2002 Ford Explorer technical service bulletins
258 technical service bulletins and manufacturer communications cover the 2002 Ford Explorer.
Bulletins tell dealers how to fix known problems. A warranty extension means the manufacturer pays for that repair for longer.
- Corrosion concerns appearing as bubbled and/or peeling paint with or without accompanying white dust
- Ford: some vehicles may exhibit oil separation from the internal lube found in the unitized cartridge seal
- Some 1997-2008 vehicles equipped with a 4.6L 2V, 5.4L 2V, or 6.8L 2V engine--spark plug thread repair...
- Low oil pressure indication/warning, a/c compressor inoperative and/or no crank condition on 4.6L equipped...
- Limited slip axle chatter, shudder, binding sensation, or vibration during low speed turning maneuvers
- Malfunction indicator lamp on with PCM diagnostic trouble code P0463 and/or ic diagnostic trouble code...
- Extended coverage program 05N04 - extended coverage for composite intake manifold
- Wds cop kit diagnostic tip - coil on plug (COP) ignition systems - engine misfire or rough running
- Fuel gauge slow to update after refueling
- Noise from rear wheel hub bearings
- Malfunction indicator lamp coming on with diagnostic trouble codes (DTCS) P0171, P0172, P0174 and/or P0175...
- Axle seal leaks
- Driveline 1ST order vibration/boom/drone
- Safety belt retraction speed
- Axle seal leaks
- No start/hard start n hot soak restart
- Rear axle noise repair
- Front seat(s) slight movement when accelerating and/or decelerating
- Axle whine howl
- Axle whine howl service with individual parts instead of an axle assembly
- Rear power window(s) inoperative
- Liftgate glass applique damaged/cracked
- Open fuse F2.20 (5 amp) and/or F2.1 (30 amp) which may result in loss of function of several systems...
- Rear axle noise repair
- Hard start/no start condition during cold ambeint temperatures after short hot soak PERIOD-4.0L engine
- Backglass difficult to close and an intermittent door ajar lamp
- Warning indicators-parking aid-reverse sensing system (RSS) and forward sensing system (fss)-false...
- Aluminum corrosion - service tip
- Rear window defroster grid/integral antenna diagnosis and repair - terminal tab repair
- General (PCM) power train control module programming procedures
- 5R55W transmission - no 3RD gear or slipping 2-3 shift - diagnostic trouble code P0733 and P0745 -...
- Gear selector lever - increased effort to shift from drive to park
- Broken rear cargo storage door lift handle
- Multiple vehicles - fuel level indication concerns - service tip
- Rear axle noise
- Runs rough or misfire - diagnostic trouble codes P0300-P0308 or P0316
- Chatter, shudder, a binding sensation, or vibration during low speed turns on vehicles equipped with the...
- Malfunction indicator lamp (MIL) illuminated - system lean diagnostic trouble codes (dtc's) - service tips
- Fuel gauge slow to update
- Updated rear halfshaft removal procedure
- No crank/no start condition when vehicle temperature is below freezing (32F/0C)
- Engine misfire or running - coil on plug (COP) ignition systems - wds cop kit diagnostic tips
- Rattle noise from primary chain drive area 2000-3000 RPM - 4.0L sohc engine
- Inoperative electric rear window defroster (heated backlite) grid lines, integral antenna concerns
- Multiple vehicles using fehp rear axle fluid
- Streamlined diagnostic procedure for vehicles with malfunction indicator lamp (MIL) on and diagnostic...
- Customer satisfaction program 02M01 supplement #4
- Rear axle date code inspection and service
- Rear axle chatter, shudder, binding sensation, or vibration during low speed turns
- Message center displays computing fuel instead of distance to empty
- Belt slippage
- Rear axle noise
- Poor fit between driver air bag and steering wheel
- Rear 3.55 axle noise
- Generator noise in cold ambient temperatures
- Certified rear axle available
- Intermittent air bag warning lamp on, memory seat, and/or adjustable pedal concerns
- Rear axle noise
- Streamlined diagnostic procedure for vehicles with malfunction indicator lamp on and diagnostic trouble...
- Distance to empty not displayed
- Engine-romeo built 4.6L 2V-TICK noise from engine-engines built before 9/17/2003
- Fuel signal to instrument cluster service tip
- Malfunction indicator lamp (MIL) on and hard start/long crank
- Instrument cluster locking up and accessories such as the radio, power windows, power locks and moonroof...
- Generator whistle/hoot noise in cold ambient temperatures
- Remote keyless entry (RKE) - service tips
- Driveline vibration on drone/boom at highway speeds
- Excessive engine cooling fan noise
- Multiple vehicles with 3.0L or 4.0L engines lacks power/runs rough/black smoke
- The amber anti-lock brake system (ABS) warning light on with diagnostic trouble codes C1235, C1236/C1237...
- Breakage of a liftgate window hinge
- Air conditioner hooting noise during light load acceleration at low speeds, from 1000-1300 RPM
- Some vehicles, equipped with the 4.6L 2V engine, with an engine build date prior to 8/29/03 may exhibit an...
- Malfunction indicator lamp (MIL) illuminated and diagnostic trouble codes (dtc's) P0171, P0172, P0174, or...
- Rough idle / engine shake
- Axle whine at cruise or during acceleration/ deceleration
- Rough/rolling idle or hesitation after first startup or a rough/rolling engine speed when returning to...
- Engine misfire or rough running condition with coil on plug (COP) ignition systems may be more accurately...
- Shudder during 4/5 upshift and/or 5/4 downshift on vehicles equipped with a 4.6L engine and 5R55W...
- New transmission cooler flusher - service tips
- No crank condition
- Anti-lock brake system (ABS) lamp illuminated and diagnostic trouble code (DTC) C1235, C1236, C1237 on...
- Rear axle vibration/drone above 60 mph
- Cluster locking up & various accessories such as the radio, power windows, power locks and moonroof being...
- Driveability conditions due to calibration vehicles equipped with the 4.0L sohc engine
- An intermittent or continuous open of fuse 1.15
- Liftgate glass applique damaged/cracked - service procedure
- A whine noise on tip-in at speeds of 45 to 65 mph
- Anti-lock brake system (ABS) indicator lamp on with codes C1235 and C1236 or C1237
- Stability assist (advancetrac/ivd) systems may not be recalibrated properly using wds
- Throttle cable routing and splash shield modification when replacing throttle cable during normal service
- Malfunction indicator lamp (MIL) illumination with diagnostic trouble codes P0442, P0455, P0456, P0457,...
- Excessive whine noise from the rear axle at cruise, or on acceleration and/or deceleration
- Rough / rolling idle and hesitation on acceleration after a first cold startup
- Fluid leaks from the rear halfshaft seal
- Malfunction indicator lamp on with or without rough running, lack of power, surge or poor fuel economy...
- Intermittent fuel gauge level dropping to empty when fuel level is not actually empty
- Fluid leak from the converter housing area
- Back glass hinge rattling/looseness, glass misalignment and/or glass hard-to-close
- 4X4 control module not interchangeable issues
- Battery light on or an alternator that is not charging
- Squeaking accelerator pedal while driving during cold, hot, dusty, and dry conditions
- An audible creak / click / pop (not a clunk) from the rear driveline
- Idle air control (IAC) valve diagnostic service tips
- Streamlined diagnostic procedure for vehicles with malfunction indicator lamp (MIL) on and diagnostic...
- Unintended door unlocks without key in ignition (QSF)
- Open F2.20 5 amp fuse which may result in loss of function of several systems including power seats,...
- Illuminated air bag warning lamp with diagnostic trouble code (DTC) B2292
- Rear driveline ping/creak/pop noise
- Blinking/half illuminated supplemental restraint system (SRS) and/or anti-lock brake (ABS) warning...
- Vibration condition
- Inoperative or inacurrate speedometer, 4X4 lamp illuminatd, and / or diagnostic trouble code P1635 or P1639
- Low speed or stationary noise/vibration at lower steering shaft area when turning
- Excessive sulfur smell from exhaust
- Incorrectly installed gear driven camshaft position (CMP) sensor synchronizer assemblies causing surge,...
- Sun visor rattle / detroit area dealers contact request
- High side pressure fluctuations on vehicles equipped with a fixed scroll a/c compressor
- Paint-premature clearcoat cracking-service tips
- Lamp-brake-invadvertent disabling of brake shift interlock
- Electrical-central security module (CSM) service tips
- Contact st louis assembly plant/st louis vicinity only
- Some 4DR vehicles may exhibit seating appearance or related issues
- Some vehicles may exhibit fuel diagnostic trouble codes P0171, P0172, P0174, P0175 or mass air flow...
- Some vehicles may exhibit unintended smart unlock activation without key in ignition
- Subject regarding intermittent engine quit during transmission engagements or parking maneuvers
- Subject regarding rear liftgate applique (trim panel) cracks
- Subject regarding theft light relocation
- Information on power steering leak condition
- Concerns with brake vibration, roughness and / or grinding noise, and excessive brake rotor corrosion
- Information used when replacing the drivers seat module
- Some vehicles equipped with the 4.0 sohc (single over-head cam) engine may exhibit a primary timing chain...
- Information on diagnosing engine rattle noise from primary chain drive area between 2000-3000 RPM on cold...
- Subject regarding 5R55W automatic transmission harsh upshifts during light to medium throttle concerns
- Some vehicles may exhibit excessive sulphur smeel from the exhaust under certain drive modes
- Some vehicles built since october 1, 2001 may exhibit a no start condition or an intermittent no start...
- Subject regarding cigar lighter revised installation procedures
- This bulletin involves proper procedures for preparation of service sheet metal parts coated with electro...
- Information regarding discharged battery charging service tips and guidelines
- Some vehicles may exhibit a need for headlamp aim adjust after driving on rough roads
- Exhibiting squeak / creak noises during front suspension movement
- Some vehicles equipped with the 4.0L sohc engine may exhibit a check engine light on with diagnostic...
- Some vehicles may exhibit an intake manifold crossover (first runner) coolant seepage condition
- Some vehicles may exhibit driveability conditions and / or check engine lamp illuminated with a diagnostic...
- Concerns with clunk noise from front axle area
- Some vehicles equipped with a V6 engine may exhibit a steering rattle noise which may be heard and felt in...
- Some engine assemblies with aluminum cylinder heads repaired in-vehile have been found to leak coolant...
- Information on vehicles exhibitng fuel line damage due to pinching/squeezing of the fuel return line
- Some vehicles may exhibit driveabilty conditions and/or check engine lamp illuminated with a diagnostic...
- Some vehicles may experienced a strong sulphur odor during certain drive modes
- Information regarding engine wind noise
- Information regarding malfunction indicator light illuminating with diagnostic trouble code P0300/P0301
- Some vehicles may exhibit the drivers door unlocking after it has been locked
- Some 4 door vehicles may exhibit a steering column rattle at speeds of 10-20 mph on uneven surfaces
- Some vehicles may exhibit a battery draw and/or a dead battery condition
- Some vehicles equipped with the 4.0L engine may exhibit a condition of unable to access with the...
- Engine oil system priming procedures, service tips for reports of premature engine failure
- Concerns with spark knock noise or chain rattle noise between 2000-3000 RPM, during cold engine operation only
- Some vehicles may exhibit a check engine lamp illuminated with diagnostic trouble code P0457 (gross leak...
- Some vehicles equipped with 4.6L engines may exhibit a high frequency whine noise (hair dryer type noise),...
- Some vehicles built prior to 11/11/2001 equipped with 5R55W transmission and 4.6L engine, may exhibit a...
- Some vehicles with the 4.0L engine may exhibit an engine flutter noise
- Some vehicles may exhibit an intermittent no crank condition and no communication from the powertrain...
- Some vehicles equipped with dual automatic temperature control (DATC) may exhibit inoperative redundant...
- Exhibiting rough idle, or rough idle upon initial start-up that clears up after a few minutes
- Some vehicles may exhibit a rattle noise when closing either the midgate or the rear liftgate
- Exhibit harsh 1-2, 3-4 upshifts at light to medium throttle on some vehicles equipped with a 4.6L engine...
- Some vehicles may exhibit vacuum or air leaks in the intake manifold and / or engine system causing...
- Some vehicles produced before 9/6/2001 equipped with the 5R55W transmission may exhibit a tick noise...
- Owner notification program supplement 7 revised information - regarding replacement of wilderness at tires
- Some vehicles may exhibit a flutter/turbulence noise condition (i.e., helicopter noise) at highway speeds...
- Some vehicles may exhibit an intermittent no crank condition and no communication from the powertrain...
- Some 4.0L sohc may exhibit an engine oil leak condition, coming from the oil pan or ladder frame area
- Some vehicles equipped with 3RD row seating may exhibit a condition with the seat release latch...
- Concerns with squeak and rattle noiss coming from the instrument panel and from the side door windows
- Brake shift interlock
- Information regarding misdiagnosis of main controls - incorrect pressures
- Information regarding the smokers package
- Some vehicles equpped with 4.0L engine may exhibit excessive sulphur smell fromthe exhaust system while...
- Some vehicles may exhibit drivability conditions or check engine lamp illuminated with diagnostic trouble...
- Some vehicles may exhibit drivability conditions or check engine lamp illuminated with diagnostic trouble...
- Some vehicles may exhibit uneven air discharge temperatures in a/c cooling modes
- Some owners may notice a knocking noise from the rear of the vehicle when the brakes are applied
- Some 4X4 vehicles with fewer than 10,000 miles may exhibit grease oozing from the front driveshaft cv joint
- Concerns with a/c performance temp
- Some vehicles with 5R5W may exhibit a no engagement condition
- Some vehicles may exhibit heater core leaks
- Information regarding transmission fluid usage charts
- Some vehicles may exhibit damage to the radio antenna after running through certain car washes
- Information regarding autolock enabled/disable procedure correction
- Information regarding new compass setting procedure, pdi must set all
- Some vehicles may exhibit intermittent difficulty turning the ignition key upon starting
- Some vehicles equipped with 4.6L engine and 5R55W transmission may exhibit various firm and/or soft shifts
- Some vehicles, built prior to 8/01/2001, may exhibit a whine or howl noise during cold starts at...
- Some vehicles produced before 6/3/2001 may exhibit the moonroof opening interior molding coming loose or...
- Fuel hesitation while making hard sweeping right hand turns (such as a highway on-ramp)
- Some vehicles may exhibit a transmission shifter stuck in the park gear position
- Vehicles with 4.0L engine may exhibit an intermittent hesitation on acceleration
- Information on the location of the heated seat switch
- Some vehicles equipped with a 5R55W automatic transmission may exhibit a tick noise while at idle in park...
- Vehicles equipped with the 5R55W automatic transmission built prior to 08/01/2001 may exhibit a neutral...
- Some vehicles with fewer than 10,000 miles may exhibit grease oozing from the front driveshaft cv joint
- Steering wheel shudder during low-speed turning maneuvers
- Some vehicles equipped with 5R55W transmission may exhibit no transmission engagement into forward and /...
- Some vehicles may develop yellow stains on the rear liftgate paint, usually noticed on white colored vehicles
- Some vehicles may exhibit a scrunch noise from the upper steering column when making near full lock turns
- Exhibiting drivability conditions or check engine lamp illuminated with diagnostic trouble code P0455...
- Some vehicles may exhibit a rough idle or rought idle after initial start-up that clears up after a few...
- Some vehicles may exhibit a rough idle or rough idle after initial start-up that clears up after a few minutes
- Some vehicles equipped with a 4.0L engine may exhibit an intermittent hesitation on acceleration
- Some vehicles may require excessive effort when trying to insert the key into the ignition lock cylinder
- Some vehicles equipped with the manual a/c system may exhibit a continuous clicking noise from the blend...
- Some vehicles equipped with a 4.0L engine and 5R55W automatic transmission built 11/13/2000 through...
- Fluid leak in the converter housing area on vehicles built 11/13/2000 through 4/27/2001
- Some vehicles equipped with a class II hitch may exhibit insufficient clearance int he receiver to attach...
- Some vehicles may exhibit a noisy and / or loose front wheel bearing
- Some vehicles equipped with 4.0L engine may exhibit excessive sulphur smell from the exhaust system while...
- Some vehicles equipped with 4.0L engine may exhibit a rough idle condition
- Stiff steering or poor steering wheel returnability
- Some vehicles equipped with 5R55W transmission may exhibit a whine noise that occurs in 3RD gear only
- A fluid leak at the transmission cooler line-to-transmission case connection
- Some vehicles built 11/13/2000 through 3/8/2001 equipped with a 5R55W transmission may exhibit a...
- Information regarding trailer wiring - brake controller connector location
- Some vehicles may exhibit driveability conditions or check engine lamp (MIL) illuminated with a diagnostic...
- Some vehicles may exhibit a transmission shifter stuck in the park gear position
- Some vehicles equipped with 7 passenger seating may exhibit the 2ND row 40 percent seat back staying in...
- Some vehicles may exhibit excessive efforts when trying to insert or remove the key from the ignition lock
- Some vehicles may exhibit a repetitive thump / knock noise from the rear which is proportional to wheel...
- Some vehicles may exhibit an error indicating that there is no communication or return diagnostic trouble...
- Some vehicles may exhibit an anti-lock brake system light on with diagnostic trouble code C1230 and / or...
- Some vehicles may exhibit a condition in which the rear door(s) will not unlock via manual or power operation
- Information on performing any passtive anti-theft (PATS) system functions including key replacements with...
- Some vehicles equipped with 5R55W transmission may exhibit various firm and / or soft shifts
- Some vehicles may exhibit a yellow four wheel anti-lock brake (4WABS) lamp illuminated and a diagnostic...
- Some vehicles may exhibit a steering wheel shudder during low speed turning maneuvers
- Some 4-DOOR vehicles built 11/13/2000 through 4/2/2001 equipped with the 5R55W transmission may exhibit a...
- Some vehicles built 11/13/2000 thorugh 3/8/2001 equipped with a 5R55W transmission may exhibit a...
- On some vehicles, including sport and sport trac, the front axle leaks fluid from the vent tube
- Vehicles equipped with passive anti-theft system (PATS) may not start or crank
- Special service instructions for the liftgate glass bracket inspection and torque procedure
- Information on front wheel hub assemblies
- Information on vehicles equipped with with 5R55W transmission having a (powertrain control module) PCM...
- Some vehicles equipped with the 4.0 sohc engine may exhibit a primary chain rattle noise (sometimes...
- Liftgate glass bracket inspection and torque procedure
- Subject regarding edsr bonus points
- Information on availability of neutral tow kit
- Information on the intake manifold valley stuffer bag
- Information on obtaining engineering assistance for anti-lock brake system
- Information regarding transmission oil level checking guidelines
- Some vehicles may exhibit a tinny rattle noise coming from the center steering column area while driving...
- Malfunction indicator lamp on with diagnostic trouble code P1633 and / or P1639 with no driveability...
- Some vehicles may exhibit a malfunction indicator lamp (MIL) on with EGR system related diagnostic trouble...
- Subject regarding contamination from prior transmission concerns or excess wear may be trapped in the...
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