1996 Ford Explorer REPAIR MANUAL -- HOW TO FIX YOUR CAR OR TRUCK

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1996 Ford Explorer CAR/TRUCK REPAIR PROCEDURES AND DIAGRAMS - WHAT Ford REPAIR SHOPS DON'T WANT YOU TO KNOW

Learn how to repair a car or truck, install or remove parts, wire an engine, reset warning lights, replace fuel filter, fix auto body and more. Get Automotix DIY!

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Get Full Access Automotix DIY provides automotive consumers and do it yourselfers; the most comprehensive repair information about 1996 Ford Explorer car and truck repair procedures including Ford engine diagrams, wiring diagrams, repair work estimating measures, technical service bulletins, auto body work guidance, starter & alternator replacement procedures, serpentine belt replacement procedures, radiator & hose replacement procedures, tune-up & drivability specifications, quick lube illustrations, preventive maintenance guide, engine light reset instructions, parts removal and install procedures, fuel filter replacement directions, component location diagrams, air filter locations & replacement instructions, a/c system specifications, and general auto service procedures. You don't have to be a car mechanic or technician to know how to fix your Ford Explorer automobile. Try the Automotix DIY solution today!
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Using the Automotix DIY repair procedures will save you hundreds and even thousands of dollars! In addition, it will save you hours of touring the city searching for Ford mechanics you can trust. The Automotix DIY solution is particularly affordable. A full access to the entire DIY repair procedures and diagrams for your 1996 Ford Explorer vehicle will cost less than a single gallon of gas. Here are some of the DIY repair tips and procedures you will find here:

A/C & HEATER SERVICE PROCEDURES FOR 1996 Ford Explorer AUTOMOBILES

Component Replacement & Adjustment -> Light Duty Trucks & Vans -> Condenser, Replace -> 1996 -> 1997 -> 1997 Expedition & F-Series -> Aerostar & Ranger -> Bronco & 1996 F-Series -> Econoline -> Explorer & Mountaineer -> Villager -> Windstar
Vehicle: 1996 Ford Explorer 5.0 V8 GAS

Econoline
1996
  • Recover refrigerant as outlined under .
  • Disconnect and cap compressor discharge line and liquid line from condenser using the spring lock coupling tool, Fig. .
  • Remove top left and right side radiator bolts, then loosen bottom bolts.
  • Carefully push top part of radiator rearward.
  • Remove two bolts retaining top of condenser core to radiator upper support, then remove from vehicle.
  • Reverse procedure to install. Use new O-rings lubricated with refrigerant oil.
1997
  • Recover refrigerant as outlined...

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BRAKE SERVICE PROCEDURES FOR 1996 Ford Explorer AUTOMOBILES

Power Brake Units -> Bendix Vacuum Brake Booster -> Adjustments -> Bronco, E-Series & F-Series -> Pushrod -> Windstar
Vehicle: 1996 Ford Explorer 4.0 V6 GAS

Pushrod

Bronco, E-Series & F-Series

To check adjustment of pushrod, fabricate a gauge and position it against the master cylinder mounting surface as shown in Fig. . Adjust pushrod screw by turning it until the end just touches inner edge of slot in gauge.

Windstar
  • Without disconnecting brake tubes...

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FUEL FILTER REPLACEMENT PROCEDURES FOR 1996 Ford Explorer AUTOMOBILES

Ford Motor Co. Light Trucks, SUVs & Vans -> Fuel Filter Scheduled Maintenance -> 1994-98 Bronco II, Escape, Explorer, Explorer Sport & Sport Trac, Mariner & Mountaineer -> Normal Service -> Severe Service
Vehicle: 1996 Ford Explorer 5.0 V8 GAS

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DRIVELINE, U-JOINT & CV AXLES REPLACEMENT PROCEDURES FOR 1996 Ford Explorer AUTOMOBILES

DRIVESHAFT U-JOINT, Replace -> Assemble -> Disassemble -> Single Cardan, Flange Yoke -> Single Cardan, Slip Yoke
Vehicle: 1996 Ford Explorer 5.0 V8 GAS

Single Cardan, Slip Yoke

Disassemble

Do not, under any circumstance, clamp the shaft in the jaws of a vise or similar holding fixture. Denting or localizing fracture can result, causing shaft failure during vehicle operation. Place the shaft on a suitable workbench. Do not damage the tube. If components are not marked and installed incorrectly, driveline imbalance can occur.

  • Index-mark the shaft components.
  • Remove and discard all four snap rings.
  • Clamp bearing cup removal tool No. 205-086 or equivalent in a vise.
  • If necessary, use a pair of pliers to remove a bearing cup t...

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STARTER & ALTERNATOR REPLACEMENT PROCEDURES FOR 1996 Ford Explorer AUTOMOBILES

Alternator, Replace
Vehicle: 1996 Ford Explorer 5.0 V8 GAS

  • Disconnect battery ground cable.
  • Disconnect intake air temperature sensor electrical connector.
  • Loosen air cleaner outlet tube clamps and remove air cleaner outlet tube.
  • Remove cooling fan blade and fan shroud.
  • Disconnect wiring at voltage regulator.
  • Remove alternator output terminal nut and wiring terminal from altern...

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MAINTENANCE LAMP RESET PROCEDURES FOR 1996 Ford Explorer AUTOMOBILES

Ford Motor Co. Trucks -> Air Bag Warning Lamp ->
Vehicle: 1996 Ford Explorer 5.0 V8 GAS

This lamp should light for a approximately 6-8 seconds when the ignition is turned On as a bulb check. If the Air Bag warning ...

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RADIATOR & HOSE REPLACEMENT PROCEDURES FOR 1996 Ford Explorer AUTOMOBILES

Coolant Hose, Replace -> Lower -> Upper
Vehicle: 1996 Ford Explorer 5.0 V8 GAS

Lower

  • Drain cooling system into a suitable container.
  • Reposition hose clamp from radiator.
  • Remove radiator outlet hose from radiator.
  • Reposition hose clamp from water pump connection.
  • Remove radiator outlet hose from water pump connection and from vehicle.
  • Reverse procedure...

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SERPENTINE BELT SERVICE PROCEDURES FOR 1996 Ford Explorer AUTOMOBILES

Serpentine Drive Belt, Replace
Vehicle: 1996 Ford Explorer 5.0 V8 GAS

  • Rotate or lift the belt tensioner arm, using a suitable tool to relieve tension from dr...

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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+.

I/P Modules & Related Components Diagram for 1996 Ford Explorer  4.0 V6 GASI/P Modules & Related Components Diagram for 1996 Ford Explorer 4.0 V6 GAS

Components on diagram:
  • In-Car Temperature Sensor
  • Liftgate Wiper/Washer Switch
  • Air Bag Diagnostic Monitor
  • Inertial Fuel Shutoff
  • Auxiliary Power
  • Power Distribution Box Components Diagram for 1996 Ford Explorer  5.0 V8 GASPower Distribution Box Components Diagram for 1996 Ford Explorer 5.0 V8 GAS

    Components on diagram:
  • PCM Power Relay
  • Horn Relay
  • Wide Open Throttle Relay
  • Ignition
  • Wiper Hi/Low Relay
  • CLICK HERE TO GET FULL ACCESS TO 1996 Ford Explorer PARTS/COMPONENTS LOCATION DIAGRAMS!

    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  4.0 V6 GAS Wiring Diagram1996 Ford Explorer 4.0 V6 GAS Wiring Diagram

    Components on diagram:
  • Battery
  • Starter Relay
  • Ignition Switch
  • Starter Motor
  • Generator
  • 1996 Ford Explorer  5.0 V8 GAS Wiring Diagram1996 Ford Explorer 5.0 V8 GAS Wiring Diagram

    Components on diagram:
  • Headlamp Switch
  • Lamp Out Warning Module
  • Multi-Function Switch
  • Daytime Running Lamps Module
  • LH/RH Headlamp
  • CLICK HERE TO GET FULL ACCESS TO 1996 Ford Explorer WIRING DIAGRAMS!

    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:
  • Chassis Electrical, Wiring, Fuses & Breakers, Wipers, Motors
  • Document: RECALL - 1992-2004 MULTIPLE VEHICLE LINES - SPEED CONTROL SYSTEM MODIFICATION
    Vehicle: 1996 Ford Explorer 4.0 V6 GAS

    CLICK HERE TO GET FULL ACCESS TO 1996 Ford Explorer TECHNICAL SERVICE BULLETINS!

    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

    CLICK HERE TO GET FULL ACCESS TO 1996 Ford Explorer SPECIFICATIONS DATA!

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