2002 Mercury Mountaineer Service and Repair Manual

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Factory-Grade Data

The 2002 Mercury Mountaineer Service and Repair Manual is a practical, workshop-ready reference for maintenance, diagnostics, and repairs. Use it to troubleshoot symptoms, follow step-by-step procedures, verify specifications, and confirm wiring and connector locations before replacing parts.

Ideal for technicians and DIY owners, it supports everything from routine service to deeper mechanical and electrical work—including drivability, no-start, warning lights, overheating, brake and suspension issues, HVAC faults, and circuit testing.

Trims covered

  • Base Sport Utility 4-Door

Engines covered

  • 4.0L 245Cu. In. V6 FLEX SOHC Naturally Aspirated
  • 4.0L 245Cu. In. V6 GAS SOHC Naturally Aspirated
  • 4.6L 281Cu. In. V8 GAS SOHC Naturally Aspirated

What’s inside

  • 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

Why this manual matters

  • Faster diagnostics with system-based troubleshooting and wiring diagrams
  • Clear procedures and reference sections to reduce guesswork and rework
  • Helpful for maintenance planning and verifying parts/specs before repairs

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Vehicle Safety Data

2002 Mercury Mountaineer 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 EXPLORER, 1997 AND 2002

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 SCDS. ON

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 #10028736

FORD: SOME VEHICLES MAY EXHIBIT OIL SEPARATION FROM THE INTERNAL LUBE FOUND IN THE UNITIZED CARTRIDGE SEAL. OIL SEPARATION APPEARS TO BE AND IS OFTEN MISDIAGNOSED, AS AN AXLE LUBE LEAK. *PE

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 #10019800

LOW OIL PRESSURE INDICATION/WARNING, A/C COMPRESSOR INOPERATIVE AND/OR NO CRANK CONDITION ON 4.6L EQUIPPED VEHICLES. *TT

TSB #10019379

MALFUNCTION INDICATOR LAMP ON WITH PCM DIAGNOSTIC TROUBLE CODE P0463 AND/OR IC DIAGNOSTIC TROUBLE CODE B1201 - FUEL GAUGE DROPS TO EMPTY OR SLOW TO UPDATE AFTER REFUELING. *TT

TSB #10018959

EXTENDED COVERAGE PROGRAM 05N04 - EXTENDED COVERAGE FOR COMPOSITE INTAKE MANIFOLD. THIS PROGRAM IS BEING PROVIDED AS A SETTLEMENT TO A CLASS ACTION LAWSUIT. THE TERMS OF THE SETTLEMENT EXTEND THE COVERAGE OF THE ALL-COMPOSITE INTAKE MANIFOL

TSB #10018745

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

Showing the 8 most recent of 247 technical service bulletins on file with NHTSA.

20070511Component: POWER TRAIN:DRIVELINECrash reported10 injured

TL*THE CONTACT OWNS A 2002 MERCURY MOUNTAINEER. WHILE DRIVING 35MPH AND LOSING CONTROL, THE VEHICLE WAS IN A DITCH ON A DIRT ROAD. THE TIE ROD BROKE AND TWO FRONT TIRES HAD TO BE REPLACED AND THE

20061012Component: AIR BAGSCrash reported3 injured

DT*: THE CONTACT STATED THE VEHICLE WAS IN TWO ACCIDENTS AND THE AIRBAGS DID NOT DEPLOY. IN THE FIRST ACCIDENT WHICH OCCURRED IN JULY 2005, THE VEHICLE WAS STOLEN WHEN THE ACCIDENT OCCURRED AND THE A

20080221Component: AIR BAGSCrash reported2 injured

MY WIFE AND MOTHER-IN-LAW WERE INVOLVED IN A HEAD ON CRASH ON 2/12/2008. THE AIR BAGS ON THE 2002 MERCURY MOUNTAINEER DID NOT DEPLOY. *TR

20190306Component: AIR BAGSCrash reported1 injured

TL* THE CONTACT OWNED A 2002 MERCURY MOUNTAINEER. WHILE DRIVING, THE VEHICLE SLID ON ICE. THE CONTACT LOST CONTROL OF THE VEHICLE AND CRASHED INTO A DITCH. THE AIR BAGS FAILED TO DEPLOY. THE CONTACT S

20080507Component: AIR BAGS:FRONTALCrash reported1 injured

TL*THE CONTACT OWNS A 2002 MERCURY MOUNTAINEER. WHILE DRIVING BETWEEN 10-20 MPH, THE CONTACT SWERVED TO AVOID A DOG IN THE ROAD. THE VEHICLE ACCELERATED DOWN AN INCLINE INTO SOME SMALL TREES. THE C

Showing the 5 most serious of 504 complaints filed with NHTSA.

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