2002 FORD EXPLORER manual transmission

²After you have traveled 80 km (50 miles), thoroughly check your
hitch, electrical connections and trailer wheel lug nuts.
²When stopped in traffic for long periods of time in hot weather, place
the gearshift in P (Park) (automatic transmissions) or N (Neutral)
(manual transmissions). This aids engine cooling and air conditioner
efficiency.
²Vehicles with trailers should not be parked on a grade. If you must
park on a grade, place wheel chocks under the trailer's wheels.
Launching or retrieving a boat
When backing down a ramp during boat launching or retrieval,
²Do not allow the static water level to rise above the bottom edge of
the rear bumper and
²Do not allow waves to break higher than 15 cm (6 inches) above the
bottom edge of the rear bumper.
Exceeding these limits may allow water to enter critical vehicle
components, adversely affecting driveability, emissions, reliability and
causing internal transmission damage.
Replace the rear axle lubricant anytime the axle has been submerged in
water. Rear axle lubricant quantities are not to be checked or changed
unless a leak is suspected or repair required.
Disconnect the wiring to the trailer before backing the trailer into the
water. Reconnect the wiring to the trailer after the trailer is removed
from the water.
Recreational towing (all wheels on the ground)
Follow these guidelines for your specific powertrain combination to tow
your vehicle with all four wheels on the ground (such as behind a
recreational vehicle).
These guidelines are designed to ensure that your transmission is not
damaged due to insufficient lubrication.
Driving
202

The fuses are coded as follows:
Fuse/Relay
LocationFuse Amp
RatingPassenger Compartment Fuse
Panel Description
1 30A Radio Sense, 4x4, ABS Control
Module
2 20A Folding Mirror, Moon Roof,
Heated Seats, Moon roof
3 20A Radio, Amplifier, Power Antenna
4 5A Digital Transmission Range Sensor
5 15A Flasher Relay (Turn, Hazards)
6 10A Right Horn
7 15A Heated Mirrors
8 30A Washer Pump Relays (Front and
Rear), Front Wiper Control
9 15A Rear Wiper Coil and Contact
10 10A Heated Backlight Relay Coil,
Heated Seat Module, Temp Blend
Actuator, A/C Clutch Contact
11 Ð Not Used
12 5A Foglamp Switch,4x4module
13 5A Over Drive Cancel Switch, GEM
Start, Flex Fuel Sender
14 5A PATS Module
15 5A 4 x 4, Memory Seat Disable
16 5A Power Mirror, Security Module
(turn), Manual Climate Control
17 15A Delayed Acc. Coil, Battery Saver,
Interior Lamps
18 10A Left Horn
19 Ð Not Used
20 5A Memory Module, GEM Module
21 5A Instrument Cluster, Compass,
Flasher Coil
22 Ð Not Used
23 15A Brake Pedal Position Switch
24 15A Cigar Lighter, OBD II
Roadside emergencies
210

3. Turn the wrench
counterclockwise until tire is
lowered to the ground making sure
the other end of the wrench does
not scuff kick plate, the tire can be
slid rearward and the cable is
slightly slack.
4. Lift tire on one side and remove
the retainer from the spare tire.
Tire change procedure
To prevent the vehicle from moving when you change a tire, be
sure the parking brake is set, then block (in both directions) the
wheel that is diagonally opposite (other side and end of the vehicle) to
the tire being changed.
If the vehicle slips off the jack, you or someone else could be
seriously injured.
Refer to the tire changing instruction sheet for detailed tire change
instructions.
1. Park on a level surface, activate
hazard flashers and set the parking
brake.
2. Place gearshift lever in P (Park)
or in the reverse gear (manual
transmission) and turn engine OFF.
Roadside emergencies
219

When one of the rear wheels is off the ground, the transmission
alone will not prevent the vehicle from moving or slipping off the
jack, even if the transmission is in P (Park) (automatic transmission)
or reverse (manual transmission).
3. Block the diagonally opposite
wheel.
4. Use the tip of the lug wrench to
remove any beauty cap by twisting
the tip under the cap. The carpeted
floor lid can be used as a kneeling
pad.
5. Loosen each wheel lug nut by half
a turn, but do not remove them
until the wheel is raised off the
ground.
6. Assemble the jack handle
extension on the lug nut wrench by
sliding the square end of the jack
handle through the plastic grommet
on the lug nut wrench and into the
square hole on the other side.
Roadside emergencies
220

Working with the engine off
²Automatic transmission:
1. Set the parking brake and ensure the gearshift is securely latched in P
(Park).
2. Turn off the engine and remove the key.
3. Block the wheels to prevent the vehicle from moving unexpectedly.
²Manual transmission:
1. Set the parking brake.
2. Depress the clutch and place the gearshift in 1 (First).
3. Turn off the engine and remove the key.
4. Block the wheels to prevent the vehicle from moving unexpectedly.
Working with the engine on
²Automatic transmission:
1. Set the parking brake and ensure the gearshift is securely latched in P
(Park).
2. Block the wheels to prevent the vehicle from moving unexpectedly.
Do not start your engine with the air cleaner removed and do
not remove it while the engine is running.
²Manual transmission:
1. Set the parking brake, depress the clutch and place the gearshift in
neutral.
2. Block the wheels to prevent the vehicle from moving unexpectedly.
Do not start your engine with the air cleaner removed and do
not remove it while the engine is running.
The cooling fan is automatic and may come on at any time.
Always disconnect the negative terminal of the battery before
working near the fan.
Maintenance and care
230

BRAKE FLUIDAND CLUTCH FLUID
Checking and adding brake fluid/clutch fluid
When equipped with a manual
transmission, your vehicle uses the
same reservoir for brake and clutch
fluid.
Brake/clutch fluid should be
checked and refilled as needed.
Refer to the scheduled maintenance
guide for the service interval
schedules.
1. Clean the reservoir cap before
removal to prevent dirt or water from entering the reservoir.
2. Visually inspect the fluid level.
3. If necessary, add brake/clutch
fluid from a clean un-opened
container until the level reaches
MAX. Do not fill above this line.
4. Use only a DOT 3 brake/clutch
fluid certified to meet Ford specifications. Refer toLubricant
specificationsin theCapacities and specificationschapter.
Brake fluid/clutch fluid is toxic. If brake/clutch fluid contacts the
eyes, flush eyes with running water for 15 minutes. Seek medical
attention if irritation persists. If taken internally, drink water and
induce vomiting. Seek medical attention immediately.
If you use a brake fluid that is not DOT 3, you will cause
permanent damage to your brakes.
Do not let the reservoir for the master cylinder run dry. This
may cause the brakes to fail.
MAX
Maintenance and care
240

Refer to your scheduled maintenance guide for scheduled intervals for
fluid checks and changes. Your transmission does not consume fluid.
However, the fluid level should be checked if the transmission is not
working properly, i.e., if the transmission slips or shifts slowly or if you
notice some sign of fluid leakage.
Transmission fluid should be checked and, if required, fluid
should be added by a qualified technician.
Checking and adding manual transmission fluid (if equipped)
1. Make sure the vehicle is on a
level surface or level hoist.
2. Clean the filler plug or dirt and
debris.
3. Remove the filler plug and
inspect the fluid level.
4. Fluid level should be at bottom of
the opening.
5. Add enough fluid through the
filler opening so that the fluid level
is at the bottom of the opening.
6. Install and tighten the fill plug
securely.
Maintenance and care
249

MOTORCRAFT PART NUMBERS
Component 4.0L SOHC V6 engine 4.6L V8 engine
Air filter element FA-1695 FA-1695
Fuel filter FG-986B FG-986B
Battery BXT-65-650 BXT-65-650
Oil filter FL-820S FL-820S
PCV valve EV-243 F6ZE-6C324-CA
Spark plugs* AGSF-22PP ** AWSF-32P
* Refer to Vehicle Emissions Control Information (VECI) decal for spark
plug gap information.
** If a spark plug is removed for inspection, it must be reinstalled in the
same cylinder. If a spark plug needs to be replaced, use only spark plugs
with the service number suffix letter as shown on the engine decal.
REFILL CAPACITIES
Fluid Ford Part Name Application Capacity
Brake fluid and
Clutch fluid (if
equipped)High Performance
DOT 3 Motor
Vehicle Brake
FluidAll Fill to line on
reservoir
Engine oil
(including filter
change)Motorcraft SAE
5W-30 Super
Premium Motor Oil4.0L 4.7L
(5.0 quarts)
Motorcraft SAE
5W-20 Super
Premium Motor Oil4.6L 5.7L
(6.0 quarts)
Fuel tank N/A All 85.2L
(22.5 gallons)
Power steering
fluidMotorcraft
MERCONtAT FAll Fill between
the MIN and
MAX lines on
reservoir
Transmission
fluid
1Motorcraft
MERCONtAT F5-speed manual 2.4L
(5.1 pints)2
Motorcraft
MERCONtVATFAutomatic
transmissions
only.12.0L
(12.7 quarts)3
Capacities and specifications
283