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2002 Ford Explorer

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

Body SUV

The 2002 Ford Explorer is an SUV that uses 5.0 quarts of 5W-30 API engine oil. Within the Explorer's 1990–2025 complaint record, the 2002 model stands out as the most reported year, logging 3,620 owner complaints and 14 recalls, with the power train generating the most reports. That volume makes it the statistical peak of owner-reported problems across three decades of the nameplate, meaning researchers should treat power-train documentation and recall records as primary reference points for this model year.

Model year2026 2025 2024 2023 2021 2020 2019 2018 2002

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

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.

Dimensions & weight NHTSA vPIC

Overall length	180.3 in
Overall width	70.1 in
Overall height	67.7 in
Wheelbase	101.6 in
Curb weight	3962 lb
Track (front / rear)	58.7 / 58.7 in
Weight distribution (front / rear)	54/46

Performance & power Independent road tests

0–60 mph, quarter-mile, horsepower and torque from independent road tests.

Independent road tests for the Explorer of this era, listed by trim and engine — this page spans more than one engine, so no single horsepower figure is shown.

8.7–10.7 sec0–60 mph (tested)quickest 8.70 sec — 2002 Limited

Year	Trim / engine	0–60	¼ mile	HP	Drivetrain
2002	Limited 4.0L V6	8.70 sec	16.50 sec	210 hp	4x4
2002	Limited 4.0L V6	8.80 sec	16.50 sec	210 hp	4x4
2002	XLT 4.0L V6	9.00 sec	16.90 sec	210 hp	4x4
2002	Eddie Bauer 4.0L V6	10.70 sec	17.90 sec	210 hp	4x4
2005	XLT 4.6L V8	8.20 sec	16.40 sec	239 hp	4x4

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 Fluid	DOT 3
Differential Gear Oil	SYNTHETIC · 75W-140 · GL-5
Differential Gear Oil Capacity	3.6 Pints Rear
Engine Oil	5W-30 · API
Engine Oil Capacity	5.0 qt
Engine Oil	5W-20 · API
Engine Oil Capacity	6.0 qt
Power Steering Fluid	ATF

Engine torques

Camshaft Bearing/Carrier Cap Bolts or Studs	11-12 ft-lbs
Camshaft Bearing/Carrier Cap Bolts or Studs	7.4 ft-lbs
Engine Flywheel Bolts	59 ft-lbs
Exhaust Manifold to Cylinder Head Bolts	18 ft-lbs
Intake Manifold to Engine Bolts	7.4 ft-lbs
Exhaust Manifold to Cylinder Head Bolts	16 ft-lbs
Main Bearings	67-74 ft-lbs
Engine Oil Pan Drain Plug	17.0-22.0 ft-lbs

Chassis torques

Lug Nuts	100 ft-lbs
Transfer Case Fill Plug	4WD: 18.0, With AWD: 13.0 ft-lbs
Transfer Case Drain Plug	4WD: 18.0, With AWD: 13.0 ft-lbs
Rear Wheel Hub	203 ft-lbs
Front Wheel Hub	184-250 ft-lbs
Rear Wheel Hub	203 ft-lbs

Ignition

Cylinder Firing Order	1-4-2-5-3-6
Cylinder Firing Order	1-3-7-2-6-5-4-8
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 Manufacturer	Motorcraft

Battery & A/C

Refrigerant	R134a
Refrigerant Capacity	Less auxiliary A/C, 1.88. With auxiliary A/C, 3.50. lbs
Oil Group	PAG
Oil Type	68
Oil Capacity	Less auxiliary A/C, 9.00. With auxiliary A/C, 13.00. oz
Standard BCI Group Number	65
Standard BCI Cranking Performance	650 cca
Standard BCI Group Number	65

Service checks

Pressure Test	13-18 psi
Radiator Cap Pressure Relief	13-18 psi
Thermostat Opening Temperature	183-190 °F
Pressure Test	13-18 psi
Radiator Cap Pressure Relief	13-18 psi
Thermostat Opening Temperature	183-190 °F
Key ON Engine OFF (KOEO)	30-45
Injector Primary Resistance	11.4-12.6 na Flex Fuel ohms

Brakes

Brake Application	WITH REAR DISC / WITH STANDARD
Torque Caliper to Bracket	20 ft-lbs / 21-26 ft-lbs
Torque to Knuckle	80 ft-lbs / 73-97 ft-lbs
Minimum Pad Thickness	Front: 0.060; Rear: 0.030 in
Brake Application	WITH REAR DISC / WITH STANDARD
Rotor Max Parallel Variation	0.0002 in
Rotor Runout Limit	0.005 in
Rotor Discard at or Under	0.433 in / 0.965 in

Multi-step torque procedures OEM · verified

Connecting Rod (Large End) Bearings — tightening sequence 1 stages

15 ft. lbs., Step 2: 90

15 ft. lbs

Connecting Rod (Large End) Bearings — tightening sequence 1 stages

18 ft. lbs., Step 2: 33 degrees, Step 3: 90

18 ft. lbs

Crankshaft Pulley and/or Damper Bolts — tightening sequence 1 stages

66 ft. lbs., Step 2: loosen one turn, step 3: 37 ft. lbs., step 4: 90

66 ft. lbs

Cylinder Head — tightening sequence 3 stages

1	24 ft. lbs.	24 ft. lbs
2	turn 80 degrees	80 degrees
3	turn 80

Cylinder Head — tightening sequence 3 stages

1	26 ft. lbs.	26 ft. lbs
2	90 degrees	90 degrees
3	90 degrees	90 degrees

Engine Flywheel Bolts — tightening sequence 1 stages

10 ft. lbs., Step 2: 52

10 ft. lbs

Intake Manifold to Engine Bolts — tightening sequence 1 stages

3.7 ft. lbs., step 2: 18

3.7 ft. lbs

Main Bearings — tightening sequence 1 stages

7.4 ft. lbs., Step 2: 18 ft. lbs., Step 3: 30 ft. lbs., Step 4: 90 degrees

7.4 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 mi	Engine Oil (drain & refill) · Engine Oil Filter (replace) · Tire & Wheel Assembly (rotate)
Every 15,000 mi	Brake Drum Assembly (inspect) · Brake Line (inspect) · Brake Linings (inspect) · Brake Rotor (inspect) · CV Joint Boot (inspect) · Cabin Air Filter (replace)
Every 30,000 mi	Engine Air Filter Element (replace) · Exhaust System (Complete) (inspect) · Exhaust System Heat Shield (inspect) · Fuel Filter (replace)
Every 50,000 mi	Engine Coolant System (drain, flush & refill)
Every 60,000 mi	Transmission Assembly (drain & refill) · Wheel Bearing (repack)
At 100,000 mi	Engine Coolant System (drain, flush & refill)
Every 100,000 mi	PCV Valve (replace) · Spark Plugs (replace)
At 150,000 mi	Accessory Drive Belt (inspect) · Drive Axle Assembly (drain & refill) · Transfer Case Assembly (drain & refill) · Transmission Fluid & Filter (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.

From 1990 through 1998 complaints rose steadily, peaking at 2,248 in 1998 before declining to 765 in 2001. The 2002 model year shows a sharp reversal, with complaints jumping to 3,620—more than four times the 2001 total—and investigations increasing to nine, while recalls remained at 14, similar to surrounding years. After 2002, complaints fell to 1,313 in 2003 and continued at lower levels through the mid‑2000s, indicating that 2002 sits at a distinct peak in the complaint and investigation arc for this generation. The data do not specify any root cause for the spike, only the reported numbers. Consequently, the 2002 Explorer exhibits a higher incidence of reported issues than the model years immediately before and after, suggesting that a buyer should exercise caution and weigh any price advantage against this elevated risk.

Open recalls

NHTSA campaigns

370

Service bulletins

Manufacturer communications

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 by model year NHTSA · this generation & adjacent

’90 ’91 ’92 ’93 ’94 ’95 ’96 ’97 ’98 ’99 ’00 ’01’02’03 ’04 ’05 ’06 ’07 ’08 ’09 ’10 ’11 ’12 ’13 ’14 ’15 ’16 ’17 ’18 ’19 ’20 ’21 ’22 ’23 ’24 ’25

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 10 campaigns on record for this vehicle.

06E049000Exterior LightingReported 24/05/2006

CERTAIN CK MOTORSPORTS COMBINATION HEADLIGHTS, CLEAR CORNER, BUMPER, AND SIDE MARKER LIGHTS SOLD AS REPLACEMENT LAMPS FOR USE ON THE PASSENGER VEHICLES LISTED ABOVE. SOME COMBINATION LAMPS THAT ARE NOT EQUIPPED WITH… Remedy: CK MOTORSPORT WILL NOTIFY OWNERS AND REPLACE THE NONCOMPLIANT LAMPS FREE OF CHARGE. THE RECALL BEGAN ON JULY 1, 2006. OWNERS MAY CONTACT CK MOTORSPORT AT 1-909-610-7211.

07E104000Visibility:Glass, Side/RearReported 11/12/2007

CERTAIN CURVED TEMPERED REPLACEMENT GLASS MANUFACTURED BY HANGZHOU SAFETY GLASS LTD AND SUPPLIED TO SAFELITE BY AUTO TEMP INC., IDENTIFIED AS DOT-430, AND SOLD FOR USE ON CERTAIN DOMESTIC AND FOREIGN VEHICLES MAY NOT… Remedy: SAFELITE WILL NOTIFY ITS RETAIL CUSTOMERS AND REPLACE THE GLASS FREE OF CHARGE. RETAIL CUSTOMERS CAN CONTACT SAFELITE TOLL FREE AT 1-888-843-2906. SAFELITE WILL NOTIFY ITS…

Technical service bulletins NHTSA · verified

Showing 5 of 370 bulletins on record with NHTSA.

Bulletin	Date	Component	Summary
TSB 19-2026	2019-02-07	Structure	Some 2000 and newer Ford, Lincoln and Mercury vehicles equipped with aluminum body panels…
TSB 19-2026	2019-02-07	Structure	Some 2000 and newer Ford, Lincoln and Mercury vehicles equipped with aluminum body panels…
TSB-08-19-3	2009-05-01	Power Train	FORD: SOME VEHICLES MAY EXHIBIT OIL SEPARATION FROM THE INTERNAL LUBE FOUND IN THE…
07212	2007-10-01	Engine And Engine Cooling	SOME 1997-2008 VEHICLES EQUIPPED WITH A 4.6L 2V, 5.4L 2V, OR 6.8L 2V ENGINE--SPARK PLUG…
06216	2006-01-01	Power Train	LIMITED 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. 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.

Group 65 battery Vehicles taking 5.0 qt

Reference guides

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

Vehicle recalls & TSBs OBD-II trouble codes Torque specifications Maintenance schedules Fluid capacities & specs

Frequently asked

How much oil does the 2002 Explorer take?

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

Does the 2002 Explorer have open recalls?

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