🏷️ Basic Information

Make:

Ford

Model:

Explorer

Year:

2002

Generation:

Third Generation (UN94)

Chassis Code:

UN94

👋 Introduction

Market Position:

The 2002 Ford Explorer marked a significant redesign, introducing a new chassis and powertrain options, solidifying its position as a leading mid-size SUV with strong appeal to families and those seeking off-road capability.

Competitive Analysis:

Competed directly with vehicles like the Chevrolet TrailBlazer, Jeep Grand Cherokee, Toyota 4Runner, and Nissan Pathfinder. The 2002 model year introduced a more refined interior and improved ride quality compared to its predecessors.

Key Features:

Independent front suspension, available V8 engine, advanced Safety Canopy system, redesigned interior with improved ergonomics and materials.

📋 Manual Details

Coverage Areas:

Full vehicle service, repair, and maintenance for 2002 Ford Explorer

Page Count:

1850

Manual Type:

Factory Service Manual (FSM)

Language:

English

Format:

Printed

📖 Manual Coverage

Systems Covered:

Engine, Transmission (Automatic & Manual), Drivetrain (4WD/AWD), Suspension, Steering, Brakes, HVAC, Electrical System (including Powertrain Control Module - PCM, Body Control Module - BCM, Anti-lock Braking System - ABS, Supplemental Restraint System - SRS), Fuel System, Exhaust System, Body & Chassis, Interior Components

Procedures Included:

Routine maintenance, scheduled servicing, diagnostic procedures, troubleshooting guides, component removal and installation, repair procedures, wiring diagrams, specifications, tightening torques, fluid capacities and types, emission control systems, lubrication points

Technical Depth:

Comprehensive; covers basic maintenance to complex engine and transmission rebuilds. Includes detailed diagnostic flowcharts and specific component testing.

📊 Manual Specifications

File Format:

N/A (Printed Manual)

Print Quality:

High-quality, professional printing with clear diagrams and text.

Binding Type:

Perfect Bound with Durable Cover

Paper Type:

Heavy-duty, matte finish paper resistant to workshop grease and fluids.

⚙️ Engine Specifications

Primary Engine:

4.0L SOHC V6

Engine Code:

E

Displacement:

3958 cc

Bore X Stroke:

90.2 mm x 77.2 mm

Compression Ratio:

9.7:1

Horsepower:

210 hp @ 5000 rpm

Torque:

255 lb-ft @ 3500 rpm

Optional Engine:

4.6L SOHC V8

Engine Code:

V

Displacement:

4605 cc

Bore X Stroke:

90.2 mm x 90.0 mm

Compression Ratio:

9.0:1

Horsepower:

239 hp @ 4750 rpm

Torque:

282 lb-ft @ 3750 rpm

Fuel System:

Electronic Fuel Injection (EFI) with Sequential Port Injection

Fuel Type:

Unleaded gasoline, 87 octane (minimum)

Ignition System:

Coil-on-plug (COP) ignition system

🔧 Transmission

Standard Transmission:

4-speed Automatic Overdrive (4R55E/4R70W)

Optional Transmission:

5-speed Manual (M5R2 - limited availability on V6 models)

Features:

Electronic control, torque converter lock-up, available overdrive

Automatic Transmission Fluid:

Mercon V

Manual Transmission Fluid:

Mercon ATF or equivalent (check specific manual for exact type)

Automatic Transmission Fluid Capacity:

Approx. 10.5 quarts (9.9 liters) with torque converter

Manual Transmission Fluid Capacity:

Approx. 2.5 quarts (2.4 liters)

📐 Dimensions

Wheelbase:

113.7 inches (2888 mm)

Length:

188.5 inches (4788 mm)

Width:

72.1 inches (1831 mm)

Height:

70.2 inches (1783 mm)

Ground Clearance:

8.6 inches (218 mm)

Cargo Volume Behind 3Rd Row:

24.5 cu ft (694 liters)

Cargo Volume Behind 2Nd Row:

81.6 cu ft (2311 liters)

Curb Weight:

4250 - 4500 lbs (1928 - 2041 kg) depending on configuration

Gross Vehicle Weight Rating Gvwr:

5700 - 6000 lbs (2585 - 2722 kg)

Standard Tire Size:

P235/70R16

Optional Tire Size:

P245/65R17

Wheel Bolt Pattern:

5 x 135 mm

Wheel Size:

16 or 17 inches

🛡️ Safety Features

NHTSA Front Impact Rating:

Driver: 5-star, Passenger: 5-star (for models with side airbags)

NHTSA Side Impact Rating:

Front: 4-star, Rear: 4-star (for models with side airbags)

IIHS Rating:

Good (Frontal Offset)

Active Features:

Anti-lock Braking System (ABS), Traction Control System (TCS - optional)

Passive Features:

Front airbags, available Side Curtain Airbags (Safety Canopy), front seatbelt pretensioners, reinforced frame construction

💡 Technology Features

Infotainment System:

Factory-installed AM/FM stereo with CD player, optional premium sound system, optional in-dash 6-disc CD changer.

Display:

Digital clock, basic radio display. Higher trims may feature a more advanced display for climate control and audio.

Driver Assistance Features:

Cruise control, optional parking assist sensors (rear).

Connectivity Features:

No standard Bluetooth or USB connectivity. Auxiliary audio input may be available on premium sound systems.

🔧 Maintenance

Oil Change Interval:

Every 5,000 miles (8,000 km) or 6 months, whichever comes first (severe service may require more frequent changes).

Engine Coolant Flush:

Every 100,000 miles (160,000 km) or 5 years

Transmission Fluid Change:

Every 100,000 miles (160,000 km) or 5 years (or more frequently under severe usage)

Spark Plug Replacement:

100,000 miles (160,000 km) for V6 and V8 (Long-life platinum)

Engine Oil Specification:

SAE 5W-30 Synthetic Blend (API Service SG, SH, SJ, or ILSAC GF-2)

Engine Oil Capacity:

V6: 6.0 quarts (5.7 liters); V8: 7.0 quarts (6.6 liters)

Brake Fluid:

DOT 3

Power Steering Fluid:

Mercon V or Ford recommended power steering fluid

Known Issues:

Rear axle seal leaks, intake manifold gasket failures (especially on V8), transmission solenoid pack issues, potential for catalytic converter failure, exhaust manifold cracks (V8).

Oil Filter Part Number:

Motorcraft FL-820-S or equivalent

Air Filter Part Number:

Motorcraft FA-1677 or equivalent

📚 Vehicle History

Brand Heritage:

Ford has a long-standing history in the SUV market, with the Explorer being a foundational model in the segment since its introduction in 1990, building on Ford's truck and utility vehicle expertise.

Model Evolution:

The 2002 model represents the third generation of the Ford Explorer, a complete redesign from the previous generation. It shifted from body-on-frame construction to a unibody platform, offering improved ride comfort and handling. This generation also introduced a longer wheelbase option for the extended version (Explorer Sport Trac).

Production Years:

1990-2010 (for this platform lineage before the 2011 redesign)

Manufacturing Locations:

Kentucky Truck Plant, Louisville, Kentucky; St. Louis Assembly Plant, St. Louis, Missouri

🏆 Awards & Recognition

Recognitions:

The Ford Explorer has historically been a best-selling SUV and has received numerous accolades throughout its various generations, though specific awards for the 2002 model year are more difficult to pinpoint due to the sheer volume of automotive awards.