Inspection and Verification, Ranger

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1 file://c:\tso\tsocache\vdtom_5368\svk~us~en~file=svk53a03.htm~gen~ref.htm Page 1 of 1 Section 05-03A: Wheel Hubs and Bearings, Front Wheels, 4- Wheel Drive DIAGNOSIS AND TESTING 1997 Ranger 4x4 with Dana IFS Axle Workshop Manual Inspection and Verification, Ranger Visually inspect hubs and check for cracks or leaks. Verify hub operation by road testing and shifting from 2WD to 4WD several times.

2 file://c:\tso\tsocache\vdtom_5368\svk~us~en~file=svk53a04.htm~gen~ref.htm Page 1 of 1 Section 05-03A: Wheel Hubs and Bearings, Front Wheels, 4- Wheel Drive DIAGNOSIS AND TESTING 1997 Ranger 4x4 with Dana IFS Axle Workshop Manual Symptom Chart Noise Concerns NOISE CONCERNS Condition Possible Source Action Ratcheting or Buzzing Noise in Front Axle in Two-Wheel Drive, Shortly After Four-Wheel Drive Usage Popping Sound from Front Axle When in Four-Wheel Drive, Especially While Cornering Right or left side hublock. Right or left side hublock. REPLACE hublocks as necessary. REPLACE hublocks as necessary. REFER to Pinpoint Test A.

3 file://c:\tso\tsocache\vdtom_5368\svk~us~en~file=svk53a05.htm~gen~ref.htm Page 1 of 2 Section 05-03A: Wheel Hubs and Bearings, Front Wheels, 4- Wheel Drive DIAGNOSIS AND TESTING 1997 Ranger 4x4 with Dana IFS Axle Workshop Manual Pinpoint Test (for Automatic Locking Hubs Only) PINPOINT TEST A: NOISE WHILE ENGAGING IN FOUR-WHEEL DRIVE A1 VERIFY LUBRICANT Drain and refill front axle differential with 1.66 liters (56 oz.) of 4x4 gear oil F1TZ A meeting Ford specification WSL-M2C191-A. NOTE: There is no equivalent for F1TZ A meeting Ford specification WSL-M2C191-A. Do not substitute any other lubricant. Is lubricant to specifications? GO to A2. Yes No REPLACE differential lubricant with 1.66 liters (56 oz.) of 4x4 gear oil F1TZ A meeting Ford specification WSL-M2C191-A. GO to A2. A2 VERIFY HUBLOCKS ARE OPERATIONAL Verify that the hubs lock and unlock using the procedure in this section. Do hublocks work properly? Yes ROAD TEST vehicle. GO to A3. No INSPECT right and left side hublocks and REPLACE as necessary. REPEAT A2. If hublock is satisfactory, GO to A3. A3 VERIFY OUTPUT OF TRANSFER CASE CLUTCH While road testing vehicle, push 4x4 button. Does vehicle shift to 4x4 mode without ratcheting? Yes No REPLACE clutch coil, housing, lockup collar, lockup fork, return spring and sleeve spring.

4 file://c:\tso\tsocache\vdtom_5368\svk~us~en~file=svk53a05.htm~gen~ref.htm Page 2 of 2 REPAIR is complete. REFER to Section 07-07D Disassembly and Assembly. REPEAT road test procedure.

5 file://c:\tso\tsocache\vdtom_5368\svk~us~en~file=svk53a06.htm~gen~ref.htm Page 1 of 2 Section 05-03A: Wheel Hubs and Bearings, Front Wheels, 4- Wheel Drive DIAGNOSIS AND TESTING 1997 Ranger 4x4 with Dana IFS Axle Workshop Manual Hub Diagnosis, Locking and Unlocking Hubs Hubs, Manual Locking Manual locking hubs are simple to diagnose. Place the transfer case (7A195) in two-wheel drive and raise the front wheels (1007) off the ground. When in the unlocked position, the wheels should be able to turn freely. Then lock each of the front hubs and rotate the front wheels. The additional load of the drivetrain components should be felt once the hub has been engaged. In addition, the front axle and front driveshaft should be moving along with the wheel. Disengage the hubs and repeat the procedure to check that the hubs have smoothly disengaged. Hubs, Automatic Locking Raise vehicle on hoist with engine off. Turn front driveshaft by hand to engage front hubs. Front wheels should turn if hubs lock properly. Spin front wheels by hand in opposite direction to disengage hubs (an audible "click" should be heard). Turn front driveshaft by hand in opposite direction and wheels should turn in opposite direction also if the hubs are locking properly. Disengage hubs by spinning front wheels by hand opposite of the direction they spun while turning the driveshaft. When checking front hubs for proper operation, road test the vehicle to ensure that the hubs will remain engaged while under load. This can be accomplished by engaging four-wheel drive and taking the vehicle through several turns (both forward and backward) on dry pavement. Driving through several turns while traveling in different directions will ensure that both sides of the hub teeth have been tested under load. Hubs that are not sufficiently engaged will "pop" out when loaded. This is due to the driveline releasing windup and is an indication of hub malfunction. If slippage is suspected, mark the tire and axle with chalk (after locking the hub) and apply a heavy torque load several times. Then inspect your original indexing marks. If they are no longer aligned, the hubs are not remaining locked when under load. They will have to be replaced. Should manual or automatic hublocks become submerged in water or mud for a long period of time, water may get past the seals and into the hubs and axle. In this case, all water must be expelled from the system. For automatic hublocks, the axle must be drained by siphoning out old lubricant through the drain hole in the axle arm which also serves as the carrier cover. Use new 4x4 Gear Oil F1TZ A meeting Ford specification WSL-M2C191-A to refill the axle (F1TZ A has no equivalent). Replace hubs using Automatic Locking Hub Front Wheel Bearing Adjustments procedure in this section.

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7 file://c:\tso\tsocache\vdtom_5368\svk~us~en~file=svk53a07.htm~gen~ref.htm Page 1 of 2 Section 05-03A: Wheel Hubs and Bearings, Front Wheels, 4- Wheel Drive REMOVAL AND INSTALLATION 1997 Ranger 4x4 with Dana IFS Axle Workshop Manual Locking Hubs, Manual, Ranger Removal and Installation 1. Raise the vehicle and install Rotunda Car/Truck Stands or equivalent. 2. Remove lug nuts (1012) and the wheel and tire assembly. Refer to Section Remove lugnut retainer washer from studs. 4. Remove the manual locking hub assembly. 5. CAUTION: Do not remove the screw from the plastic dial. Slide internal hub lock assembly, spring and clutch gear out of hub body. For installation, follow removal procedures in reverse order. Tighten lugnuts to 135 Nm (100 lb-ft).

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9 file://c:\tso\tsocache\vdtom_5368\svk~us~en~file=svk53a09.htm~gen~ref.htm Page 1 of 3 Section 05-03A: Wheel Hubs and Bearings, Front Wheels, 4- Wheel Drive REMOVAL AND INSTALLATION 1997 Ranger 4x4 with Dana IFS Axle Workshop Manual Speed Sensor Indicator Ring, Ranger Removal 1. Raise vehicle on hoist. 2. Remove wheel and tire assembly. 3. Remove front disc brake caliper (2B121), and hub and rotor assemblies. Refer to Section Refer also to Ranger Locking Hub exploded views in this section. 4. CAUTION: Discard speed sensor ring after removal. Do not reuse old ring. Using a 3-jaw puller, remove front brake anti-lock sensor indicator (2C182) from hub.

10 file://c:\tso\tsocache\vdtom_5368\svk~us~en~file=svk53a09.htm~gen~ref.htm Page 2 of 3 Installation 1. Support center of hub so that wheel studs do not rest on work surface. 2. CAUTION: When performing the following step, make sure indicator ring is pressed on straight. Position new front brake anti-lock sensor indicator on hub. Using a cylinder with 79mm (3.1-in.) ID and 96mm (3.8-in.) OD, press the front brake anti-lock sensor indicator onto the hub. The front brake anti-lock sensor indicator must be fully seated against the shoulder in the hub.

11 file://c:\tso\tsocache\vdtom_5368\svk~us~en~file=svk53a09.htm~gen~ref.htm Page 3 of 3 3. Install hub, rotor and caliper assemblies. Refer to Section Install wheel and tire assembly. Tighten wheel lugnuts to 135 Nm (100 lb-ft).

12 file://c:\tso\tsocache\vdtom_5368\svk~us~en~file=svk53a10.htm~gen~ref.htm Page 1 of 4 Section 05-03A: Wheel Hubs and Bearings, Front Wheels, 4- Wheel Drive DISASSEMBLY AND ASSEMBLY 1997 Ranger 4x4 with Dana IFS Axle Workshop Manual Wheel Grease Seal and Bearing, Front Replacement and Repacking SPECIAL SERVICE TOOL(S) REQUIRED Description Tool Number Impact Slide Hammer T50T-100-A Bearing Cup Replacer T80T-4000-P Driver Handle Seal Replacer T80T-4000-W T80T-4000-T Spindle Seal Replacer T95T-3132-D The recommended wheel bearing lubricant is lithium-base High-Temperature Constant Velocity Joint Grease E43Z A or equivalent meeting Ford specification ESP-M1C207-A. CAUTION: Sodium-base grease is not compatible with lithium-base grease. Do not intermix. Clean all old lubricant grease prior to lubricating front/rear wheel bearing. Use of incompatible bearing lubricant could result in premature lubricant breakdown. NOTE: If bearing adjustment does not eliminate looseness or rough and noisy operation, clean, inspect and repack the hub and wheel bearings with specified wheel grease. If wheel bearing cup or the cone and roller assemblies are worn or damaged, they should be replaced. Manual Locking Hub, Ranger Item Part Number Description B Wheel Hub Grease Seal Wheel Bearing Cup

13 file://c:\tso\tsocache\vdtom_5368\svk~us~en~file=svk53a10.htm~gen~ref.htm Page 2 of Rotor Inner Locknut 5 3B549 Washer 6 3B548 Axle Shaft Spacer 7 3B396 Hub 8 1A107 Retainer Washer 9 3B457 Snap Ring Outer Locknut Wheel Bearing Outer Wheel Bearing Inner A Excluder Seal Front Wheel Spindle Automatic Locking Hub, Exploded View, Ranger Item Part Number Description Front Wheel Spindle B Wheel Hub Grease Seal Wheel Bearing Cup Rotor 5 3N105 Wheel Bearing Adjusting Nut 6 3N105 Thrust Spacers 7 3B477 Front Axle Wheel Hub Retainer 8 3B458 Axle Shaft Spacer 9 3B396 Hub 10 1A107 Retaining Washer 11 3B548 Axle Shaft Spacer 12 3B549 Single Hump Locking Key Wheel Bearing Outer

14 file://c:\tso\tsocache\vdtom_5368\svk~us~en~file=svk53a10.htm~gen~ref.htm Page 3 of Wheel Bearing Inner A Excluder Seal Disassembly 1. Raise the vehicle and install Rotunda Car/Truck Stands or equivalent. 2. Remove the wheel and tire assembly. 3. Remove the retainer washers and remove the hub assembly. Refer to Manual Locking or Automatic Locking Hubs under Front Wheel Bearing Adjustment in this section for removal. 4. Remove the disc brake caliper (2B120) as described in Section Remove the hub and rotor. Remove the outer wheel bearing cone. 6. Remove the wheel hub grease seal (1190) from the rotor with Seal Remover TOOL-1175-AC or equivalent and Impact Slide Hammer T50T-100-A. Discard wheel hub grease seal and replace upon assembly. 7. Remove excluder seal. 8. Remove the inner wheel bearing. 9. NOTE: If new wheel bearing cups are installed, install new cone and roller assemblies. Inspect the wheel bearing cups for pits or cracks. If necessary, remove them with Internal Puller D80L-943-A or equivalent and Impact Slide Hammer T50T-100-A. Assembly 1. Lubricate the wheel bearings with High Temperature Constant Velocity Grease E43Z A or equivalent meeting Ford specification ESP-M1C207-A. Clean all grease from the hub. Pack the cones and rollers. If a bearing packer is not available, work as much lubricant as possible between the rollers and the cages. 2. If wheel bearing cups are to be installed, position wheel bearing cups in rotor and drive in place with Bearing Cup Replacer T80T-4000-P and Driver Handle T80T-4000-W. 3. Position excluder seal on spindle and drive into position using Spindle Seal Replacer T95T-3132-D. 4. Position the inner wheel bearing in the inner wheel bearing cup in the rotor. Install the wheel hub grease seal by driving in place with Seal Replacer T80T-4000-T and Driver Handle T80T-4000-W. 5. Carefully install the rotor onto the front wheel spindle (3105). Refer to Section Install outer wheel bearing into rotor. 7. Refer to Automatic Locking Hubs under Front Wheel Bearing Adjustment in this section for remainder of installation.

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16 file://c:\tso\tsocache\vdtom_5368\svk~us~en~file=svk53a11.htm~gen~ref.htm Page 1 of 12 Section 05-03A: Wheel Hubs and Bearings, Front Wheels, 4- Wheel Drive ADJUSTMENTS 1997 Ranger 4x4 with Dana IFS Axle Workshop Manual Front Wheel Bearing SPECIAL SERVICE TOOL(S) REQUIRED Description Tool Number Hub Locknut Wrench Prong T83T-1197-B Hex Locknut Wrench T70T-4252-B Manual Locking Hubs, Ranger 1. Raise the vehicle and install safety stands. 2. Remove the lug nuts (1012) and wheel and tire assembly. Refer to Section in the Body, Chassis Manual. 3. Remove the retainer washers from the wheel hub bolt nut studs and the manual locking hub assembly from the front wheel spindle (3105). 4. Remove the snap ring from the end of the shaft of the front wheel spindle. Manual Locking Hub, Exploded View, Ranger Item Part Number Description B Wheel Hub Grease Seal Wheel Bearing Cup Rotor Inner Locknut 5 3B549 Washer

17 file://c:\tso\tsocache\vdtom_5368\svk~us~en~file=svk53a11.htm~gen~ref.htm Page 2 of B548 Axle Shaft Spacer 7 3B396 Hub 8 1A107 Retainer Washer 9 3B457 Snap Ring Outer Locknut Wheel Bearing (Outer) Wheel Bearing (Inner) A Excluder Seal Front Wheel Spindle 5. Remove the axle shaft spacers. 6. Remove the outer wheel bearing locknut from the front wheel spindlej using Hub Locknut Wrench Prong T83T-1197-B. Engage tool tabs into locknut slots. 7. Remove locknut washer from front wheel spindle.

18 file://c:\tso\tsocache\vdtom_5368\svk~us~en~file=svk53a11.htm~gen~ref.htm Page 3 of Loosen the inner wheel bearing locknut. Engage tool tab in locknut slots. Make sure tool is centered over the locknut pin.

19 file://c:\tso\tsocache\vdtom_5368\svk~us~en~file=svk53a11.htm~gen~ref.htm Page 4 of Tighten the inner locknut to 47 Nm (35 lb-ft) while turning the rotor in the opposite direction to seat wheel bearings. 10. NOTE: If necessary, tighten inner locknut slightly to align the locknut pin with lockwasher hole. Spin the rotor and back off the inner locknut one-quarter turn. Retighten the inner locknut to 1.8 Nm (16 lb-in). 11. Install the lockwasher on the front wheel spindle.

20 file://c:\tso\tsocache\vdtom_5368\svk~us~en~file=svk53a11.htm~gen~ref.htm Page 5 of Install the outer wheel bearing locknut using locknut wrench. Tighten locknut to 203 Nm (150 lb-ft). 13. Check the end play of the wheel and tire assembly on the front wheel spindle. Final end play should be mm ( inch). The maximum torque to rotate the hub is 2.8 Nm (25 lb-in). 14. Install the axle shaft spacer. 15. Clip the snap ring onto the end of the shaft of the front wheel spindle. 16. Install the manual hub assembly over the front wheel spindle. Install the retainer washers. 17. Install the wheel and tire assembly. Install and tighten lug nuts to 135 Nm (100 lb-ft). Automatic Locking Hubs, Ranger 1. Raise the vehicle and install safety stands. 2. Remove the lug nuts and the wheel and tire assembly. Refer to Section Remove the retainer washers from the wheel hub bolt nut studs. Remove the automatic locking hub assembly from the front wheel spindle. Automatic Locking Hub, Ranger

21 file://c:\tso\tsocache\vdtom_5368\svk~us~en~file=svk53a11.htm~gen~ref.htm Page 6 of 12 Item Part Number Description Front Wheel Spindle B Wheel Hub Grease Seal Wheel Bearing Cup Rotor 5 3N105 Wheel Bearing Adjusting Nut 6 3N105 Thrust Spacers 7 3B477 Front Axle Wheel Hub Retainer 8 3B458 Axle Shaft Spacer 9 3B396 Hub 10 1A107 Retaining Washer 11 3B548 Axle Shaft Spacers 12 3B549 Single Hump Locking Key Wheel Bearing (Outer) Wheel Bearing (Inner) A Excluder Seal 4. Remove the snap ring from the end of the shaft of the front wheel spindle. 5. Remove the axle shaft spacer.

22 file://c:\tso\tsocache\vdtom_5368\svk~us~en~file=svk53a11.htm~gen~ref.htm Page 7 of CAUTION: Do not pry on the cam or thrust spacers during removal. Prying may damage the cam or spacers. Pull cam assembly off the wheel bearing adjusting nut and remove the two metal thrust spacers from the adjusting nut.

23 file://c:\tso\tsocache\vdtom_5368\svk~us~en~file=svk53a11.htm~gen~ref.htm Page 8 of CAUTION: To prevent damage to the threads of the front wheel spindle, look into the keyway of the front wheel spindle under the adjusting nut and remove the separate locking key before removing the adjusting nut. NOTE: If required, rotate the adjusting nut slightly to relieve pressure against the locking key, before the key can be removed. Using a magnet, remove the locking key. 8. Loosen the wheel bearing adjusting nut from the front wheel spindle using a Hex Locknut Wrench T70T-4252-B. 9. While rotating the hub and rotor assembly, tighten the wheel bearing adjusting nut to 47 Nm (35 lb-ft) to seat the wheel bearings. Spin the rotor and back off the nut one-quarter turn (90 degrees).

24 file://c:\tso\tsocache\vdtom_5368\svk~us~en~file=svk53a11.htm~gen~ref.htm Page 9 of Retighten the adjusting nut to 1.8 Nm (16 lb-in) using a torque wrench. 11. Make sure the final end play of the wheel on the front wheel spindle is mm ( inch). The maximum torque to rotate the hub is 2.8 Nm (25 lb-in). 12. WARNING: EXTREME CARE MUST BE TAKEN WHEN ALIGNING THE NUT OF THE FRONT WHEEL SPINDLE ADJUSTMENT LUG WITH THE CENTER OF THE KEYWAY SLOT OF THE FRONT WHEEL SPINDLE TO PREVENT DAMAGE TO THE SEPARATE LOCKING KEY. THE WHEEL AND TIRE ASSEMBLY MAY COME OFF WHILE THE VEHICLE IS IN MOTION IF THE KEY IS DAMAGED. Align the closest lug in the wheel bearing adjustment nut with the center of the keyway slot of the front wheel spindle. Advance the nut to the next lug if required. Install the separate locking key in the keyway of the front wheel spindle under the adjusting nut. 13. CAUTION: Extreme care must be taken when aligning the fixed cam key with the keyway of the front wheel spindle to prevent damage to the fixed cam. Install the two thrust spacers and push or press the cam assembly onto the locknut by lining up the key in the fixed cam with the keyway of the front wheel spindle.

25 file://c:\tso\tsocache\vdtom_5368\svk~us~en~file=svk53a11.htm~gen~ref.htm Page 10 of Install the axle shaft spacer. 15. Clip the snap ring onto the end of the shaft of the front wheel spindle. 16. Install the automatic locking hub assembly over the front wheel spindle. Align three hub assembly legs with three pockets in cam assembly. Install the retainer washers.

26 file://c:\tso\tsocache\vdtom_5368\svk~us~en~file=svk53a11.htm~gen~ref.htm Page 11 of Install the wheel and tire assembly. Install and tighten lug nuts to 135 Nm (100 lb-ft).

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28 file://c:\tso\tsocache\vdtom_5368\svk~us~en~file=svk53a12.htm~gen~ref.htm Page 1 of 1 Section 05-03A: Wheel Hubs and Bearings, Front Wheels, 4- Wheel Drive SPECIFICATIONS 1997 Ranger 4x4 with Dana IFS Axle Workshop Manual SPECIFICATIONS TORQUE SPECIFICATIONS Description Nm Lb-Ft Lb-In Lugnuts Outer Wheel Bearing Locknut Wheel Bearing Nut

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