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2002 Ford Explorer CAR/TRUCK REPAIR PROCEDURES AND DIAGRAMS - WHAT Ford REPAIR SHOPS DON'T WANT YOU TO KNOW
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- A/C & Heater Service
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- Fuel Filter Replacement
- Driveline, U-Joint & CV Axles Replacement
- Starter & Alternator Replacement
- Maintenance Lamp Reset
- Radiator & Hose Replacement
- Serpentine Belt Service
Automotix DIY provides automotive consumers and do it yourselfers; the most comprehensive repair information about 2002 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
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A/C & HEATER SERVICE PROCEDURES FOR 2002 Ford Explorer AUTOMOBILES
Module Configuration Procedure -> Ford Motor Company -> 1999-2003 -> Calibration Update -> Programmable Module Installation (PMI) -> Programmable Parameters
Vehicle: 2002 Ford Explorer 4.6 V8 GAS
Some modules will need to be programmed as part of a repair procedure, Fig. . If not the module will not function properly and may set a number of diagnostic trouble codes including B2477 or P1639 indicating necessary data has not been programmed into the new module.
Module parameters and values are unique to each vehicle, therefore modules should not be exchanged from vehicle to vehicle.
There are two types of configuration data. The first type is used by the module so that it can interact with the vehicle correctly. The second type is customer preference driven. These ...
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BRAKE SERVICE PROCEDURES FOR 2002 Ford Explorer AUTOMOBILES
Disc Brakes -> Rotor Replacement -> 1999-2001 -> 2002-03 -> Aviator -> E-Series -> Escape -> Excursion, F-Super Duty & Motorhome -> Expedition & Navigator -> Explorer & Mountaineer -> Explorer Sport/Sport Trac -> F-250 & F-350 2WD -> F-250 & F-350 4WD, F-450 & F-550 -> F-Series -> Front -> Installation -> Motorhome -> Ranger -> Rear -> Removal -> Windstar & Villager
Vehicle: 2002 Ford Explorer 4.0 V6 GAS
Aviator
Front
- Raise and support vehicle.
- Remove front tire and wheel assemblies.
- Remove front brake components in sequence, Fig. .
- Reverse procedure to install.
Rear
Refer to Fig. , and remove rear brake components in sequence listed.
Escape
- Remove disc brake caliper and anchor plate as outlined in "Caliper Service".
- Remove rotor
- Reverse Procedure to install. Tighten all nuts and bolts to specification.
E-Series
Front
Refer to Figs. through , and remove components in sequence listed.
Rear
Removal
- Remove disc brake caliper, refer to "Caliper Service."
- Remove axle shafts as outlined in "Rear Axle & S... "
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FUEL FILTER REPLACEMENT PROCEDURES FOR 2002 Ford Explorer AUTOMOBILES
Ford Motor Co. Light Trucks, SUVs & Vans -> Fuel Filter Scheduled Maintenance -> 1999-06 Bronco II, Escape, Explorer, Explorer Sport & Sport Trac, Mariner & Mountaineer -> Normal Service -> Severe Service
Vehicle: 2002 Ford Explorer 4.6 V8 GAS
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DRIVELINE, U-JOINT & CV AXLES REPLACEMENT PROCEDURES FOR 2002 Ford Explorer AUTOMOBILES
DRIVESHAFT, Replace -> Four Wheel Drive (4WD) -> Front -> Rear -> Two Wheel Drive (2WD)
Vehicle: 2002 Ford Explorer 4.6 V8 GAS
Front
The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the rear jack storage area. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations.
- With vehicle in neutral, raise and support vehicle.
- Index-mark front axle pinion flange to front driveshaft.
- Remove transfer case skid plate.
- Index-mark transfer case pinion flange to front ...
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STARTER & ALTERNATOR REPLACEMENT PROCEDURES FOR 2002 Ford Explorer AUTOMOBILES
Alternator, Replace
Vehicle: 2002 Ford Explorer Sport 4.0 V6 GAS
- Disconnect battery ground cable:
- Disconnect alternator drive belt.
- Position protective cover aside, remove and discard generator B+ terminal nut.
- Disconnect alternator B+ terminal and electrical connectors.
- Remove alternator mounting bolts.
- Remov...
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MAINTENANCE LAMP RESET PROCEDURES FOR 2002 Ford Explorer AUTOMOBILES
Ford Motor Co. Trucks -> Low Oil Level Warning Indicator ->
Vehicle: 2002 Ford Explorer Sport 4.0 V6 GAS
This system is used to indicate a low engine oil level condition. The lamp should light during engine starting. If oil level is sufficient, the lamp should go off when engine is operating. If oil level is low the...
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RADIATOR & HOSE REPLACEMENT PROCEDURES FOR 2002 Ford Explorer AUTOMOBILES
Coolant Hose, Replace -> Lower -> Upper
Vehicle: 2002 Ford Explorer 4.0 V6 FLEX
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.
- Remove radiator outlet hose from water pump and from vehicle.
- Reverse procedure to in...
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SERPENTINE BELT SERVICE PROCEDURES FOR 2002 Ford Explorer AUTOMOBILES
Serpentine Drive Belt, Replace
Vehicle: 2002 Ford Explorer Sport 4.0 V6 GAS
- Remove air cleaner outlet tube.
- Rotate tensioner by turning counterclockwis...
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COMPONENT LOCATION DIAGRAMS FOR 2002 Ford Explorer AUTOMOBILES
Component location diagrams for most 2002 Ford Explorer cars and light trucks sold in the U.S. from 1990+.
 Transmission Component Location Views Diagram for 2002 Ford Explorer 4.0 V6 GASComponents on diagram: |
 Engine Bulkhead Component Location Views Diagram for 2002 Ford Explorer 4.6 V8 GASComponents on diagram: |
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WIRING DIAGRAMS FOR 2002 Ford Explorer AUTOMOBILES
OEM drawn wiring diagrams for most 2002 Ford Explorer cars and light trucks sold in the U.S.
 2002 Ford Explorer Sport 4.0 V6 GAS Wiring DiagramComponents on diagram: |
 2002 Ford Explorer 4.6 V8 GAS Wiring DiagramComponents on diagram: |
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TECHNICAL SERVICE BULLETINS FOR 2002 Ford Explorer AUTOMOBILES
OEM TSB listings for most 2002 Ford Explorer cars and light trucks sold in the U.S. from 1985+.
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Document: 4 WHEEL DRIVE/ALL WHEEL DRIVE - WITH CONTROL TRAC - SHUDDER ON ACCELERATION / DECELERATION OR BINDING ON SLOW TURNS Vehicle: 2002 Ford Explorer 4.6 V8 GAS Symptoms: |
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Document: UNITIZED SEAL DIAGNOSIS - LEAK / GREASE OIL SEPARATION - AXLE BEARING SEAL 8.8 IFS, 8.8 IRS, AND 9.75 IRS AXLES - REVISED Vehicle: 2002 Ford Explorer 4.6 V8 GAS Symptoms: |
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COMPONENT/PARTS SPECIFICATIONS FOR 2002 Ford Explorer AUTOMOBILES
BRAKE SPECIFICATIONS: Brake drum, rotor, caliper, and related specifications for most 2002 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 2002 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 2002 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 2002 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
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