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2002 Ford Explorer Sport (2-door) Technical Service Bulletins (TSBs)

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TSB Date Problem Area TSB Text
12/14/05 NHTSA ID: 10018061
TSB ID: 0427

Steering shudder during low speed maneuvers - 4.0l engine.
12/05/05 NHTSA ID: 10017860
TSB ID: 18719

Malfunction indicator lamp coming on with diagnostic trouble codes (dtcs) p0171, p0172, p0174 and/or p0175 (fuel system too rich or lean).
04/28/05 NHTSA ID: 10014096
TSB ID: 042419

Revised procedure for adjusting alignment on all suspensions - new right hand upper control arm design for torsion bar front suspensions.
04/07/05 NHTSA ID: 10013064
TSB ID: 02216

Excessive sulfur smell from exhaust. *eh
01/04/05 NHTSA ID: 10011150
TSB ID: 020801

Rattle noise from primary chain drive area 2000-3000 rpm - 4.0l sohc engine.
08/05/04 NHTSA ID: 10008580
TSB ID: 02176

Lamp-brake-invadvertent disabling of brake shift interlock. *mj
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07/27/04 NHTSA ID: 10008333
TSB ID: 16402

Front brake wear - under investigation. *mj
07/22/04 NHTSA ID: 10008189
TSB ID: 17376

Lacks power/runs rough/black smoke condition.
07/22/04 NHTSA ID: 10008190
TSB ID: 17378

Intermittent engine driveability issues. vehcles with automatic transmission built between 03/04/2002 and 12/01/2002.
07/22/04 NHTSA ID: 10008191
TSB ID: 17379

Rough idle, hesitation on cold engine tip-in and/or hesitation during a 5-3 downshift.
07/22/04 NHTSA ID: 10008115
TSB ID: 17544

Generator noise in cold ambient temperatures. *mj
06/16/04 NHTSA ID: 10007369
TSB ID: 031912

Steering shudder felt when turning, driving at slow speeds or at stop.
06/03/04 NHTSA ID: 10007207
TSB ID: 02M01

Customer satisfaction program 02m01 supplement #4. certain ford 2000 through 2003 vehicles equipped with a tube-mounted egr pressure sensor - additional egr pressure sensor warranty coverage. supplement #3. *mj supplement #6
01/14/04 NHTSA ID: 10004908
TSB ID: 17254

Clicking/popping noise from upper steering column area when turning. 2004 e series and explorer sport trac also included.
11/18/03 NHTSA ID: 10004087
TSB ID: 17231

Anti-lock brake system (abs) light flashing with diagnostic trouble code (dtc) b2477 after replacement of the abs module.
11/17/03 NHTSA ID: 10004060
TSB ID: 17167

Multiple vehicles with 3.0l or 4.0l engines lacks power/runs rough/black smoke. 2004 sport trac included.
11/17/03 NHTSA ID: 10004069
TSB ID: 17198

Wear-through condition on the abrasion sleeve of the upper radiator hose near the air conditioning accumulator or transmission fluid dipstick.
11/14/03 NHTSA ID: 10004041
TSB ID: 031912

Steering wheel shudder during low speed turning maneuvers. 2004 explorer sport trac included.
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10/09/03 NHTSA ID: 10003165
TSB ID: 17055

Lacks power / black smoke / runs rough, usually with no malfunction indicator lamp on or diagnostic trouble codes.
09/17/03 NHTSA ID: 10002780
TSB ID: 0398

Malfunction indicator lamp (mil) illumination with diagnostic trouble codes p0442, p0455, p0456, p0457, p1442 or check fuel cap lamp illuminated with diagnostic trouble code p0457.
09/10/03 NHTSA ID: 10002675
TSB ID: 16810

Rough idle and/or check engine lamp due to closure hose which becomes loose or disconnected at the right hand cam cover.
09/09/03 NHTSA ID: 10002643
TSB ID: 16735

Various noise issues from the rear leaf springs while driving.
09/03/03 NHTSA ID: 10002472
TSB ID: 0322

Streamlined diagnostic procedure for vehicles with malfunction indicator lamp (mil) on and diagnostic trouble codes (dtcs) p0401, p0402, p1400 or p1401, or runs rough, lacks power, surge, poor fuel economy, and the above listed dtcs without
09/03/03 NHTSA ID: 10002482
TSB ID: 0335

Idle air control (iac) valve diagnostic service tips.
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09/03/03 NHTSA ID: 10002495
TSB ID: 16610

No start, no communication with power train control module (pcm) using wds/ngs or a miss/buck/jerk while driving.
09/03/03 NHTSA ID: 10002501
TSB ID: 16623

Excessive fuel gauge fluctuation while driving (qsf).
09/03/03 NHTSA ID: 10002502
TSB ID: 16624

Slow fuel fill condition.
07/23/03 NHTSA ID: 10001855
TSB ID: 0361

Malfunction indicator lamp on with or without rough running, lack of power, surge or poor fuel economy with diagnostic trouble codes p0401, p0402, p1400, p1401. *jb
03/25/03 NHTSA ID: 10000592
TSB ID: 870197

Incorrectly installed gear driven camshaft position (cmp) sensor synchronizer assemblies causing surge, lost of power, malfunction indicator lamp on and diagnostic trouble codes p1336, p1309 and p0340.
12/09/02 NHTSA ID: 637920
TSB ID: 0281

Some vehicles equipped with the 4.0 sohc (single over-head cam) engine may exhibit a primary timing chain rattle noise.
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12/06/02 NHTSA ID: 637781
TSB ID: 15898

Some vehicles may exhibit a hard start / no start condition due to fuel pressure bleed down.
12/06/02 NHTSA ID: 637803
TSB ID: 15910

Concerns with brake vibration, roughness and / or grinding noise, and excessive brake rotor corrosion.
12/06/02 NHTSA ID: 637843
TSB ID: 15936

Some vehicles equpped with 4.0l engine and automatic transmission may exhibit a rough idle, low speed engine quit, hesitation on cold engine tip-in and / or hesitation during a 5-3 donwshift.
12/04/02 NHTSA ID: 637710
TSB ID: 15859

Some vehicles with 4wabs may exhibit diagnostic trouble codes c1233 and c1234 (anti-lock brake sensor output failure).
12/03/02 NHTSA ID: 637584
TSB ID: 15835

Running change for the upper radiator sight shield.
11/26/02 NHTSA ID: 637460
TSB ID: 15769

Some vehicles may exhibit a condition of steering wheel leather peeling.
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11/08/02 NHTSA ID: 636395
TSB ID: 15754

Some vehicles equipped with 4.0l engine and manual transmission may exhibit an intermittent stumble during deceleration and / or at stops when the clutch pedal is depressed.
11/06/02 NHTSA ID: 636147
TSB ID: 16124

Some vehicles built on or after 3/4/2002 may exhibit intermittent engine driveability issues. engineer is investigating.
11/06/02 NHTSA ID: 636212
TSB ID: 16021

Some vehicles with 4wabs may exhibit diagnostic trouble codes c1233 and c1234 (anti-lock brake sensor output failures) in slippery conditions.
11/06/02 NHTSA ID: 636235
TSB ID: 16040

Experiencing a clicking / popping noise from the upper steering column area when turning the steering wheel.
11/05/02 NHTSA ID: 636143
TSB ID: 16121

Some vehicles may exhibit uneven and / or premature front brake pad wear, particularly the front inside pad.
11/04/02 NHTSA ID: 636013
TSB ID: 0276

Information on diagnosing engine rattle noise from primary chain drive area between 2000-3000 rpm on cold engine operation only.
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04/19/02 NHTSA ID: 630693
TSB ID: 15644

Some vehicles may exhbit a hard start/no start condition when trying to start the vehicle.
04/19/02 NHTSA ID: 630714
TSB ID: 15655

Concerns with excessive sulphur smell from the exhaust when operating under certain drive modes.
04/19/02 NHTSA ID: 630649
TSB ID: 15602

Concerns with low brake pedal/hydraulic control unit brake fluid leak.
04/18/02 NHTSA ID: 630515
TSB ID: 01246

Engine oil system priming procedures, service tips for reports of premature engine failure.
04/18/02 NHTSA ID: 630579
TSB ID: 15471

Some 4.0l sohc engines may exhibit excessive sulphur smell from the exhaust system while operating under certain drive modes.
04/16/02 NHTSA ID: 630276
TSB ID: 15358

Concerns with engine quitting during deceleration.
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04/16/02 NHTSA ID: 630388
TSB ID: 15378

Some vehicles with the 4.0l engine may exhibit an engine flutter noise.
04/16/02 NHTSA ID: 630391
TSB ID: 15381

Some vehicles with a manual transmission may exhibit an engine loss or reduction in power condition on deceleration, but will immediately restart.
04/12/02 NHTSA ID: 630061
TSB ID: 15531

Subject regarding engine quitting on deceleration/stopping.*yd
04/11/02 NHTSA ID: 630018
TSB ID: 15532

Information on vehicles exhibitng fuel line damage due to pinching/squeezing of the fuel return line.
02/26/02 NHTSA ID: 627927
TSB ID: 01205

Some vehicles may exhibit vacuum or air leaks in the intake manifold and / or engine system causing diagnostic trouble codes p0171 and or p0174.
02/22/02 Engine NHTSA ID: 627774
TSB ID: 012113

Some ignition switch lock cylinder assemblies may exhibit rougness and / or excess effort in turning, key does not fully return from start, a malfunction indicator lamp may illuminate with p0500, p1502 and u1039 stored in powertrian control
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12/06/05 Transmission and Drivetrain NHTSA ID: 10017891
TSB ID: 030508

Front axle leaks fluid from vent tube - vehicles equipped with 4x4 or awd.
04/28/05 Transmission and Drivetrain NHTSA ID: 10014086
TSB ID: 042107

General (pcm) power train control module programming procedures.
04/15/05 Transmission and Drivetrain NHTSA ID: 10013369
TSB ID: 04217

General power train control module (pcm) programming procedures.
07/27/04 Transmission and Drivetrain NHTSA ID: 10008305
TSB ID: 02222

Noise-gear whine noise in 1st and 2nd gear only-vehicles equipped with 5r55e transmission and 4.0l engine only. *mj
10/29/03 Transmission and Drivetrain NHTSA ID: 10003748
TSB ID: 03148

New transmission cooler flusher - service tips. 2003 escort and super duty f series included.
07/25/03 Transmission and Drivetrain NHTSA ID: 10001922
TSB ID: 0358

Fluid may leak out of the front axle vent tube. *jb
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12/09/02 Transmission and Drivetrain NHTSA ID: 637922
TSB ID: 0282

Some vehicles built prior to 9/15/2001 may exhibit low line pressure readings while in drive, no 2nd gear, no 3rd gear, no engine braking in manual 1st and slipping shifts and / or delayed engagements.
12/09/02 Transmission and Drivetrain NHTSA ID: 637924
TSB ID: 0283

Some vehicles equipped with a 2.3l, 3.0l or 4.0l engine and 5r44e or 5r55e automatic transmission may exhibit a fluid leak at the transmission servo covers in cold climates.
12/04/02 Transmission and Drivetrain NHTSA ID: 637726
TSB ID: 15869

Some vehicles may exhibit an intermittent soft clutch pedal which may cause difficulty in shifting gears (a notchy feel).
12/04/02 Transmission and Drivetrain NHTSA ID: 637755
TSB ID: 15887

Some vehicles may exhibit a no 1-2 upshift, no 2-3 upshift, a no engine braking condition in manual 1 or diagnostic trouble code p0732 (gear 2 incorrect ratio) or p0733 (gear 3 incorrect ratio).
11/26/02 Transmission and Drivetrain NHTSA ID: 637478
TSB ID: 15785

Some vehicles equipped with 5r55e/5r44e transmission may exhibit a whine noise in 1st gear that goes away after the 1-2 or 1-3 shift is completed.
11/07/02 Transmission and Drivetrain NHTSA ID: 636324
TSB ID: 15689

Some vehicles may exhibit either a very hard or very soft clutch pedal feel.
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11/06/02 Transmission and Drivetrain NHTSA ID: 636233
TSB ID: 16038

Some vehicles equipped with a 5r55e automatic transmission may exhibit a gear whine type noise in 1st and / or 2nd gears only.
11/05/02 Transmission and Drivetrain NHTSA ID: 636135
TSB ID: 16113

Some vehicles built after 03/04/2002 and equiped with a manual transmission may exhibit a hard to shift condition.
11/04/02 Transmission and Drivetrain NHTSA ID: 635998
TSB ID: 02138

Low line pressure reading at wide open throttle (wot), slipping shifts and / or delayed engagements with possible diagnostic trouble codes p0732, p0733, p1762 set on vehicles built before 12/1/2001.
11/04/02 Transmission and Drivetrain NHTSA ID: 636052
TSB ID: 0258

Inoperative or inacurrate speedometer, 4x4 lamp illuminatd, and / or diagnostic trouble code p1635 or p1639.
11/04/02 Transmission and Drivetrain NHTSA ID: 636056
TSB ID: 0242

Certain vehicles with 4x4 or all-wheel drive may have a fluid leak from the front axle vent tube.
04/16/02 Transmission and Drivetrain NHTSA ID: 630393
TSB ID: 15382

Some vehicles may exhibit either a very hard or very soft clutch pedal feel, and/or a difficulty in shifting gears.
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05/22/01 Transmission and Drivetrain NHTSA ID: 619276
TSB ID: 0186

On some vehicles, including sport and sport trac, the front axle leaks fluid from the vent tube.
04/27/05 Electrical and Air Conditioning NHTSA ID: 10014062
TSB ID: 04189

Rear window defroster grid/integral antenna diagnosis and repair - terminal tab repair.
01/04/05 Electrical and Air Conditioning NHTSA ID: 10011159
TSB ID: 041514

Rear window defroster grid/integral antenna diagnosis and repair - terminal tab repair.
09/23/04 Electrical and Air Conditioning NHTSA ID: 10009321
TSB ID: 031501

Inoperative electric rear window defroster (heated backlite) grid lines, integral antenna concerns.
09/22/04 Electrical and Air Conditioning NHTSA ID: 10009317
TSB ID: 04133

Moisture in headlamp.
07/28/04 Electrical and Air Conditioning NHTSA ID: 10008359
TSB ID: 16437

Diagnostic trouble code (dtc) c1233 & c1234 - replace anti-lock brake system euc. *mj
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07/23/04 Electrical and Air Conditioning NHTSA ID: 10008252
TSB ID: 04111

Streamlined diagnostic procedure for vehicles with malfunction indicator lamp (mil) on and diagnostic trouble codes (dtcs) p0401, p0402, p1400 or p1401. additional symptoms may include runs rough, lacks power, surge, poor fuel economy.
06/16/04 Electrical and Air Conditioning NHTSA ID: 10007360
TSB ID: 03223

Streamlined diagnostic procedure for vehicles with malfunction indicator lamp on and diagnostic trouble codes (dtcs) p0401, p0402, p1400 or p1401. additional symptoms may include runs rough, lacks power, surge, poor fuel economy.
01/20/04 Electrical and Air Conditioning NHTSA ID: 10004924
TSB ID: 17280

Generator whistle/hoot noise in cold ambient temperatures.
01/14/04 Electrical and Air Conditioning NHTSA ID: 10004886
TSB ID: 03203

Malfunction indicator lamp illuminated with diagnostic trouble codes (dtcs) p0442, p0455, p0456, p0457 or p1442 or a check fuel cap lamp illuminated with dtc p0457 for the evaporative emission system.
11/14/03 Electrical and Air Conditioning NHTSA ID: 10004027
TSB ID: 03181

Remote keyless entry (rke) - service tips.
09/10/03 Electrical and Air Conditioning NHTSA ID: 10002660
TSB ID: 16776

Servicing multifunction switch wiring interference.
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12/06/02 Electrical and Air Conditioning NHTSA ID: 637794
TSB ID: 15905

Subject regarding pioneer tremor / ultimate 450 watt audio system whine noise.
12/04/02 Electrical and Air Conditioning NHTSA ID: 637719
TSB ID: 15863

Subject regarding a whine noise condition from the speakers when using the radio or the cd with the pioneer tremore / pioneer ultimate 450 watt audio system.
11/07/02 Electrical and Air Conditioning NHTSA ID: 636366
TSB ID: 15723

Some vehicles may exhibit adhesive extruding from the headliner material around the moonroof.
11/06/02 Electrical and Air Conditioning NHTSA ID: 636161
TSB ID: 16134

Information on servicing the multifunction switch on vehicles equipped with tilt steering column.
11/05/02 Electrical and Air Conditioning NHTSA ID: 636065
TSB ID: 0245

Information regarding discharged battery charging service tips and guidelines.
04/15/02 Electrical and Air Conditioning NHTSA ID: 630148
TSB ID: 15590

Some vehicles may exhibit a battery draw and/or a dead battery condition.
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04/12/02 Electrical and Air Conditioning NHTSA ID: 630084
TSB ID: 15551

Customers may complain of moisture in headlamp. *yh
04/12/02 Electrical and Air Conditioning NHTSA ID: 630115
TSB ID: 15572

Some vehicles equipped with belt minder may exhibit the belt minder warning chime staying on after the driver seat belt buckle has been buckled.
10/31/01 Electrical and Air Conditioning NHTSA ID: 623944
TSB ID: 01156

Some vehicles may exhibit heater core leaks. *slc
04/28/05 Other NHTSA ID: 10014138
TSB ID: 042421

Safety belt retraction speed.
04/05/05 Other NHTSA ID: 10012954
TSB ID: 05310

Safety belt web stop button service. *eh
06/22/04 Other NHTSA ID: 10007416
TSB ID: 17647

Paint peeling and/or bubbling on the center finish panel of the instrument panel.
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01/14/04 Other NHTSA ID: 10004907
TSB ID: 17253

Water leak near the roof opening panel. 2004 explorer sport trac included.
11/26/02 Other NHTSA ID: 637452
TSB ID: 15765

Some vehicles may exhibit wind noise around the front doors, near the top rear-ward portion of the door / glass at highway speeds, or in a cross wind.
11/04/02 Other NHTSA ID: 636049
TSB ID: 0256

This bulletin involves proper procedures for preparation of service sheet metal parts coated with electro deposition primer (e-coat).
04/19/02 Other NHTSA ID: 630636
TSB ID: 0232

Some vehicles equipped with the 4.0l sohc engine may exhibit a check engine light on with diagnostic trouble codes p0300 (random misfire) or p0301.
04/17/02 Other NHTSA ID: 630418
TSB ID: 15406

Concerns with rear wipers that do not sufficiently clean the back glass.
03/05/02 Other NHTSA ID: 628153
TSB ID: 01B77

Owner notification program supplement 7 revised information - regarding replacement of wilderness at tires.

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Ford Explorer Sport (2-door) TSBs (Technical Service Bulletins)

Some things are often misunderstood about recalls and technical service bulletins (TSBs). Plus a disclaimer.

  1. Recalls do not have to be issued only because something is prone to failure. NHTSA (a government agency) can only require a recall if a failure will affect safety, emissions, fuel economy, or compliance with some other regulation or law. Manufacturers can voluntarily recall cars for problems that do not affect these, though.
  2. Recalls often apply to only some cars of a specific model year, rather than all of them. You should receive a letter from the manufacturer if your car has been recalled. You can also check with the dealer, which will know which (if any) recalls pertain to your car.
  3. The primary purpose of TSBs is to inform dealers about known problems with a car and how to fix them. They are not the same as recalls. As with recalls, TSBs often only apply to some cars, not the entire model year.
  4. Dealers often will not provide a preventive repair just because a problem described in a TSB might happen to your car. They'll usually want to observe symptoms that the problem is already affecting your car.
  5. Even if there are symptoms, a manufacturer doesn't have to pick up the cost of a TSB repair if the car is out of warranty, though sometimes they do.

We provide the text of recalls and TSBs as provided by NHTSA. There can be errors in the text. If you sign up for notifications in My Garage, we will try to get these to do, but for various reasons (some beyond our control) cannot guarantee you will receive them. When in doubt about a recall or TSB, contact the dealer.

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