (3,000 miles)
or every three months
Maintenance recommendations
4

Battery cables and connections5,000 km (3,000 miles)
or every three months
Fluid leaks5,000 km (3,000 miles)
or every three months
Brake fluid level5,000 km (3,000 miles)
or every three months
Front disc brake pads5,000 km (3,000 miles)
or every three months
Rear disc brake pads10,000 km (6,000
miles) or every six
months
IMPORTANT MAINTENANCE
PRECAUTIONS
For more information on
maintenance procedures and
precautions for your vehicle, refer
to theMaintenance and care
chapter of your ªOwner Guideº.
To determine the lubricant
specifications required for each
component, refer to the
Capacities and specifications
chapter of the ªOwner Guideº.
Storing your vehicle
During extended periods of vehicle
storage (60 days or more),
oxidation may cause gasoline to
deteriorate. Such deterioration
could be detrimental to your
vehicle's systems and performance.
A commercial fuel stabilizer (Ford
Gas Stabilizer E8AZ-19C544±A
[ESE-M99C112±A] or equivalent
should be added to vehicles when
Maintenance recommendations
5

ever storage exceeds 60 days.
Follow the instructions provided
with the stabilizer for proper use.
Towing your vehicle
Vehicles may be towed with a
maximum speed of 80 km/h (50
mph) on smooth roads or 56 km/h
(35 mph) on rough roads. No
matter what the road conditions,
vehicles should not be towed
further than 80 km (50 miles).
For more information on towing
procedures and guidelines, refer to
theDrivingchapter of the ªOwner
Guideº.
IMPORTANT SAFETY NOTICE
Appropriate service methods and
proper repair procedures are
essential for the safe, reliable
operation of all vehicles as well as
the personal safety of the
individual performing the
Maintenance recommendations
6

maintenance. Follow these general
safety precautions:
²Wear safety glasses for eye
protection.
²Use safety stands whenever a
procedure requires you to work
under the vehicle.
²Be sure that the ignition switch
is always in the OFF position
unless otherwise specified.
²Be sure that the gearshift is in
the P (Park) position for
automatic transmissions or the 1
(First) position for manual
transmissions and engage the
parking brake.
²Block the opposite diagonal
wheels to prevent the vehicle
from moving.
²Operate the engine only in well
ventilated areas.
²Keep yourself and loose clothing
away from moving parts while
the engine is running.
²Protect yourself from engine
heat.
²Keep smoking materials and
other lit objects away from the
vehicle.
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Maintenance recommendations
7

TRANSMISSION MAINTENANCE
Automatic transmission fluid
(if equipped)
The automatic transmission fluid
should be checked at least once
per month or every 5,000 km
(3,000 miles), whichever occurs
first. The correct fluid level is
crucial to proper vehicle
functioning. If the transmission is
not functioning properly (if the
transmission slips, shifts slowly or
if fluid leakage occurs), the fluid
level should be checked and the
leakage problem corrected.
Vehicles frequently operated in
extreme temperatures or under
fleet conditions may require more
frequent maintenance.
A burnt or rotten odor and dark
color in the transmission fluid
indicates a high temperature or
sever vehicle usage. If such an
odor or discoloration should
develop, the transmission should
be serviced immediately.
For 4R70W transmissions, use only
MERCONtfluid. For 5R55E
transmissions,use only MERCONt
V (XT-5±QM). Use of other
transmission fluid may result in
transmission damage, malfunction
or failure.
for more information on
transmission maintenance, refer to
Checking and adding automatic
transmission fluidin the
Maintenance and carechapter of
the ªOwner Guideº.
DON'T ADD IF IN CROSSHATCHED AREA • CHECK WHEN HOT IDLING IN PARK
Maintenance recommendations
8

Manual transmission and
differential fluid (if equipped)
Clean and remove the filler plug.
The fluid level should be up to the
bottom of the filler plug hole. For
more information on differential
fluid maintenance, refer to
Checking and adding differential
fluidin theMaintenance and
carechapter of the ªOwner
Guideº.
Clutch fluid (if equipped)
The clutch fluid for your vehicle is
self-adjusting and should not
require any routine service.
During normal operation, the fluid
level in the clutch fluid reservoir
will slowly rise. If the fluid level
drops, add fluid to maintain the
level at the step in the reservoir
body.
If it is necessary to remove the
fluid reservoir cap, thoroughly
clean the cap before removal to
prevent contaminants from
entering the reservoir. Remove the
internal diaphragm and add only
Ford High Performance DOT 3
Brake Fluid C6AZ-19542±AA or an
equivalent DOT 3 fluid that meets
Ford specification ESA-M6C25±A.
Maintenance recommendations
9

ENGINE MAINTENANCE
Engine oil recommendations
Ford recommends that you use
Motorcraft oil or an equivalent oil
meeting Ford specification
ESE-M2C153±E andcertified by
the American Petroleum
Institute for gasoline
engines.Look for the American
Petroleum Institutes certification
mark.
Do not use:
²non-detergant oils
²oils labeled API SA, SB, SC, SD,
SE or SF
²oil additives, oil treatments or
engine treatments
SAE 5W-30 oil is preferred for all
temperatures. SAE 10W-30 is
acceptable for moderate to hot
temperatures.
Check and add engine oil
according to the intervals listed in
the ªService Guideº. For
information on engine oil
maintenance, refer toChecking
and adding engine oilin the
Maintenance and carechapter of
the ªOwner Guideº.
MAX MIN
Maintenance recommendations
10