- 1). Place the Explorer in neutral gear and apply the parking brake. Lift the Ford using a vehicle hoist and then remove the front wheel(s) using an impact gun and socket.
- 2). Loosen the jamb nut of the outer tie rod end to the inner tie rod connection using an open end wrench. If stubborn, apply penetrating oil, allow it five to ten minutes to soak in and retry. If necessary, a portable propane or oxyacetylene torch will convince the jamb nut loose. Allow to cool down after broken free before proceeding.
- 3). Remove the cotter pin from the outer tie rod end shaft that connects to the knuckle using a pair of needle nose pliers. Remove the castle nut from the outer tie rod end shaft using the impact gun and socket.
- 4). Install a tie rod end separator onto the outer tie rod end shaft with the clamps of the separator placed on the knuckle. Tighten the separator shaft with a box-end wrench to press the shaft of the tie rod end from the knuckle.
- 5). Remove the outer tie rod end from the inner tie rod end by turning it counterclockwise. Count and record how many full turns it takes to remove the outer tie rod end in order to install the replacement close to the original toe setting.
- 6). Install the new outer tie rod end to the inner tie rod matching the amount of turns it took to remove. Place the rubber boot onto the shaft of the outer tie rod end and then install it into the knuckle and replace the castle nut. Tighten the castle nut to 60-foot pounds using a torque wrench and socket. Align the slots of the castle nut to the hole in the outer tie rod end shaft in order to insert the cotter pin into the hole and then bend the cotter pin to secure the castle nut.
- 7). Tighten the jamb nut on the inner tie rod end to the outer tie rod end.
- 8). Place the grease fitting (if applicable) onto the top of the outer tie rod end and tighten with a small wrench. Fill the grease fitting until the boot is fully expanded with a grease gun. Repeat the procedure for the other side (if desired) before replacing the wheels and having the Explorer's front end aligned.
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