2003 Ford Explorer Service and Repair Manual

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Factory-Grade Data

The 2003 Ford Explorer service and repair manual is a detailed, OEM-style reference for diagnostics, maintenance, and repair work. Use it to verify procedures, specifications, and system information before you start a job.

You'll find coverage across key vehicle systems with clear section structure, including wiring diagrams and powertrain, braking, steering, suspension, HVAC, and electrical topics. Digital format makes it easy to search while you work.

Trims covered

  • Eddie Bauer Sport Utility 4-Door
  • Limited Sport Utility 4-Door
  • XLS Sport Utility 4-Door
  • XLT Sport Utility 4-Door
  • Postal Stripped Chassis

Engines covered

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

2003 Ford Explorer Recalls & Complaints

NHTSA #04V44200013/09/2004Component: STRUCTURE:BODY:HATCHBACK/LIFTGATE:HINGE AND ATTACHMENTS

ON CERTAIN SPORT UTILITY VEHICLES, THE LIFTGATE GLASS STRUT MAY BECOME DISENGAGED OR THE HINGE MAY FRACTURE ALLOWING THE GLASS TO FALL AND POSSIBLY BREAK.

Consequence

IF THE HINGE SHOULD FRACTURE, THERE IS A POTENTIAL FOR THE GLASS TO FALL AND ULTIMATELY BR

Remedy

DEALERS WILL HAVE THE LIFTGATE GLASS STRUT BRACKETS AND GLASS HINGES REPLACED. FOR THE VE

NHTSA #09E02500011/05/2009Component: EXTERIOR LIGHTING:HEADLIGHTS

DOPE, INC. IS RECALLING 42,540 COMBINATION CORNER AND BUMPER LAMP ASSEMBLIES OF VARIOUS PART NUMBERS SOLD FOR USE AS AFTERMARKET EQUIPMENT FOR VARIOUS PASSENGER VEHICLES. THESE HE

Consequence

DECREASED LIGHTING VISIBILITY MAY RESULT IN A VEHICLE CRASH.

Remedy

DOPE, INC. WILL NOTIFY OWNERS AND OFFER A FULL REFUND FOR THE NONCOMPLIANT COMBINATION LAM

NHTSA #09E01200007/04/2009Component: EXTERIOR LIGHTING

SABERSPORT IS RECALLING 16,270 COMBINATION CORNER AND BUMPER LAMP ASSEMBLIES OF VARIOUS PART NUMBERS SOLD FOR USE AS AFTERMARKET EQUIPMENT FOR VARIOUS PASSENGER VEHICLES. THESE HE

Consequence

DECREASED LIGHTING VISIBILITY MAY RESULT IN A VEHICLE CRASH.

Remedy

SABERSPORT WILL NOTIFY OWNERS AND OFFER A FULL REFUND FOR THE NONCOMPLIANT COMBINATION LAM

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 #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 #10019384

LOW TIRE INDICATOR ON - TPMS SYSTEM SENSOR WAKE UP. *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 #10018745

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

Showing the 8 most recent of 122 technical service bulletins on file with NHTSA.

20110321Component: POWER TRAIN:AUTOMATIC TRANSMISSIONCrash reportedFire reported1 injured

I OWN A 2003 FORD EXPLORER, I HAVE OWNED IT FOR ALMOST 5 YEARS AND TOOK CARE OF IT. I ALSO PAID ALOT OF MONEY FOR IT AND AFTER ABOUT THREE YEARS OUT OF NOWHERE MY O/D LIGHT STARTED

20041113Component: AIR BAGS:FRONTALCrash reported5 injured1 fatalities

WHILE DRIVING ABOUT 50 MPH, THE OWNER WAS HIT FROM THE FRONT OF VEHICLE, INTO THE SIDE OF ANOTHER VEHICLE YET THE AIR BAGS FAILED TO DEPLOY. PROVIDE FURTHER DETAILS. *NM *TC

20160615Component: AIR BAGSCrash reported4 injured

I LOST CONTROL AROUND A BEN GOING 35MPH AFTER IT GOT DONE RAINING AND GOT IN AN ACCIDENT HIT A TELEPHONE POLE AND FARM POST AFTER SPINNING ABOUT 4XS CAR IS TOTALED AIR BAGS NEVER W

20151118Component: AIR BAGSCrash reported2 injured

TL* THE CONTACT OWNED A 2003 FORD EXPLORER. WHILE DRIVING AT 50 MPH, THE FRONT AND REAR DRIVER SIDE TIRES BLEW OUT, WHICH CAUSED THE VEHICLE TO FLIP OVER SEVERAL TIMES. THE AIR BAG

Showing the 4 most serious of 1369 complaints filed with NHTSA.

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