2003 Ford Explorer Service & Repair Manual

COMPONENT LOCATION Vehicle Component Location Index Printable View (273 KB) SECTION 100-00: General Information 2003 Explorer/Mountaineer Workshop Manual 19.03. 2012 file:///C:/Ford/2000-2004/tsocache/SHEF_3900/S3N~us~en~...

19.03. 2012 file:///C:/Ford/2000-2004/tsocache/SHEF_3900/S3N~us~en~...

DESCRIPTION AND OPERATION About This Manual Printable View (12 KB) Introduction In response to feedback from technicians, Ford Motor Company has designed this manual in a more user-friendly format, which will allow quicker access to needed information to make repairs. A comparison of numerous manufacturers' manuals was done, and a list of recommendations was given. A number of test sections were developed and presented to technician focus groups to get feedback on the recommendations. The recommendations that are being incorporated into this manual include: The addition of a "Component Location" view at the beginning of each section to assist in locating components on the vehicle. The "Specifications" tables moved to the beginning of the section to make them easier to locate. The addition of more theory of operation within Description and Operation. The addition of "Connector Circuit Reference" tables to Diagnosis and Testing as a reference point for any connectors tested within pinpoint tests. Reformatting pinpoint tests to make them easier to use, including "Normal Operation" and "Possible Causes" explanations before the first step. Listing any Special Service Tools, General Equipment and Materials at the beginning of each procedure to better prepare the technician. Using exploded views to better aid in Removal and Installation procedures. For further information, refer to How To Use This Manual in this section. The addition of the "Component Step Table" when there are multiple serviceable components included in a procedure. Using two-column format to reduce the physical size of the manual. To make it easier to locate information, we have consolidated several small sections into a single section. Those sections are: 204-00 — Suspension System (now includes front suspension, rear suspension and wheels and tires). 205-00 — Driveline System (now includes driveshaft, axle and halfshafts). 206-00 — Brake System (now includes front brakes, rear brakes, caliper, brake booster and parking brake). 211-00 — Steering System (now includes steering gear, pump, linkage, column and column switches). 303-01 Engine (now includes accessory drive and emission controls). 303-04 Intake Air, Fuel Charging and Engine Electronics (now includes intake air, fuel charging, starting system and electronic engine controls). 307-01 — Automatic Transmission/Transaxle (now includes cooling and external controls). 310-00 — Fuel System (now includes tanks, lines, pump, filter, pedal and linkage and evaporative emissions). 412-00 — Climate Control System (now includes air distribution, heating, air conditioning, auxiliary climate control and control components). SECTION 100-00: General Information 2003 Explorer/Mountaineer Workshop Manual 19.03. 2012 file:///C:/Ford/2000-2004/tsocache/SHEF_3900/S3N~us~en~...

413-00 — Information, Gauge and Warning Devices (now includes illumination, cluster, horn, clock, message center, warning devices, and parking aid). 414-00 — Battery and Charging System (now includes battery and generator). 415-00 — Entertainment System (now includes all video and audio components). 418-00 — Module Communications Network (now includes all module diagnostics and configuration). 419-02 — Electronic Features (now includes remote convenience, telematics, cell phone, navigation and compass). 501-00 — Body System — Exterior (now includes body panels, exterior trim, mirrors, glass, bumpers and wiper system). 501-01 — Body System — Interior (now includes interior trim, instrument panel and console and roof opening panel). Replacement Parts Ford and Motorcraft products are replacement parts made to the same exacting standards as the original factory-fitted components. For this reason, Ford Motor Company recommends that you use only genuine Ford or Motorcraft replacement parts. 19.03. 2012 file:///C:/Ford/2000-2004/tsocache/SHEF_3900/S3N~us~en~...

DESCRIPTION AND OPERATION Important Safety Instructions Printable View (10 KB) Appropriate service methods and correct repair procedures are essential for the safe, reliable operation of all motor vehicles as well as the personal safety of the individual carrying out the work. This manual cannot possibly anticipate all such variations and provide advice or cautions as to each. Anyone who departs from the instructions provided in this manual must first establish that they compromise neither their personal safety nor the vehicle integrity by their choice of methods, tools or parts. Warnings, Cautions and Notes WARNING: Warnings are used to indicate that failure to follow a procedure correctly can result in personal injury. CAUTION: Cautions are used to indicate that failure to follow a procedure correctly can result in damage to the vehicle or equipment being used. NOTE: Notes are used to provide additional essential information required to carry out a complete and satisfactory repair. As you read through this manual, you will come across WARNINGS, CAUTIONS and NOTES. A warning, caution or note is placed at the beginning of a series of steps if it applies to multiple steps. If the warning, caution or note only applies to one step, it is placed at the beginning of the specific step (after the step number). SECTION 100-00: General Information 2003 Explorer/Mountaineer Workshop Manual 19.03. 2012 file:///C:/Ford/2000-2004/tsocache/SHEF_3900/S3N~us~en~...

DESCRIPTION AND OPERATION How To Use This Manual Printable View (278 KB) Manual Structure This manual is structured into groups and sections, with specific system sections collected together under their relevant group. A group covers a specific portion of the vehicle. The manual is divided into five groups: General Information, Chassis, Powertrain, Electrical and Body and Paint. The number of the group is the first number of a section. The Table of Contents at the beginning of the manual lists all sections available. Each section has a table of contents listing all procedures for that section. Component Location Index Each section begins with an illustrated component location index, which is a vehicle silhouette with a callout pointing to a component. Each callout lists the CD version hyperlink to the section that includes information about that component. Component Location Example SECTION 100-00: General Information 2003 Explorer/Mountaineer Workshop Manual 19.03. 2012 file:///C:/Ford/2000-2004/tsocache/SHEF_3900/S3N~us~en~...

Repair Procedure The repair procedures in this manual include the following: 1. Special service tools, equipment and materials tables, which list all of the special tools and materials needed for the repair. 2. Introductory steps, which list any vehicle setup or steps required to clear the way for the repair. 3. The component step table, which lists the specific steps to remove and install selected parts. 4. The overview illustration, which identifies the parts and displays their arrangement within the vehicle. This illustration also shows tightening torque, special tools, lubricants and sealants, and parts that must not be reused. Additionally, this illustration refers to important step details. Refer to these details when servicing the related part. 5. The overview illustration parts list table, which identifies the base service part number and the names of all parts in the procedure. 6. The steps after installation, which identify the need to fill and bleed, top-off fluids, or other steps 19.03. 2012 file:///C:/Ford/2000-2004/tsocache/SHEF_3900/S3N~us~en~...

required to complete the repair. 7. Important step details, which provide additional written instructions for those removal and installation steps that must be methodically carried out. Icons Item Description 1 Special service tools, equipment and materials table 2 Introductory steps 3 Component step table 4 Overview illustration 5 Overview illustration parts list table 6 Steps after installation 7 Important step details 19.03. 2012 file:///C:/Ford/2000-2004/tsocache/SHEF_3900/S3N~us~en~...

There are ten symbols indicating oil, grease, sealant, visual inspection, use of special service tools and removal and installation details. These symbols show the points of inspecting, applying or using such materials during service. Symbol Meaning Apply petroleum jelly Apply oil Apply fluid Apply grease Apply sealant Inspect Install new Use special tool 19.03. 2012 file:///C:/Ford/2000-2004/tsocache/SHEF_3900/S3N~us~en~...

2003 Ford Explorer Service & Repair Manual

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