2002 Ford Explorer REPAIR MANUAL -- HOW TO FIX YOUR CAR OR TRUCK

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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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Get Full Access 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 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 2002 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 2002 Ford Explorer AUTOMOBILES

Air Bag System Precautions -> Ford Motor Co. -> Arming -> 1990-91 -> 1990-92 -> 1991-92 -> 1992-93 -> 1992-94 -> 1992-96 -> 1992-98 -> 1993 -> 1993-94 -> 1993-95 -> 1994 -> 1994-95 -> 1994-96 -> 1994-97 -> 1995 -> 1995-2004 -> 1995-96 -> 1995-98 -> 1996-97 -> 1996-99 -> 1997-2000 -> 1997-2001 -> 1997-2004 -> 1997-99 -> 1998 -> 1998-2000 -> 1998-2002 -> 1999-2000 -> 1999-2001 -> 1999-2002 -> 1999-2004 -> 2000 -> 2000-01 -> 2000-04 -> 2001-02 -> 2001-03 -> 2001-04 -> 2002-03 -> 2002-04 -> 2004 -> Aerostar & Bronco -> Aspire -> Aviator -> Blackwood, Expedition & Navigator -> Built After February 2002 -> Built Before March 2002 -> Capri -> Continental -> Contour & Mystique -> Cougar -> Crown Victoria Grand Marquis & Marauder -> Econoline -> Escape -> Escort, Tracer & ZX2 -> Excursion -> Explorer & Mountaineer -> Explorer Sport & Sport Trac -> F Series -> Focus -> Freestar & Monterey -> Light Trucks & Vans -> LS -> Mark VII -> Mark VIII -> Mustang -> Passenger Cars -> Probe -> Ranger -> Sable & Taurus -> Tempo & Topaz -> Thunderbird -> Town Car -> Villager -> Windstar
Vehicle: 2002 Ford Explorer Sport 4.0 V6 GAS

Passenger Cars

Aspire
  • Disconnect battery ground cable.
  • Wait one minute for back-up power supply to deplete stored energy.
  • Remove restraint system diagnostic tool from driver's side air bag module electrical connector.
  • Connect driver's side air bag module electrical connector.
  • Install driver's side air bag module as outlined under "Component Service."
  • Remove restraint system diagnostic tool from passenger's side air bag module electrical connector.
  • Install passenger's side air bag module as outlined under "Component Service."
  • C...

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BRAKE SERVICE PROCEDURES FOR 2002 Ford Explorer AUTOMOBILES

Drum Brakes -> Expedition, Explorer, E-Series, F-Series, Mountaineer, Navigator & Ranger -> Parking Brake w/Rear Disc -> E-Series -> Expedition, Explorer, F-150, F-250, Mountaineer & Navigator -> F-Super Duty
Vehicle: 2002 Ford Explorer 4.0 V6 GAS

F-Super Duty

  • Raise and support vehicle, remove tire and wheel assemblies.
  • Remove rear brake disc rotor.
  • Disconnect rear parking brake cable at parking brake cable equalizer.
  • Disconnect parking brake cable at parking brake lever.
  • Remove outboard brake shoe retaining spring.
  • Remove brake shoe adjusting screw spring, brake shoe hold down springs and brake adjuster screw.
  • Remove parking brake shoe and linings along with inboard brake shoe retracting spring.
  • Reverse procedure to install.

Expedition, Explorer, F-150, F-250, Mountaineer & Navigator

  • Pull front parking brake cable and co...

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FUEL FILTER REPLACEMENT PROCEDURES FOR 2002 Ford Explorer AUTOMOBILES

Ford Motor Co. Light Trucks, SUVs & Vans -> Fuel Pressure Relief -> Gasoline Fuel Injected Engines Except Escape, Freestar, Mariner, Monterey, Villager, 2005-06 Aviator, Explorer & Mountaineer, 2005-06 Expedition & Navigator & 2004-06 F150 & Mark LT
Vehicle: 2002 Ford Explorer 4.0 V6 GAS

The fuel system remains under high pressure even when the engine is not running. This residual pressure must be relieved before servicing the fuel system. To avoid injury or fire, release pressure from the fuel system before disconnecting any fuel line.

The fuel system pressure must be relieved prior to disconnecting fuel lines to prevent accidental spray of fuel.

After the battery ...

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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 4.0 V6 FLEX

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 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 -> Electronic Throttle Control ->
Vehicle: 2002 Ford Explorer Sport 4.0 V6 GAS

Electronic throttle displays when the system has malfunctioned and the engine has defaulted to a limp-home operation. On vehicles equipped with ...

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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 4.0 V6 FLEX

  • Raise tensioner by turning counterclockwise, then remove belt.
  • Install new be...

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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+.

Body Component Location Views Diagram for 2002 Ford Explorer 4.0 V6 GASBody Component Location Views Diagram for 2002 Ford Explorer 4.0 V6 GAS

Components on diagram:
  • High Beam Lamp
  • Fog Lamp
  • Low Beam Lamp
  • Connector C-152
  • Connector C-1020
    • Under Dash Panel Component Location Views Diagram for 2002 Ford Explorer 4.0 V6 GASUnder Dash Panel Component Location Views Diagram for 2002 Ford Explorer 4.0 V6 GAS

    Components on diagram:
  • Connector C-215
  • Connector C-263
  • Connector C-270b
  • Connector C-270c

    • CLICK HERE TO GET FULL ACCESS TO 2002 Ford Explorer PARTS/COMPONENTS LOCATION DIAGRAMS!

    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 Diagram2002 Ford Explorer Sport 4.0 V6 GAS Wiring Diagram

    Components on diagram:
  • Rear Window Defrost Relay
  • Rear Window Defrost Switch
  • Rear Window Defrost Grid
  • Generic Electronic Module
    • 2002 Ford Explorer 4.0 V6 FLEX Wiring Diagram2002 Ford Explorer 4.0 V6 FLEX Wiring Diagram

    Components on diagram:
  • Data Link Connector
  • Digital Transmission Range Sensor
  • Reversing Lamp Switch
  • Parking Aid Module

    • CLICK HERE TO GET FULL ACCESS TO 2002 Ford Explorer WIRING DIAGRAMS!

    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+.

    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:
  • Sticking, Binding
  • Vibration

    • Auto Systems:
  • Drive Axles, Shafts, U-Joints, CV-Joints
    • 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:
  • Leaks

    • Auto Systems:
  • Drive Axles, Shafts, U-Joints, CV-Joints

    • CLICK HERE TO GET FULL ACCESS TO 2002 Ford Explorer TECHNICAL SERVICE BULLETINS!

    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

    CLICK HERE TO GET FULL ACCESS TO 2002 Ford Explorer SPECIFICATIONS DATA!

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