🏷️ Basic Information

Make:

Ford

Model:

Explorer

Year:

2003

Platform Code:

U152 (body-on-frame)

👋 Introduction

Segment:

Mid-size SUV (Sport Utility Vehicle).

Target Audience:

Families, individuals seeking utility, towing capability, and moderate off-road prowess. Also appeals to fleet operators and DIY mechanics.

Key Competitors:

Chevrolet TrailBlazer, Jeep Grand Cherokee, Toyota 4Runner, Nissan Pathfinder, GMC Envoy, Chevrolet Blazer.

Body Style:

Body-on-frame SUV, known for durability and towing capacity.

Drivetrain Options:

Available in Rear-Wheel Drive (RWD) and 4-Wheel Drive (4WD) configurations.

Seating Capacity:

Typically offers 5-passenger seating, with optional 3rd-row seating available on some trims for 7-passenger capacity.

📋 Manual Details

Manual Type:

Workshop Repair Service Manual

Language:

English

Format:

Digital (likely PDF, intended for electronic use)

Estimated Page Count:

Over 2000 pages (typical for comprehensive workshop manuals of this era)

📖 Manual Coverage

Engine:

Detailed coverage of all engine variants for 2003, including diagnostics, repair, and overhaul procedures for 4.0L SOHC V6 and 4.6L 2-Valve SOHC V8.

Transmission:

Complete service information for automatic transmissions (e.g., 5R55W for V6, 4R75E for V8), including disassembly, assembly, torque converter, valve body, electronic controls, and fluid specifications.

Drivetrain:

Detailed procedures for 2WD and 4WD systems, including transfer case operation and repair, differential service (front and rear), axle shaft removal and installation, and CV joints.

Suspension:

Comprehensive repair and adjustment procedures for front independent suspension (short-long arm) and rear solid axle (5-link coil spring), including shock absorbers, springs, control arms, bushings, and alignment specifications.

Brakes:

In-depth coverage of front disc and rear drum/disc brakes (depending on configuration), including hydraulic system components, ABS (Anti-lock Braking System) diagnostics and repair, brake rotor/pad replacement, and bleeding procedures.

Steering:

Service and repair of the power-assisted rack and pinion steering system, including steering gear, power steering pump, hoses, and alignment parameters.

Electrical System:

Extensive electrical schematics, component location charts, wiring diagrams, diagnostic procedures for lighting, charging system, starting system, body controls, and Powertrain Control Module (PCM) related functions.

Body And Trim:

Repair procedures for interior and exterior trim, doors, latches, hinges, glass, bumpers, and body panels. Includes information on convertible top mechanisms if applicable to specific trims.

HVAC:

Detailed service and repair information for the heating, ventilation, and air conditioning (HVAC) system, including component replacement, refrigerant handling, and diagnostic procedures.

Comfort And Convenience:

Coverage of power windows, power locks, power seats, cruise control, and other interior comfort features.

Preventive Maintenance:

Detailed recommended service intervals, fluid replacement schedules, filter changes, lubrication points, and inspection procedures.

Troubleshooting:

Systematic diagnostic charts and flowcharts for identifying and resolving common and complex problems across all vehicle systems.

Component Removal And Installation:

Step-by-step instructions for removing, repairing, and reinstalling virtually every major and minor component of the vehicle.

Rebuilding And Overhaul:

In-depth guides for rebuilding engines, transmissions, and other major mechanical assemblies, including specifications and tolerances.

Torque Specifications:

Precise torque values for all critical fasteners, ensuring proper assembly and component integrity.

Wiring Diagrams:

Comprehensive and detailed wiring schematics for all electrical systems, crucial for electrical troubleshooting and repair.

Diagnostic Trouble Codes:

Explanation and diagnostic procedures for OBD-II (On-Board Diagnostics II) codes, including generic and manufacturer-specific codes.

Diagnostic Capabilities:

Advanced diagnostic procedures, including sensor testing, actuator control, and PCM reprogramming guidance.

Repair Complexity:

Covers tasks ranging from basic fluid changes and brake pad replacement to complete engine and transmission overhauls, including specialized procedures.

📊 Manual Specifications

File Type:

PDF (Portable Document Format) is standard for digital workshop manuals, offering searchability and printability.

Image Resolution:

High-resolution scans or digitally created graphics ensuring clarity of diagrams, schematics, and illustrations.

Binding:

N/A (for digital format), but if a physical copy were referenced, it would typically be a comb-bound or spiral-bound manual for lay-flat usability.

Paper Quality:

N/A (for digital format), but for a physical manual, high-quality, durable paper would be expected to withstand shop use.

⚙️ Engine Specifications

Engine 1 Variant:

4.0L SOHC V6

Engine 1 Displacement:

3958 cc (241.5 cubic inches)

Engine 1 Horsepower:

202 hp @ 5000 rpm

Engine 1 Torque:

232 lb-ft @ 3500 rpm

Engine 1 Bore X Stroke:

92.26 mm x 94.0 mm (3.63 in x 3.70 in)

Engine 1 Compression Ratio:

9.7:1

Engine 1 Fuel Induction:

Electronic Fuel Injection (EFI), Sequential Multi-Port Fuel Injection (MPFI)

Engine 1 Firing Order:

1-6-5-4-3-2

Engine 1 Oiling System:

Wet sump, forced lubrication with oil pump and filter. Oil Capacity: 5.0 US quarts (4.7 L) with filter change.

Engine 1 Cooling System:

Pressurized, liquid-cooled. Coolant Capacity: 12.8 US quarts (12.1 L) (V6). Recommended: Motorcraft® Orange Coolant (Ford specification WSS-M97B44-D).

Engine 2 Variant:

4.6L 2-Valve SOHC V8

Engine 2 Displacement:

4606 cc (281.1 cubic inches)

Engine 2 Horsepower:

232 hp @ 4750 rpm

Engine 2 Torque:

291 lb-ft @ 3450 rpm

Engine 2 Bore X Stroke:

90.2 mm x 90.0 mm (3.55 in x 3.54 in)

Engine 2 Compression Ratio:

8.8:1

Engine 2 Fuel Induction:

Electronic Fuel Injection (EFI), Sequential Multi-Port Fuel Injection (MPFI)

Engine 2 Firing Order:

1-8-4-3-6-5-7-2

Engine 2 Oiling System:

Wet sump, forced lubrication with oil pump and filter. Oil Capacity: 6.0 US quarts (5.7 L) with filter change.

Engine 2 Cooling System:

Pressurized, liquid-cooled. Coolant Capacity: 14.3 US quarts (13.5 L) (V8). Recommended: Motorcraft® Orange Coolant (Ford specification WSS-M97B44-D).

Fuel Type:

Unleaded gasoline, minimum 87 octane (91 octane recommended for V8).

🔧 Transmission

Transmission V6:

5R55W Automatic Overdrive (5-speed)

Transmission V8:

4R75E Automatic Overdrive (4-speed)

Transmission Fluid V6:

Mercon V (Ford Specification XT-5-QM or equivalent). Fluid Capacity (with filter change): 5.7 US quarts (5.4 L).

Transmission Fluid V8:

Mercon V (Ford Specification XT-5-QM or equivalent). Fluid Capacity (with filter change): 8.0 US quarts (7.6 L).

📐 Dimensions

Wheelbase:

113.7 inches (2888 mm)

Overall Length:

190.9 inches (4849 mm)

Overall Width:

71.7 inches (1821 mm)

Overall Height:

67.3 inches (1709 mm)

Front Track:

61.6 inches (1565 mm)

Rear Track:

61.6 inches (1565 mm)

Ground Clearance:

Approximately 8.3 inches (211 mm), varies with tire size and suspension.

Front Headroom:

40.2 inches (1021 mm)

Front Legroom:

42.4 inches (1077 mm)

Rear Headroom:

39.6 inches (1006 mm)

Rear Legroom:

37.5 inches (953 mm)

Cargo Volume Behind 2Nd Row:

39.0 cubic feet (1104 L)

Cargo Volume Behind 3Rd Row:

12.5 cubic feet (354 L) (if equipped with 3rd-row seating)

Maximum Cargo Volume:

79.3 cubic feet (2245 L) (with 2nd and 3rd rows folded)

Curb Weight Min:

4350 lbs (1973 kg) (RWD V6)

Curb Weight Max:

4850 lbs (2200 kg) (4WD V8 with 3rd row)

Gross Vehicle Weight Rating Gvwr:

Approximately 5950-6300 lbs (2700-2858 kg), depending on configuration.

Towing Capacity:

Up to 7,300 lbs (3311 kg) with proper towing package and V8 engine.

🛡️ Safety Features

NHTSA Front Driver Side Impact:

5-star rating (for 2003 model year tested).

NHTSA Front Passenger Side Impact:

5-star rating (for 2003 model year tested).

NHTSA Side Driver Front:

4-star rating (for 2003 model year tested).

NHTSA Side Passenger Front:

4-star rating (for 2003 model year tested).

NHTSA Side Driver Rear:

4-star rating (for 2003 model year tested).

NHTSA Side Passenger Rear:

3-star rating (for 2003 model year tested).

NHTSA Rollover Resistance:

3-star rating (for 2WD and 4WD models).

ABS:

Standard Anti-lock Braking System (ABS) on all wheels.

Traction Control:

Optional Traction Control System (TCS).

Airbags Front:

Standard dual front airbags.

Airbags Side:

Optional front side-impact airbags.

Seatbelts:

Three-point seatbelts in all seating positions, with pretensioners for front occupants.

💡 Technology Features

Audio System:

Available with AM/FM stereo, CD player (single or in-dash 6-disc changer), cassette player, and premium sound systems (e.g., Monsoon).

Navigation:

Optional factory-installed DVD-based navigation system available on higher trim levels.

Cruise Control:

Standard electronic cruise control.

Parking Sensors:

Optional rear parking assist sensors.

Power Outlets:

Standard 12V power outlets for accessory charging.

Remote Keyless Entry:

Available remote keyless entry system.

🔧 Maintenance

Oil And Filter Change:

Every 5,000 miles (8,000 km) or 6 months, whichever comes first. Use Motorcraft® SAE 5W-20 Synthetic Blend or equivalent meeting Ford WSS-M2C153-H specification.

Air Filter Replacement:

Inspect every 15,000 miles (24,000 km), replace as needed. Typically every 30,000 miles (48,000 km).

Engine Coolant Replacement:

First change at 100,000 miles (160,000 km) or 10 years, then every 50,000 miles (80,000 km) or 5 years. Use Motorcraft® Orange Coolant (WSS-M97B44-D).

Transmission Fluid Service:

Inspect every 15,000 miles (24,000 km). Replace fluid and filter every 60,000-100,000 miles (96,000-160,000 km) under normal driving conditions, or sooner under severe duty (towing, frequent short trips).

Spark Plug Replacement:

4.0L V6: Every 100,000 miles (160,000 km) (iridium spark plugs). 4.6L V8: Every 100,000 miles (160,000 km) (platinum spark plugs).

Engine Oil:

SAE 5W-20 (Synthetic Blend or Full Synthetic), Ford WSS-M2C153-H.

Transmission Fluid:

Mercon V (XT-5-QM or equivalent).

Power Steering Fluid:

Mercon V (XT-5-QM or equivalent).

Brake Fluid:

DOT 3 (Ford specification WSS-M6C57-A or equivalent).

Coolant:

Motorcraft® Orange Coolant (Ford specification WSS-M97B44-D), a 50/50 mix of antifreeze and distilled water.

Ignition Coils 4.0L:

Premature failure of individual ignition coils is a common complaint on the 4.0L V6 engine.

Idle Air Control Valve Iacv:

The IACV can become contaminated with carbon, leading to rough idling, stalling, or difficulty starting.

Rear Differential Leaks:

Leaking rear differential seals can occur, requiring replacement of the pinion seal or axle seals.

ABS Sensor Failure:

ABS wheel speed sensors can fail, triggering ABS warning lights and disabling ABS function.

Door Lock Actuators:

Power door lock actuators can fail, preventing doors from locking or unlocking properly.

📚 Vehicle History

Ford SUV History:

Ford has a long history of producing capable SUVs, starting with the Bronco. The Explorer, launched in 1990, became a dominant force in the SUV market, popularizing the concept of a more car-like (though initially body-on-frame) utility vehicle.

Third Generation Introduction:

The 2003 model year marked the introduction of the third generation of the Ford Explorer, a significant redesign from the previous generation. This generation transitioned to unibody construction for improved ride comfort and handling, although some earlier 2003 models retained the body-on-frame construction before the full shift.

Third Generation Features:

This generation introduced independent rear suspension (IRS) for most models, a smoother ride, increased interior space, and updated styling. The engine options remained the 4.0L V6 and 4.6L V8.

Manufacturing Locations:

Primary assembly plants included the St. Louis Assembly Plant (Missouri) and the Kentucky Truck Plant (Kentucky), USA.

Production Years Third Gen:

2002-2005 (though the 2003 model year is characterized by a split in chassis types before the full unibody transition).

🏆 Awards & Recognition

Automotive Press Awards:

The Ford Explorer has historically received numerous awards and positive reviews from automotive publications for its utility, capability, and value. Specific awards for the 2003 model year would be detailed in automotive reviews from the period.

Consumer Reports Ratings:

Consumer Reports typically provided reliability ratings and road test reviews for the Explorer, which varied by model year and specific configurations.

Emissions Certification:

Vehicles comply with U.S. EPA and California Air Resources Board (CARB) emissions standards for the model year.