2002 Ford EXPLORER

Submodel: | Engine Type: V6 | Liters: 4.0Fuel Delivery: FI | Fuel: GAS

SECTION 303-01A: Engine — 4.0L SOHC 2002 Explorer/Mountaineer Workshop ManualREMOVAL Procedure revision date: 02/19/2004

Engine

Special Tool(s)

Lifting Brackets 303-050 (T70P-6000) or equivalent

Spreader Bar 303-D701 or equivalent

Retainer, Torque Converter 307-346 (T97T-7902-A)

Disconnect Tool, Transmission 307-441

Removal

All vehicles

CAUTION: If the supply manifold is used as a leverage device, damage can occur to the supply manifold. Care must be taken when working around the fuel supplymanifold.

NOTE: Inspect the engine support insulators for wear or damage.

1. Disconnect the battery cables. For additional information, refer to Section 414-01.

2. Remove the nut and disconnect the ground wire.

3. Disconnect the electrical connector and detach the wiring harness retainers.

4. Lift the cover, remove the nut and disconnect the battery cable connector.

5. Drain the cooling system. For additional information, refer to Section 303-03.

6. Recover the A/C system. For additional information, refer to Section 412-00.

7. Disconnect the windshield washer hose.

8. NOTE: Mark the hinge locations for installation reference.Remove the four bolts and the hood.

9. Remove the cooling fan. For additional information, refer to Section 303-03.

10. Remove the power steering pump pulley. For additional information, refer to Section 211-02.

11. Remove the air cleaner outlet pipe. For additional information, refer to Section 303-12.

12. Disconnect the mass air flow (MAF) sensor electrical connector.

13. Remove the air cleaner assembly.

14. Disconnect the powertrain control module (PCM) electrical connectors.

15. Release the fuel charging wiring harness from the clips on the bulkhead.

16. Disconnect the transmission control wiring harness pin-type retainers from the fuel charging wiring harness.

17. Disconnect the spring lock coupling fuel tube. For additional information, refer to Section 310-00.

18. Disconnect the evaporative emissions (EVAP) return tube and position it aside.

19. Disconnect the vacuum hose.

20. Remove the ground wire from the engine.

21. Disconnect the vacuum hose and the heater hose.

22. Disconnect the upper radiator hose and the heater hose.

23. Remove the bolts and position the heater hose bracket aside.

24. Disconnect the lower radiator hose at the water pump.

1. Release the clamp.

2. Disconnect the radiator hose.

25. Disconnect the coolant hoses from the degas bottle.

26. NOTE: Cover the accumulator opening to prevent contamination.Disconnect the A/C tube from the accumulator.

Discard the O-ring seal.

27. Remove the nut and disconnect the A/C tube from the condenser.

28. Disconnect the accelerator and the speed control cables from the throttle body.

29. Remove the accelerator cable from the accelerator cable retainers.

30. Remove the accelerator and the speed control cables from the bracket and position aside.

31. Disconnect the vacuum hoses.

32. Disconnect the A/C high-pressure cut-off switch electrical connector.

33. Remove the nut and disconnect the A/C tube from the condenser.

Discard the O-ring seal.

34. Disconnect the A/C tube from the retainer.

35. Disconnect the electrical connector and remove the differential pressure feedback exhaust gas recirculation (EGR) system from the EGR tube.

36. Remove the EGR valve tube.

1. Disconnect the EGR tube fittings.

2. Remove the EGR tube.

37. Remove the starter. For additional information, refer to Section 303-06.

38. Remove the pushpins.

39. Remove the nut and detach the battery cable retainer bracket.

4x4 vehicles

40. Install a suitable jack stand under the transfer case.

4x2 vehicles

41. WARNING: Secure the transmission to the transmission jack with a safety chain. Failure to follow these instructions can result in personal injury.Support the transmission with a transmission jack.

All vehicles

42. Remove the two bolts and position the RH heat shield aside.

43. NOTE: LH shown, RH similar.Disconnect the two heated oxygen sensor electrical connectors.

44. NOTE: RH shown, LH similar.Disconnect the two catalyst monitor sensor electrical connectors.

45. Remove the RH heat shield bolts.

46. Remove the RH heat shield bolt and remove the heat shield.

47. Remove the LH heat shield bolt.

48. Remove the two nuts and the plastic shield on the right side of the crossmember.

49. NOTE: RH shown, LH similar.Remove the four upper crossmember bolts.

50. NOTE: RH shown, LH similar.Remove the four lower crossmember bolts.

4x2 vehicles

51. Remove the bolts and cable bracket from the transmission.

All vehicles

52. Remove the transmission support insulator nuts and remove the crossmember.

53. Remove the bolts, springs, flag nuts and separate the muffler from the converter.

Discard the gasket.

Discard the flag nuts.

54. NOTE: LH shown, RH similar.Remove the four converter-to-manifold nuts.

55. NOTE: The assistance of another technician may be required.Remove the transmission-mounted exhaust hanger, the three-way converter system and the RH heat shield.

1. Remove the bolt and the converter assembly.

2. If required, remove the second bolt and mount.

56. Disconnect the shift cable and remove the bracket.

57. Position the manual shift lever out of PARK.

4x4 vehicles

58. Index-mark the front axle pinion flange and the front driveshaft.

59. Index-mark the front output shaft assembly and the front driveshaft constant velocity (CV) joint.

60. Remove and discard the bolts and washers.

61. Remove and discard the bolts and universal joint retainers.

62. CAUTION: Always disconnect the front driveshaft from the transfer case first. Otherwise, the weight of the driveshaft can pinch the boot and cause theboot to tear.

CAUTION: Tape the bearing cups to the driveshaft to prevent them from falling off the spider.Remove the front driveshaft.

All vehicles

63. NOTE: The axle pinion flange is shown, the transfer case output flange, if equipped, is similar.Mark the driveshaft flange to the rear axle pinion flange, and if equipped, the transfer case rear output flange for assembly reference.

64. Remove the four rear axle flange bolts.

4x2 vehicles

65. Index-mark the driveshaft at the six o'clock position.

4x4 vehicles

66. Remove the four transfer case flange bolts.

All vehicles

67. CAUTION: The driveshaft flange fits tightly on the rear axle pinion flange pilot. Never hammer on the driveshaft or any of its components to disconnect thedriveshaft flange from the pinion flange.

NOTE: Do not rotate the driveshaft.Using a suitable tool as shown, disconnect the driveshaft flange and remove the driveshaft.

4x2 vehicles

68. Index-mark the transmission output shaft at the six o'clock position.

1. Pull the seal away from the transmission output shaft.

2. Mark the output shaft at the six o'clock position.

All vehicles

69. Disconnect the RH catalyst monitor connector and the fuel lines from the bracket.

70. Disconnect the RH heated oxygen sensor electrical connector from the transmission.

71. If equipped, disconnect the shift motor electrical connector.

72. Disconnect the LH heated oxygen sensor electrical connector retainer and the harness clip from the transmission.

73. Disconnect the LH catalyst monitor connector from the transmission.

74. NOTE: Make an identifying mark on the nut, stud and flexplate to allow for correct installation.Remove the four torque converter nuts.

Rotate the crankshaft to access all the nuts.

75. Move the rubber boot back to gain access to the connector.

76. Disconnect the digital transmission range sensor.

77. Disconnect the electrical connectors.

78. NOTE: Clean the area around the connector to prevent contamination of the solenoid body connector.Remove the screw and disconnect the solenoid body electrical connector.

79. Disconnect the harness retainers.

80. CAUTION: Do not damage the cooler tubes. Hold the transmission case fitting with a wrench.Disconnect the transmission cooler tubes.

81. Disconnect the cooler tubes and allow them to drain into a suitable container.

82. Remove the nut and the cooler tubes and the cooler tube bracket.

4x4 vehicles

83. WARNING: Secure the transmission to the jack with a safety chain. Failure to follow these instructions can result in personal injury.Support the transmission with a transmission jack.

84. Remove the jack stand from the transfer case.

All vehicles

85. Remove the eight engine-to-transmission retaining bolts.

86. Remove the transmission.

87. Install the special tool.

88. Disconnect the power steering return hose and allow it to drain into a suitable container.

89. Drain the engine oil.

Install the drain plug when finished.

90. Remove the LH engine support insulator bolt.

91. Lower the vehicle.

92. Remove the bolt and power steering tube support bracket.

93. Disconnect the power steering pressure tube from the power steering pump.

94. Remove the RH engine support insulator nuts.

95. Remove the bolt and the LH radiator support bracket.

96. Remove the bolts and the RH radiator support bracket.

97. Remove the radiator and A/C condenser as an assembly.

98. Install the right side lifting bracket.

99. Install the left side lifting bracket.

100. Attach a floor crane to the Spreader Bar and remove the engine.