2002 Ford Expedition Service and Repair Manual

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Factory-Grade Data

2002 Ford Expedition 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

  • Eddie Bauer Sport Utility 4-Door
  • XLT Sport Utility 4-Door

Engines covered

  • 4.6L 281Cu. In. V8 GAS SOHC 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 Expedition Recalls & Complaints

NHTSA #05V38800007/09/2005Component: VEHICLE SPEED CONTROL

ON CERTAIN PICKUP TRUCKS AND SPORT UTILITY VEHICLES EQUIPPED WITH SPEED CONTROL, THE SPEED CONTROL DEACTIVATION SWITCH MAY OVERHEAT, SMOKE, OR BURN.

Consequence

A FIRE AT THE SWITCH COULD OCCUR.

Remedy

BY LETTER DATED SEPTEMBER 12, 2005, OWNERS WERE INSTRUCTED TO RETURN THEIR VEHICLES TO THE

NHTSA #03V09400007/03/2003Component: STRUCTURE

CERTAIN PICKUP TRUCK, VAN, AND MINI VAN CONVERSIONS EQUIPPED WITH SOUTHERN COMFORT BUILT RUNNING BOARDS THAT CONTAIN CERTAIN COURTESY LIGHTS MANUFACTURED BY AMERICAN TECHNOLOGY COM

Consequence

THIS OVERHEATING CONDITION CAN CAUSE THE RUNNING BOARD TO MELT OR CAUSE A FIRE.

Remedy

DEALERS WILL REPLACE THE WIRING HARNESS ON THESE RUNNING BOARDS. OWNER NOTIFICATION BEGAN

TSB #10177863

This article supersedes TSB 19-2026 to update the vehicle model years affected. Some 2000 and newer Ford/Lincoln/Mercury vehicles equipped with aluminum body panels may exhibit corrosion concerns appearing as bubbled and/or peeling paint wi

TSB #10156863

Some 2000 and newer Ford, Lincoln and Mercury vehicles equipped with aluminum body panels may exhibit corrosion concerns appearing as bubbled and/or peeling paint with or without accompanying white dust. Panel replacement is recommended. Fo

TSB #10155551

Some 2000 and newer Ford, Lincoln and Mercury vehicles equipped with aluminum body panels may exhibit corrosion concerns appearing as bubbled and/or peeling paint with or without accompanying white dust. Panel replacement is recommended. Fo

TSB #10023943

SOME 1997-2008 VEHICLES EQUIPPED WITH A 4.6L 2V, 5.4L 2V, OR 6.8L 2V ENGINE--SPARK PLUG THREAD REPAIR PROCEDURE--NOT COVERED UNDER NEW VEHICLE LIMITED WARRANTY. *NJ THIS INCLUDES F-53 MOTORHOME CHASSIS. UPDATED 2/23/10. *PE

TSB #10018745

WDS COP KIT DIAGNOSTIC TIP - COIL ON PLUG (COP) IGNITION SYSTEMS - ENGINE MISFIRE OR ROUGH RUNNING. *TT

TSB #10017892

REAR AXLE NOISE REPAIR. *TT

TSB #10016789

REAR AXLE NOISE REPAIR. *SC

TSB #10014685

USE OF STAINLESS STEEL EXHAUST STUDS IN SERVICE FOR 5.4L 2V ENGINE. *TT

Showing the 8 most recent of 102 technical service bulletins on file with NHTSA.

20031120Component: AIR BAGS:FRONTALCrash reportedFire reported1 injured

I REAR ENDED A TRUCK AT ABOUT 35-40 MPH AND NEITHER AIR BAG DEPLOYED. MY VEHICLE IS AT PLANET FORD HERE IN TEXAS AND THEY TOLD ME LAST WEEK THEY WAS GOING TO INVESTIGATE WHY THEY

20060628Component: AIR BAGS:FRONTALCrash reported3 injured2 fatalities

VEHICLE WITH 29,300 MILES. LIGHTLY DRIVEN, WELL MAINTAINED, INSPECTED, TIRES CHECKED & OIL CHANGED MARCH OF 2006. BORROWED MY MOM'S EXPEDITION. (BIG MISTAKE), LEAVING THE HOUSTON A

20060628Component: SEATSCrash reported3 injured2 fatalities

VEHICLE WITH 29,300 MILES. LIGHTLY DRIVEN, WELL MAINTAINED, INSPECTED, TIRES CHECKED & OIL CHANGED MARCH OF 2006. BORROWED MY MOM'S EXPEDITION. (BIG MISTAKE), LEAVING THE HOUSTON A

20050119Component: AIR BAGS:FRONTALCrash reported3 injured

AFTER HITTING BLACK ICE, THE VEHICLE SLID TO THE LEFT ACROSS THE ROAD, HIT A TREE HEAD ON AND THE FRONT AIR BAGS DID NOT DEPLOY. *TC (THE CONSUMER NO LONGER OWNS THE VEHICLE)*JB

Showing the 4 most serious of 415 complaints filed with NHTSA.

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