2008 Ford Explorer 2WD V6-4.0LFACTORY OEM SERVICE PROCEDURE

Procedures




Frame Drilling
1. Holes that would weaken the frame sidemember should not be drilled in the frame.
2. Holes are not to be drilled in the sidemember's top or bottom flange.
3. Holes to mount brackets, out-riggers and supports may be drilled in the vertical frame side rail web with the following restrictions:
- Material between edge of hole and inside of upper or lower flange must not be less than 38.1 mm (1.50 in) for low carbon steel (36,000 psi yield).
- The minimum edge distance between any 2 holes up to 15.74 mm (0.625 in) diameter must be 25.4 mm (1.00 in). For larger than 15.74 mm (0.625 in) diameter holes, the minimum edge distance must be 1.5 times the diameter of the largest hole.
- No holes will be allowed to exceed 19.05 mm (0.75 in) in diameter.
- Avoid close vertical succession of fasteners.
- All attaching fasteners, including flat washers, must be of high strength steel (Grade 8).
Factory Service Tools

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.

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