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1997 Ford EXPLORER Workshop OEM Service DIY Repair Manual
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🏷️ Basic Information Identification Make: Ford Model: Explorer Model Variant: Second generation (UN105/UN150), 2-door and 4-door SUV Production Years Covered: 1997 model year (coverage typically spans 1995-1997 second-generation platform) Body...
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🏷️ Basic Information
Identification
Make:
Ford
Model:
Explorer
Model Variant:
Second generation (UN105/UN150), 2-door and 4-door SUV
Production Years Covered:
1997 model year (coverage typically spans 1995-1997 second-generation platform)
Body Styles:
2-door (Sport) and 4-door
Drivetrain Options:
RWD (4x2) and 4WD (4x4)
👋 Introduction
Market Position
Target Audience:
Professional technicians, independent repair shops, and experienced DIY owners servicing the second-generation Explorer
Vehicle Segment:
Mid-size sport utility vehicle
Primary Competitors:
Jeep Cherokee, Chevrolet Blazer, Toyota 4Runner, Nissan Pathfinder
Key Features
Factory-Level Procedures:
OEM service procedures matching Ford dealer documentation
Wiring Diagrams:
Complete electrical schematics and component location charts
Diagnostic Content:
Troubleshooting trees, fault code tables, and symptom-based diagnostics
Torque Specifications:
Factory torque values for fasteners throughout the vehicle
📋 Manual Details
Publication Details
Manual Type:
OEM workshop / factory service repair manual
Coverage Areas:
Engine, transmission, driveline, brakes, suspension, steering, electrical, HVAC, body, and diagnostics
Language:
English
Format and Delivery
File Format:
PDF
Delivery Method:
Instant digital download
Binding:
Digital (PDF, print-ready from your own printer)
📖 Manual Coverage
Systems Covered
Engine:
4.0L OHV and 4.0L SOHC V6, plus 5.0L V8 — removal, overhaul, timing, and specifications
Cooling and Lubrication:
Radiator, water pump, thermostat, oil pump, and lubrication circuits
Fuel and Emissions:
Multi-port fuel injection, fuel tank and lines, evaporative emissions, and exhaust system
Ignition and Controls:
Distributor-less ignition (EDIS) and powertrain control module (PCM) diagnostics
Automatic Transmission:
4R55E / 5R55E and 4-speed electronic automatic transmission service
Driveline:
Transfer case, front differential, rear differential (open and limited-slip), driveshafts, and hubs
Brakes:
Anti-lock brake system (4WABS), hydraulic system, disc and drum brake service
Suspension:
Front twin I-beam / independent front suspension, rear leaf springs, shock absorbers
Steering:
Recirculating-ball power steering gear and pump
Electrical:
Charging, starting, lighting, gauges, wipers, power accessories, and complete wiring diagrams
HVAC:
Heating, ventilation, air conditioning components and refrigerant service
Body and Interior:
Doors, latches, glass, seats, trim, and body panels
Procedures Included
Diagnostics:
Symptom charts, pinpoint tests, self-test and fault code retrieval procedures
Removal and Installation:
Step-by-step component R&I with supporting illustrations
Disassembly and Assembly:
Engine, transmission, and transfer case overhaul procedures
Adjustments:
Valve lash, belt tension, alignment references, and switch/linkage settings
Special Tools:
Factory special tool callouts and acceptable substitutes where applicable
Technical Depth
Specification Tables:
Full factory specifications for clearances, torque, pressures, and capacities
Schematics:
Component locators and circuit diagrams
Skill Level:
Appropriate for professional shops and competent DIY mechanics with proper tools
Parts Information
Part References:
Ford service part numbers where listed in OEM procedures
Fluid Capacities:
Factory fill quantities for oil, coolant, transmission, and differentials
Fastener Data:
Torque specifications throughout all sections
📊 Manual Specifications
File & Compatibility
File Format:
PDF (searchable, bookmarked, zoomable)
Compatibility:
Windows, macOS, Linux, iOS, and Android — any device with a PDF reader
Requirements:
A PDF reader application (e.g. Adobe Acrobat Reader, free)
Searchability:
Fully text searchable for fast lookup of any topic
Print & Binding
Print Quality:
High-resolution digital pages, printable at full clarity
Binding Type:
N/A — digital download, no physical binding
Paper Type:
N/A — digital download, no physical paper
⚙️ Engine Specifications
Engine Options
Base Engine:
4.0L OHV V6 (EFI)
Optional Engine:
4.0L SOHC V6 and 5.0L V8 (EFI)
Fuel System:
Sequential multi-port electronic fuel injection
Fuel Type:
Regular unleaded gasoline
Performance
4.0L OHV Output:
Approximately 160 hp (per factory ratings)
4.0L SOHC Output:
Approximately 205 hp (per factory ratings)
5.0L V8 Output:
Approximately 210-215 hp (per factory ratings)
Fundamentals
Cooling:
Liquid-cooled with pressurized radiator and electric cooling fans
Ignition:
Electronic distributor-less ignition (EDIS) on applicable engines
Engine Control:
Ford EEC-V powertrain control module
🔧 Transmission
Transmission
Standard Transmission:
4-speed electronic automatic transmission (4R55E)
Optional Transmission:
5-speed electronic automatic transmission (5R55E)
Features:
Electronic shift control interfaced with PCM; overdrive top gear on 5R55E
Driveline
Transfer Case (4WD):
Borg-Warner electric-shift transfer case (4x4 models)
Drive Modes:
2H, 4H, and 4L range selection
📐 Dimensions
Exterior
Wheelbase (2-door):
Approximately 102 in
Wheelbase (4-door):
Approximately 111.5 in
Length (4-door):
Approximately 190 in
Weights
Curb Weight:
Approximately 3,600-4,300 lb depending on body style, drivetrain, and equipment
GVWR:
Refer to vehicle certification label; varies by configuration
🛡️ Safety Features
Active Features
ABS:
Four-wheel anti-lock braking system (4WABS) on equipped models
Braking:
Front disc, rear drum brakes with power assist
Steering Control:
Power recirculating-ball steering
Passive Features
Airbags:
Driver and front passenger airbags (dual airbags in 1997)
Restraints:
Three-point front seatbelts; rear lap/shoulder belts
Structure:
Steel ladder frame with reinforced safety-cage body structure
Ratings
Crash Test Data:
N/A - not covered in the service manual; consult NHTSA records for 1997 model year results
💡 Technology Features
Infotainment
Audio System:
AM/FM stereo with cassette; optional premium sound and CD player
Wiring Support:
Audio and accessory circuits documented in manual wiring diagrams
Driver Assistance
ADAS Features:
None - not available for the 1997 model year
4WD Electronics:
Electric-shift transfer case control module on 4x4 models
Convenience Electronics:
Power windows, locks, mirrors, and optional keyless entry with documented circuits
🔧 Maintenance
Service Intervals
Oil and Filter:
Normal service approximately every 5,000 miles / 6 months (per Ford 1997 schedule)
Spark Plugs:
Replace at 60,000-mile intervals (per Ford schedule)
Coolant:
Replace per Ford scheduled maintenance chart in the manual
Automatic Transmission Fluid:
Normal service approximately every 30,000 miles (severe service shorter)
Differential and Transfer Case:
Fluid change per Ford severe-service schedule
Fluid Specifications
Engine Oil:
5W-30 (typical factory recommendation for 4.0L and 5.0L engines)
Automatic Transmission Fluid:
Motorcraft Mercon ATF
Coolant:
Ford green extended-life ethylene glycol coolant of the era
Refrigerant:
R-134a for 1997 air conditioning systems
Known Issues / Wear Items
Common Wear:
Ball joints, tie-rod ends, idler arm, and rear leaf spring bushings
Known Concerns:
4.0L OHV timing chain guides and intake manifold gaskets on high-mileage engines
Brakes:
Rear drum adjustment and ABS wheel-speed sensor service
📚 Vehicle History
Brand Heritage
Manufacturer:
Ford Motor Company, Dearborn, Michigan, USA
Model Lineage:
Explorer introduced in 1990 as Ford's mid-size SUV, derived from the Ranger truck platform
Model Evolution
Generation:
Second generation, launched for the 1995 model year
1997 Updates:
Refined powertrains including the 4.0L SOHC V6 option and continued dual-airbag safety package
Body Styles:
2-door Sport and 4-door configurations
Production
Production Location:
Assembled in the United States (St. Louis, Missouri assembly plant, per Ford production records)
🏆 Awards & Recognition
Recognition
Market Standing:
Consistently among the best-selling SUVs in North America during the 1990s
Segment Role:
Widely credited with defining the mainstream family SUV segment
Documented Awards:
N/A - specific 1997 award listings not stated in the source material