Target Audience:
Families, recreational users, light off-road enthusiasts.
Key Competitors:
Chevrolet TrailBlazer, Jeep Grand Cherokee, Toyota 4Runner, Nissan Pathfinder.
Platform:
Body-on-frame construction (shared with Ranger pickup truck).
Drivetrain Options:
Rear-Wheel Drive (RWD) and optional All-Wheel Drive (AWD).
Seating Capacity:
Standard 5-passenger, optional 7-passenger with third-row seating.
Main Coverage Areas:
Engine, Transmission, Drivetrain, Suspension, Steering, Brakes, HVAC, Electrical System, Body, Interior, Emissions, Diagnostic Trouble Codes (DTCs)
Estimated Page Count:
2500+
Type:
Workshop Service Repair Manual
Powertrain:
Detailed coverage of 4.0L OHV V6 and 4.6L SOHC V8 engines, including disassembly, inspection, assembly, timing, and overhaul procedures. Coverage of 5R55E automatic transmission, including diagnosis, repair, and overhaul.
Chassis:
Comprehensive coverage of front and rear suspension (including independent rear suspension on some models), steering systems (rack and pinion, power steering), brake systems (ABS, front disc, rear disc/drum), wheel bearing service, and driveline components (transfer case, axles, driveshafts).
Electrical:
Extensive wiring diagrams, component locations, diagnostic procedures for lighting, power accessories, charging system, starting system, ignition system, instrument cluster, and onboard diagnostics (OBD-II).
Body Interior:
Procedures for body panel removal and installation, door mechanisms, interior trim, seats, glass replacement, HVAC system service (including refrigerant handling), and body sealant information.
Maintenance:
Oil changes, filter replacements, fluid checks and changes (coolant, brake fluid, power steering fluid, transmission fluid), spark plug replacement, air filter replacement, belt and hose inspection and replacement.
Diagnostics:
Step-by-step diagnostic flowcharts for common drivability issues, electrical faults, HVAC problems, and brake system malfunctions. OBD-II code interpretation and troubleshooting.
Repair Overhaul:
Detailed instructions for engine repair (head gaskets, piston rings, valve jobs), transmission overhaul, brake caliper and master cylinder replacement, suspension component replacement (ball joints, tie rod ends, shocks), and steering rack replacement.
Specifications Tolerances:
Precise torque specifications for all fasteners, critical component clearances, alignment specifications, and diagnostic specifications for various systems.
Depth:
Comprehensive, covering from basic maintenance and fluid changes to complete engine and transmission rebuilds, advanced electrical diagnostics, and body repair.
Format:
PDF (Portable Document Format)
Searchability:
Fully searchable text for quick information retrieval.
Printability:
Printable pages for on-site workshop use.
Image Resolution:
High-resolution images, diagrams, and schematics for clarity.
Binding Type:
N/A (Digital Format)
Paper Type:
N/A (Digital Format)
Completeness:
Complete factory service manual covering all aspects of the vehicle's operation, maintenance, and repair for the specified model year.
Transmission Type V6:
5-speed automatic (5R55E)
Transmission Type V8:
5-speed automatic (5R55W - Wide Ratio)
Manual Transmission:
Not available for 2003 model year.
Overdrive:
All transmissions feature overdrive.
Transfer Case:
Optional Command-Trac (part-time 4WD) or optional Control Trac (full-time AWD) on AWD models.
Transmission Fluid Type:
Mercon V ATF
Automatic Transmission Fluid Capacity:
Approx. 12.6 quarts (11.9 L) (fill)
NHTSA Rollover Resistance:
4/5 stars (for 2003 model year)
ABS:
Standard Anti-lock Braking System (ABS) on all wheels.
Traction Control:
Optional Traction Assist (on AWD models).
Airbags:
Standard front airbags. Optional side-impact airbags.
Seatbelts:
3-point safety belts with pretensioners for front occupants.
Audio System:
Available AM/FM stereo with CD player, optional premium audio system with subwoofer, available in-dash 6-disc CD changer.
Navigation:
Not available as a factory option for the 2003 model year.
Cruise Control:
Standard cruise control system.
OBD Ii:
On-Board Diagnostics II (OBD-II) system for emissions and vehicle monitoring.
Oil Change Interval:
Every 5,000 miles (8,000 km) or 6 months, whichever comes first.
Transmission Fluid Change Interval:
Every 30,000 miles (48,000 km) or 24 months, under normal driving conditions.
Coolant Change Interval:
Every 100,000 miles (160,000 km) or 5 years, whichever comes first (with initial fill of Ford Premium All Season Coolant).
Engine Oil Specification:
SAE 5W-30 (API SG, SH, SJ, or SL)
Engine Oil Capacity:
5.7 quarts (5.4 L) for 4.0L V6; 6.0 quarts (5.7 L) for 4.6L V8 (with filter change).
Coolant Type:
Ford Premium All Season Engine Coolant (VC-7B or equivalent).
Common Issues Engine:
Spark plug blowout (especially on 4.0L OHV), intake manifold gasket leaks, rear main crankshaft seal leaks, timing chain wear (on 4.6L V8).
Common Issues Transmission:
Slipping or delayed engagement, particularly in the 5R55E transmission; potential issues with solenoid packs and torque converter clutches.
Common Issues Suspension:
Worn ball joints, tie rod ends, and sway bar links; premature wear of front control arm bushings.
Common Issues Electrical:
Window regulator failures, power lock actuator issues, HVAC blower motor resistor failure, instrument cluster failure (dim or flickering gauges).
Ford SUV Legacy:
Ford has a long history of producing rugged, capable SUVs, dating back to the Bronco.
Second Generation:
The 2003 model year represents the second generation of the Ford Explorer, introduced for the 2002 model year. Key changes from the first generation included a new chassis, revised styling, and updated powertrains.
Assembly Locations:
Louisville, Kentucky, USA; St. Louis, Missouri, USA.
Motor Trend SUV Of The Year:
The Ford Explorer was NOT awarded MotorTrend SUV of the Year for 2003.
Consumer Reports Reliability:
Reliability ratings varied significantly by model year and specific components. Consumer Reports often noted average to below-average reliability for this generation of Explorer.
