FordExplorer Sport2002Overview/ford/explorer-sport/2002/base/

2002 Ford Explorer Sport

Factory specifications, fluid capacities, torque values, EPA fuel economy and the federal safety record for the 2002 Explorer Sport.

Body SUVTransmission Automatic 5-spd

The 2002 Ford Explorer Sport is an SUV fitted with an automatic five-speed transmission and EPA fuel-economy ratings of 15/20/17 mpg, with routine oil service calling for 5.0 quarts of 5W-30 API oil. Its reliability record, however, is the more commanding story for researchers: the model accumulated 14 recalls and 3,620 owner complaints, with Power Train issues standing out as the dominant trouble area. That volume of reported problems makes this model year a critical case study for anyone evaluating long-term durability or pre-purchase risk in the Explorer Sport line.

Model year200320022001

Quick specs

Fluid capacities, tune-up values and fuel economy at a glance.

Engine oil capacity5.0 qtOEM · verified
Engine oil type5W-30 APIOEM · verified
Lug nut torque100 ft-lbsOEM · verified
EPA fuel economy15/20/17 mpgEPA · verified

Fitment & sizes

Replacement part sizes and factory part numbers — battery, bulbs, filters and belts.

From the factory this vehicle uses a BCI 65 · 650 CCA battery. Each part links to every other vehicle that shares it, so a part you already stock may fit more of your fleet than you'd expect.

Battery groupBCI 65 · 650 CCAOEM · verified
Tire sizeP235-70R16OEM · verified
Wheel / rim7.0 inOEM · verified

Full specifications

Engine, drivetrain, dimensions and economy.

Engine & drivetrain NHTSA vPIC

TransmissionAutomatic 5-spd

Dimensions & weight NHTSA vPIC

Overall length180.3 in
Overall width70.1 in
Overall height67.7 in
Wheelbase101.6 in
Curb weight3962 lb
Track (front / rear)58.7 / 58.7 in
Weight distribution (front / rear)54/46

Ratings & economy EPA / vPIC

EPA city / highway / combined15 / 20 / 17 mpg
DrivetrainRear-Wheel Drive
Recommended fuelRegular Gasoline

Service quick specs OEM factory data

Capacities, torques and tune-up values from the factory service manual.

This engine holds 5.0 qt of 5W-30 API engine oil, SYNTHETIC · 75W-140 · GL-5 in the differential, DOT 3 brake fluid. Torque lug nuts to 100 ft-lbs, the oil drain plug to 17.0-22.0 ft-lbs. The firing order is 1-3-7-2-6-5-4-8. Note the cylinder-head bolts finish on a torque angle (torque-to-yield) — they stretch permanently and should be replaced, not reused, during any head service.

Lubricants & capacities

Brake FluidDOT 3
Differential Gear OilSYNTHETIC · 75W-140 · GL-5
Differential Gear Oil Capacity3.6 Pints Rear
Engine Oil5W-30 · API
Engine Oil Capacity5.0 qt
Engine Oil5W-20 · API
Engine Oil Capacity6.0 qt
Power Steering FluidATF

Engine torques

Camshaft Bearing/Carrier Cap Bolts or Studs11-12 ft-lbs
Camshaft Bearing/Carrier Cap Bolts or Studs7.4 ft-lbs
Engine Flywheel Bolts59 ft-lbs
Exhaust Manifold to Cylinder Head Bolts18 ft-lbs
Intake Manifold to Engine Bolts7.4 ft-lbs
Exhaust Manifold to Cylinder Head Bolts16 ft-lbs
Main Bearings67-74 ft-lbs
Engine Oil Pan Drain Plug17.0-22.0 ft-lbs

Chassis torques

Lug Nuts100 ft-lbs
Transfer Case Fill Plug4WD: 18.0, With AWD: 13.0 ft-lbs
Transfer Case Drain Plug4WD: 18.0, With AWD: 13.0 ft-lbs
Rear Wheel Hub203 ft-lbs
Front Wheel Hub184-250 ft-lbs
Rear Wheel Hub203 ft-lbs

Ignition

Cylinder Firing Order1-4-2-5-3-6
Cylinder Firing Order1-3-7-2-6-5-4-8
Curb Idle Speed (No Load)MT: 850, AT: 710 rpm
Curb Idle Speed Variance (No Load)MT: 50, AT: 40 rpm
Curb Idle Speed (No Load)890 rpm
Curb Idle Speed (No Load)755 rpm
Curb Idle Speed Variance (No Load)75 rpm
Spark Plug ManufacturerMotorcraft

Battery & A/C

RefrigerantR134a
Refrigerant CapacityLess auxiliary A/C, 1.88. With auxiliary A/C, 3.50. lbs
Oil GroupPAG
Oil Type68
Oil CapacityLess auxiliary A/C, 9.00. With auxiliary A/C, 13.00. oz
Standard BCI Group Number65
Standard BCI Cranking Performance650 cca
Standard BCI Group Number65

Service checks

Pressure Test13-18 psi
Radiator Cap Pressure Relief13-18 psi
Thermostat Opening Temperature183-190 °F
Pressure Test13-18 psi
Radiator Cap Pressure Relief13-18 psi
Thermostat Opening Temperature183-190 °F
Key ON Engine OFF (KOEO)30-45
Injector Primary Resistance11.4-12.6 na Flex Fuel ohms

Brakes

Brake ApplicationWITH REAR DISC / WITH STANDARD
Torque Caliper to Bracket20 ft-lbs / 21-26 ft-lbs
Torque to Knuckle80 ft-lbs / 73-97 ft-lbs
Minimum Pad ThicknessFront: 0.060; Rear: 0.030 in
Brake ApplicationWITH REAR DISC / WITH STANDARD
Rotor Max Parallel Variation0.0002 in
Rotor Runout Limit0.005 in
Rotor Discard at or Under0.433 in / 0.965 in

Multi-step torque procedures OEM · verified

Connecting Rod (Large End) Bearings — tightening sequence 1 stages
115 ft. lbs., Step 2: 9015 ft. lbs
Connecting Rod (Large End) Bearings — tightening sequence 1 stages
118 ft. lbs., Step 2: 33 degrees, Step 3: 9018 ft. lbs
Crankshaft Pulley and/or Damper Bolts — tightening sequence 1 stages
166 ft. lbs., Step 2: loosen one turn, step 3: 37 ft. lbs., step 4: 9066 ft. lbs
Cylinder Head — tightening sequence 3 stages
124 ft. lbs.24 ft. lbs
2turn 80 degrees80 degrees
3turn 80
Cylinder Head — tightening sequence 3 stages
126 ft. lbs.26 ft. lbs
290 degrees90 degrees
390 degrees90 degrees
Engine Flywheel Bolts — tightening sequence 1 stages
110 ft. lbs., Step 2: 5210 ft. lbs
Intake Manifold to Engine Bolts — tightening sequence 1 stages
13.7 ft. lbs., step 2: 183.7 ft. lbs
Main Bearings — tightening sequence 1 stages
17.4 ft. lbs., Step 2: 18 ft. lbs., Step 3: 30 ft. lbs., Step 4: 90 degrees7.4 ft. lbs

Factory maintenance schedule OEM · verified

Normal service, condensed from the factory interval matrix.

Under the factory schedule, replace the engine oil and filter every 5,000 mi; spark plugs every 100,000 mi; coolant every 50,000 mi. The big-interval services (every 50,000 mi for coolant, and the transmission fluid) are the ones owners most often skip — on a lower-mileage example, assume the original fluids are still in it and check them first.

Every 5,000 miEngine Oil (drain & refill) · Engine Oil Filter (replace) · Tire & Wheel Assembly (rotate)
Every 15,000 miBrake Drum Assembly (inspect) · Brake Line (inspect) · Brake Linings (inspect) · Brake Rotor (inspect) · Brake System (inspect) · CV Joint Boot (inspect)
Every 30,000 miAccessory Drive Belt (inspect) · Engine Air Filter Element (replace) · Exhaust System (Complete) (inspect) · Exhaust System Heat Shield (inspect) · Fuel Filter (replace) · Temperature Controlled Seat Air Filter (replace)
Every 50,000 miEngine Coolant System (drain, flush & refill)
Every 60,000 miTransmission Assembly (drain & refill) · Wheel Bearing (repack)
At 100,000 miEngine Coolant System (drain, flush & refill)
Every 100,000 miSpark Plugs (replace)
At 105,000 miDrive Belt (replace)
At 120,000 miPCV Valve (replace)

Reliability & federal safety record

Owner-reported issues, recalls, investigations and service bulletins on record with NHTSA — an unfiltered look at what owners actually experience.

In 2002 the Explorer Sport logged 3,620 complaints, 14 recalls, 9 investigations and 370 TSBs. By 2003 those figures fell to 1,313 complaints, 7 recalls, 3 investigations and 176 TSBs, showing a clear downward trend across the two‑year span. The 2002 model’s top complaint categories were Power Train (1,295), Structure (434), Suspension (304) and Vehicle Speed Control (145), with 163 crash‑related and 71 fire‑related complaints. Because 2002 sits at the higher end of the observed complaint and recall arc, it suggests a relatively higher incidence of issues compared with the following year. Consequently, if choosing between the two model years based solely on federal‑record metrics, the 2003 Explorer Sport presents a more favorable profile than the 2002.

14
Open recalls
NHTSA campaigns
370
Service bulletins
Manufacturer communications
9
ODI investigations
Office of Defects Investigation
3,620
Owner complaints
163 involved a crash · 71 a fire
NHTSA crash-test rating federal NCAP · out of 5 stars
Rollover★★★★★

Owner complaints filed with NHTSA, by component

All 3,620 complaints on record, top 8 components.

Power Train1295
Structure434
Suspension304
Vehicle Speed Control145
Engine & Engine Cooling137
Air Bags122
Electrical System88
Visibility85

Source: NHTSA Office of Defects Investigation complaint database.

Recalls NHTSA · verified

Showing 2 of 5 campaigns on record for this vehicle.

06V114000Seats:Front Assembly:ReclinerReported 10/04/2006

ON CERTAIN SPORT UTILITY VEHICLES EQUIPPED WITH HIGH BACK SEATS, THE UPPER BOLT ON THE DRIVER'S SIDE HIGH BACK SEAT THAT ATTACHES THE SEAT RECLINER MECHANISM TO THE SEAT BACK FRAME, COULD FRACTURE. IF THE BOLT… Remedy: DEALERS WILL REPLACE THE DRIVER SEAT UPPER BOLT WITH A METAL SPACER AND BOLT. IN ADDITION, SEATS WITH TUBULAR BACK FRAMES WILL HAVE THE FULLY THREADED LOWER RECLINER BOLT REPLACED…

06E026000Exterior LightingReported 23/03/2006

CERTAIN PRO-A MOTORS CORNER LAMPS, TURN SIGNALS, AND HEADLIGHTS SOLD AS REPLACEMENT LAMPS FOR USE ON CERTAIN PASSENGER VEHICLES LISTED ABOVE. SOME COMBINATION LAMPS THAT ARE NOT EQUIPPED WITH AMBER SIDE REFLECTORS FAIL… Remedy: PRO-A MOTORS WILL NOTIFY OWNERS AND OFFER TO REPURCHASE THE LAMPS. THE RECALL BEGAN ON APRIL 3, 2006. OWNERS MAY CONTACT PRO-A MOTORS AT 323-838-2988.

Technical service bulletins NHTSA · verified

Showing 5 of 370 bulletins on record with NHTSA.

BulletinDateComponentSummary
TSB 19-20262019-02-07StructureSome 2000 and newer Ford, Lincoln and Mercury vehicles equipped with aluminum body panels…
TSB 19-20262019-02-07StructureSome 2000 and newer Ford, Lincoln and Mercury vehicles equipped with aluminum body panels…
TSB-08-19-32009-05-01Power TrainFORD: SOME VEHICLES MAY EXHIBIT OIL SEPARATION FROM THE INTERNAL LUBE FOUND IN THE…
072122007-10-01Engine And Engine CoolingSOME 1997-2008 VEHICLES EQUIPPED WITH A 4.6L 2V, 5.4L 2V, OR 6.8L 2V ENGINE--SPARK PLUG…
062162006-01-01Power TrainLIMITED SLIP AXLE CHATTER, SHUDDER, BINDING SENSATION, OR VIBRATION DURING LOW SPEED…

Common OBD-II trouble codes

The most common OBD-II codes for this vehicle's emissions system. These are standardized SAE J2012 definitions, not vehicle-specific fault reports.

P0420
Catalyst system efficiency below threshold — Bank 1
P0300
Random / multiple cylinder misfire detected
P0171
System too lean — Bank 1
P0455
Evaporative emission system leak detected — large leak
P0128
Coolant thermostat below regulating temperature
P0442
Evaporative emission system leak detected — small leak

VIN tools

Decode factory build data for a specific vehicle by VIN.

VIN
Decode a VIN to confirm the transmission and build data for a specific Explorer Sport. OEM
Build data
Plant, GVWR class, engine and body data for any 17-character VIN.
Recalls
Check open recall campaigns against a specific vehicle by VIN.

Vehicles with shared specs

Find every vehicle that shares this one's battery, bulbs, oil capacity, platform or parts.

Reference guides

Cross-vehicle references for the kinds of data on this page.

Frequently asked

How much oil does the 2002 Explorer Sport take?

5.0 qt of 5W-30 API MEETING FORD SPECIFICATION WSS-M2C946-A, per the factory manual.

Does the 2002 Explorer Sport have open recalls?

NHTSA lists 14 recall campaign(s) for this model year. Check your specific vehicle by VIN.

What gas mileage does the Explorer Sport get?

EPA figures are 15 city / 20 highway / 17 combined mpg.