2002 Ford E-150 Service and Repair Manual

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Factory-Grade Data

2002 Ford E-150 service and repair manual — a detailed, factory-style reference for maintenance, diagnostics, and repair. Use it to confirm correct procedures, specifications, and system coverage before you start work.

Built for technicians and DIY owners, this manual helps you troubleshoot accurately, follow step-by-step repair procedures, and use wiring diagrams and system sections to diagnose problems faster.

What’s included

  • Step-by-step repair procedures and service information
  • Specifications and reference data (where provided)
  • Electrical coverage with wiring diagrams
  • Coverage across key systems: engine, transmission, brakes, steering, suspension, HVAC, and more

Trims covered

  • XL Standard Passenger Van 3-Door

Engines covered

  • 4.2L 256Cu. In. V6 GAS OHV Naturally Aspirated
  • 5.4L 330Cu. In. V8 GAS SOHC Naturally Aspirated

Index / Table of contents

  • Body
  • Brakes
  • Chassis Electrical
  • Driveline
  • Engine Cooling
  • Engine Electrical
  • Engine Mechanical
  • Engine Performance & Emission Controls
  • Fuel System
  • General Information & Identification
  • Heating, Ventilation, & Air Conditioning
  • Hybrid & Electric Vehicle Systems
  • Steering
  • Suspension
  • Transmission, Clutch, & Transfer Case
  • Wiring Diagrams

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Vehicle Safety Data

2002 Ford E-150 Recalls & Complaints

NHTSA #09V39900013/10/2009Component: VEHICLE SPEED CONTROL

FORD IS RECALLING MODEL YEARS 1995-2003 WINDSTAR, 2000-2003 EXCURSION DIESEL, 1993-1997 AND 1999-2003 F-250 SD THROUGH F-550 SD DIESEL, 1992-2003 E-150 THROUGH E-550, 1995-2002 EXP

Consequence

A VEHICLE FIRE COULD OCCUR WITH OR WITHOUT THE ENGINE RUNNING.

Remedy

FORD WILL NOTIFY OWNERS THAT DEALERS WILL INSTALL A FUSED WIRING HARNESS IN LINE WITH THE

TSB #10022675

BRAKE BOOSTER SYSTEM MAY EXHIBIT A BRAKE PEDAL KICKBACK AND/OR GRABBING CONDITION WHEN APPLYING THE BRAKES. *NJ

TSB #10022232

HEADLIGHT ADJUSTMENT NEEDED. *KB

TSB #10018941

VIBRATION/HARSHNESS ABOVE 45 MPH (72 KM/H) AFTER TIRE BALANCE. *TT

TSB #10018741

MALFUNCTION INDICATOR LAMP ON WITH DIAGNOSTIC TROUBLE CODE P1131 AND/OR P1151 - 4.2L ENGINE. *TT

TSB #10017865

HEADLIGHT ADJUSTMENT - CHASSIS CAB INCOMPLETE VEHICLES. *TT

TSB #10010743

INTERMITTENT CLUNK ON 3-2 DOWNSHIFT DURING COASTDOWN/TIP-IN. OASIS. TO INCLUDE 2005 F-150, E-SERIES AND EXPEDITION. *TT

TSB #10008193

FRONT BRAKE PAD WEAR. *TT

TSB #10007350

CLUNK FROM FRONT SUSPENSION. *TT

Showing the 8 most recent of 13 technical service bulletins on file with NHTSA.

20030416Component: AIR BAGSCrash reported1 injured

AS THE RESULT OF A HEAD-ON COLLISION, THE AIRBAGS FAILED TO DEPLOY. THE COLLISION WAS SLIGHTLY OFF-CENTER TO THE DRIVERS SIDE OF THE VEHICLE. SUBJECT VEHICLE WAS TRAVELING AT APPRO

20240307Component: WHEELSFire reported

The contact owns a 2002 Ford E-150. The contact stated while driving at approximately 75 MPH, he smelled a burning odor in the passenger cabin. The contact stated that he turned th

20240307Component: SERVICE BRAKESFire reported

The contact owns a 2002 Ford E-150. The contact stated while driving at approximately 75 MPH, he smelled a burning odor in the passenger cabin. The contact stated that he turned th

20121231Component: SUSPENSIONFire reported

TL* THE CONTACT OWNS A 2002 FORD REGENCY. THE CONTACT STATED THAT WHILE DRIVING APPROXIMATELY 50-55 MPH, THE DRIVER'S SIDE REAR TIRE DETACHED FROM THE VEHICLE. THE CONTACT WAS RIDI

Showing the 4 most serious of 37 complaints filed with NHTSA.

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