2003 Ford Explorer Service and Repair Manual

This factory service and repair manual for the 2003 Ford Explorer is written for two single overhead-cam engines, the 4.0L V6 running on gasoline or flex-fuel and the 4.6L V8 on gasoline, both naturally aspirated. It covers the 4-door sport utility and the chassis body, and five trims are listed: Eddie Bauer, Limited, Postal Stripped, XLS and XLT. Engine, transmission, driveline, brake, suspension, steering, body and electrical work is supported with procedures, specifications, torque values, wiring diagrams and diagnostics, with separate figures for the V6 and the V8.

Engines covered

• 4.0L V6 (245 cu in) — SOHC, naturally aspirated, gasoline or flex-fuel
• 4.6L V8 (281 cu in) — SOHC, naturally aspirated, gasoline

Body styles covered

• 4-door sport utility
• Chassis

Trims covered

• Eddie Bauer
• Limited
• Postal Stripped
• XLS
• XLT

Known issues on the 2003 Explorer. Seven recalls are on the federal record. The liftgate glass strut could disengage or its hinge could fracture and let the glass fall and break; replacement tempered glass from one supplier could fail to break into small pieces in a crash; and courtesy lights in conversion running boards could overheat when the harness was exposed to moisture and road salt. Owners have filed 1,313 complaints with NHTSA, clustered on structure at 349, the power train at 318 and engine and engine cooling at 83. Liftgate hinges, glass and struts, the transmission and engine cooling are covered with procedures and specifications.