2002 Explorer Sport/Sport Trac

2002 EXPLORER SPORT/SPORT TRAC

2002 Explorer Sport/Sport Trac 1New or Revised—0727/01

INDEXSubject Page NumberModel/Series/Trim Availability 2Seating Capacity And Standard Equipment Specifications: 2

— U207/P207 2-3Technical Specifications:

— Axles 4— Brakes 4-5— Cooling System 5— Fuel System 5— Steering 5— Suspension (Frame) 5— Tires and Wheels 5-6— Transfer Case 6— Transmissions and Clutch 6

Payload/Weight Ratings (Curb Weights) 9Special Applications (Trailer Tow) 10


2 2002 Explorer Sport/Sport Trac New or Revised—07/27/01

MODEL / SERIES / TRIM AVAILABILITY

ModelTrim LevelStd.

Explorer Sport 2-Dr Model — 101.8” WB 4 x 2/4x4 �

Explorer Sport Trac 4-Dr Model — 125.9” WB 4 x 2/4x4 �

SEATING CAPACITY AND STANDARD EQUIPMENT SPECIFICATIONSSERIES 2-Dr Explorer Sport 4-Dr Explorer Sport Trac

Passenger Package STD STDPassenger Capacity 4 5

SEATING ARRANGEMENTS INCLUDE:Standard Buckets — Dual front � �

Bench— 2-pass. rear �

— 3-pass. rear �

Min. Pass/Cargo Capacities (lbs.) 600 750MAXIMUM PAYLOAD RATING:(1) (lbs.)

— 125.9" WB SportTrac only

— 4x2 1260 1540— 4x4 1240 1500

GVWR: (lbs.)(Computer SelectedExplorer Sport - not tobe advertised)

— 4x2 4760 5660

— 4x4 4920 5840GAWR (lbs.)

4x2 Models — Front Min. 2400 2710— Front Max. 2400 2710— Rear Min. 2650 3200— Rear Max. 2650 3200

4x4 Models — Front Min. 2620 2900— Front Max. 2620 2900— Rear Min. 2650 3200— Rear Max. 2650 3200

POWERTRAIN: Refer to Dealer Ordering Guide For 50 State UsageEngine — Application 50 States (Low Emission Vehicle-LEV)

— Type (Ford) 4.0L (245) SOHC SEFI— Projected HP/Torque 203 hp @ 5250 rpm/237 lb/ft. @ 3000

rpm210 hp @ 5200 rpm/240 lb/ft. @ 3000 rpm

— Cooling Auxiliary Transmission Oil CoolerTransmission — Type 5-Speed Manual OD

— Low/High GearRatios

3.40:1/.79:1

Transfer Case — Type (4x4 Optiononly)

Borg Warner 1354 2-Spd Part-Time 2.48:1;1:1 (Includes Skid Plate)

AXLES:Front Axle — Type Twin-Forged Upper SLA

— Capacity (Rating @Ground)

2710 lbs. (4x2) 2850 lbs.(4x4)

2710 lbs.(4x2)

2900 lbs.(4x4)

Rear Axle — Type Semi-Floating, Ford— Capacity (Rating @

Ground)3200 lbs. 3200 lbs.

BRAKES: w/Brakeshiftinterlock

Front Disc — Type Dual-Piston, Floating Caliper— Size 12.00 Diameter

Rear Disc — Type Single-Piston, Self-Adjusting11.22” Diameter

Rear Drum — Type Self-Adjusting— Size 11.00” x 2.25”

Power-Assist Unit — Type Dual Vacuum Booster— Effective Diameter. 11.42”

Anti-Lock System — Type 4-Wheel ABSParking Brake — Rear Brakes Foot-Operated, Hand Release



ELECTRICAL:Alternator — Rating Motorcraft, 130 Amperes, 1950 Watt, Internal regulated (4G))Battery — tType Maintenance-Free

— Rating 72 Amp-hr., 650 CCA (Battery Saver System Standard)FUEL TANK: — Capacity: (Midship) 17.5 gal. (66L) 20.5 gal. (77L)JACK: — Capacity 1.5 tonSTEERING: — Type Power, Ford - Rack and Pinion (Includes Steering Cooler)

Ratio 19.1:1 StaticSUSPENSION:

Frame — Type Front ladder Type Boxed W/Single-Channel, 6-Crossmembers, 36,000 Psi Steel— Section Modulus 2.89 cu. in

Springs, Front — Type (4x2) 2400 lbs. 2900 lbs.— Type (4x4) Torsion Bar - 2620 lbs. Torsion Bar - 2900 lbs.

Springs, Rear — Type (4x2) 2650 lbs. 2-stage long taper leaf 2900 lbs. 2-stage var. rate leaf— Type (4x4) 2650 lbs. long taper leaf 2900 lbs. 2-stage var. rate leaf

Shock Absorbers — Frt/Rr (Gas-Type) 1.375”Stabilizer Bar, Front — Type 1.34” Diameter Solid SteelStabilizer Bar, Rear — Type .77” Diameter Solid Steel

TIRES: — No./Type Five/Steel-Belted Radial All -Season— Size P235/70R16 OWL A/S P235/70R16 OWL A/S— Spare Tire Carrier Rear Under Frame, Crank Up Type and road size spare

WHEELS: — No./Type Four/ 5-spoke Cast Aluminum 16” x7.0”J. (with 16” x 6.0J Steel sparewheel)

Four/ 5-spokeCast Aluminum 16” x 7.0”J.(with 16” x 6.0J Steel spare wheel)

NOTE: Refer to the end of this section for powertrain/chassis option availability.(1) Load rating represents max.allowable weight of people, cargo and body equipment and is reduced by optional equipment weight.

SEATING CAPACITY AND STANDARD EQUIPMENT SPECIFICATIONSSERIES 2-Dr Explorer Sport 4-Dr Explorer Sport Trac



TECHNICAL SPECIFICATIONS

AxleFRONT AXLE SPECIFICATIONSModel 4x2 / 4x4Make/Type Ford SLA (Short/Long Arm) Independent Front Suspension

Max. Rating @ Ground (lbs.) 2710 (Sport 4x2)/2850 (Sport 4x4) and 2900 (Sport Trac 4x2/4x4)Upper Control Arm — Material Forged Steel

Lower Control Arm — Material Stamped High Strength SteelSpring Centers Torsion Bar, Computer SelectedBall Joints Lubed-For-LifeSpindle — Material Nodular Cast Iron Body with Forged Steel StemWheel Bearings — Type Tapered Roller

REAR AXLE SPECIFICATIONSMake Ford Standard and Limited SlipModel 4x2/4x4

Max. Rating @ Ground (lbs.) 2650 (Sport)/2900/3200 (Sport Trac)Type Semi-Floating

Drive HotchkissHousing — Type Cast Center

— Cover Attachment BoltedSection — Max. Tube Size (in.) 3.00Wall Thickness — Max. (in.) .19Lubricant Capacity (pint) 5.0Spring Centers (in.) 40.3Wheel Bearings — Type Straight RollerGears — Type Hypoid

— Material Alloy SteelRatios Available (to 1) 4.10Ring Gear Pitch Diameter (in.) 8.8Pinion — Mounting OverhungDifferential — Type 2-Pinion

— Bearings Tapered RollerAxle Shaft — Minimum Diameter (in.) 1.29

— Diameter over Splines (in.) 1.32— No. of Splines 31

BrakesHYDRAULIC BRAKE EQUIPMENT SPECIFICATIONS — FRONT DISC

Type

AxleUsage(lbs.)

Rotor Dia. (in.)BrakeLiningSegment

Area (sq. in.)/Width (in.)Thickness (in.)

CaliperPistonDia.(in.)

GrossLining AreaPer Axle (sq.in.)

TotalSweptAreaPer Axle(sq. in.)OD ID

Front Disc 2710 - 4x2Sport2850 - 4x4Sport

12.0 7.09 Outboard 14.70/5.51/.34 Dual -1.81 59.80 222.5

2900 - 4x2/4x4 SportTrac

12.0 7.09 Outboard 14.70/5.51/.34 Dual -1.81 59.80 222.5

HYDRAULIC BRAKE EQUIPMENT SPECIFICATIONS—REAR DISC —4-WHEELANTI-LOCK BRAKE SYSTEM (Explorer Sport)

TypeAxle Usage(lbs.)

Rotor Dia. (in.)BrakeLiningSegment

Area (sq. in.)/Width (in.)/Thickness(in.)

CaliperPistonDia.(in.)

GrossLiningAreaPer Axle(sq. in.)

TotalSweptAreaPer Axle(sq. in.)OD ID

Disc 2650 11.22 8.02 Outboard 7.6/4.92/.37 Single 2.0 30.49 205.0Inboard 7.6/4.92/.37



TECHNICAL SPECIFICATIONSHYDRAULIC BRAKE EQUIPMENT SPECIFICATIONS — REAR DRUM — FOURWHEEL ANTI-LOCK BRAKE SYSTEM (Explorer Sport Trac)

Type SeriesAxle Usage(lbs.)

Brake Size(in.)

Lining Thickness (in.) WheelCylinderDia (in.)

GrossLining AreaPer Axle(sq. in.

TotalSweptAreaAxle(sq. in.)Primary Secondary

Drum 4x2/4x4 2900/3200 11.00 x 2.25 0.14 0.22 0.75 94.82 155.35

BRAKE MASTER CYLINDER SPECIFICATIONSType Bore Dia. (in.)Dual System, Dash-Mounted(1)

(1) Includes 4-Wheel Anti-lock System - Operates in all Drive Modes.1.062

POWER BRAKES VACUUM BOOSTER SPECIFICATIONS

Make/TypeModel/Series

EffectiveDia. (in.)

OutsideDia. (in.)

DiaphragmType

Dash-Mounted 4x2/4x4 8.98/9.06 9.92 Dual

Cooling SystemsCOOLING SYSTEM SPECIFICATIONS

Engine CoolingTrans.Usage

FrontalArea (sq.in.)

Core Size (in.)RowsofTubes

FinsPerInch

CoolingSystemCap.(approx.qts.)

Fan Specs

Height Width Thick

Type/No. ofBlades

BladeDia.In.

4.0L (245)SOHC V-6

Std. Auto. 492 23.68 20.79 2.22 2 10.2 7.8 Plastic/11 18.0

AUXILIARY AUTOMATIC TRANSMISSION OIL COOLER (Standard)Model/Series Engine Transmission Size No. of PlatesAll 4.0L (245) SOHC SEFI V-6 5-Speed Auto. OD (5R55E) 10.0” x 7.0” x 1.25” 22

Fuel SystemFUEL SYSTEM DATAElectronic Fuel Injection 4.0L (245) SOHC SEFI V-6

Injectors Six Port-Mounted Sequential InjectorsFuel Tank Capacity 17.5 gals. (66L) (Sport)/20.5 gals. (77L) (Sport Trac)Fuel Pump - in tank Single Electric -In Tank High PressureFuel Filter In-Line Large Capacity (One)Air Cleaner Dry Element, Replaceable

SteeringSTEERING SPECIFICATIONS

Model/Series WB (in.)Power Steering Gear Ratios Turning Dia. (ft.)Static Dynamic Curb-to-Curb Wall-to-Wall

Sport 4x2 / 4x4 102.0 19.1:1 19.7:1:1 34.7 37.8Sport Trac 4x2 / 4x4 126.0 17.5:1 18.3:1 43.1 44.9

SuspensionsFRAME SPECIFICATIONSModel/Series Wheelbase (in.)

Maximum Side RailSection (in.)

SectionModulus (cu. in.)

Yield Strength(psi)

4x2/4x4 102.0 6.08 x 2.34 x .150 2.89 36,000126.0 6.12 x 2.36 x .150 3.68(1)

(1) The Sport Trac Section Modulus is measured between X=3300 and 3800 (Ctr S/R) and includes the turned up/down flanges.36,000



TECHNICAL SPECIFICATIONSSHOCK ABSORBER SPECIFICATION

Model/Series

Wheel-Base (in.) Usage

Front RearNo.Used

PistonDia. (in.) Type

No.Used

PistonDia. (in.) Type

4x2/4x4 102.0/126.0 Std. 2 1.375 Gas-Pressurized 2 1.375 Gas-Pressurized

SPRING SPECIFICATIONS — FRONT TORSION BARS

Model/Series

Wheel-base (in.)

CombinedRating @Ground (lbs.)

Diameter(in.)

Torsion Bar Active Length@ Normal Load (in.)R.H. — L.H.

DeflectionRate @Wheel (lbs.per in. ea.)

Bar Rate(in.-lbs./degree) R.H.& L.H.

Sport 4x2 102 2400 1.08 40.32 36.73 230 641.7 / 662.1Sport Trac 4x2 126 2900 1.10 40.35 39.13 235 671.8 / 693.0Sport 4x4 102 2620 1.14 40.37 39.15 245 695.7 / 717.8Sport Trac 4x4 126 2900 1.10 40.35 39.13 235 671.8 / 693.0

SPRING SPECIFICATIONS — REAR LEAF

Model/ SeriesWheel base(in.)

CombinedRating @Ground(lbs.)

No. ofLeaves

TotalThickness@ Pad(in.) Length (in.) Width (in.)

DeflectionRate (lbs.per in./spring)

Rating @Pad (lbs./in.per degreeRH / LH)

Sport 4x2/4x4 102 2650 4 .1.78 56.5 2.50 280 1135Sport Trac4x2/4x4

126 2900 4 1.92 56.5 2.50 280 12603200 4 1.92 56.5 2.50 370 1410

Tires and WheelsTIRE SPECIFICATIONS

SizeRim Width(in.)

SectionWidth (in.)

LoadRating

Max.InflationPressure(psi)

Load Limits @Max. InflationPressure (lbs.)

StaticLoadedRadius (in.)

RevolutionsPer Mile @ 45mph

P235/70R16 A/S OWL 7.0 9.25 Std. 35 1843 12.94 721P255/70R16 A/T OWL 7.0 10.24 Std. 35 2065 13.20 690

WHEEL SPECIFICATIONS

Wheel Type Wheel SizeNominalOffset (in.)

No. ofStuds

Bolt Circle(in.)

Max. Whl Cap. Load (lbs.@ ground)

Cast Aluminum - Deep Dish (Sport) 16" x 7.0" J .47 5 4.5 1600Bright Cast Aluminum (Sport Trac) 16" x 7.0" J .47 5 4.5 16005-Spoke Aluminum (Sport) 16" x 7.0" J .47 5 4.5 1600

Transfer CaseTRANSFER CASE SPECIFICATIONSMake and Model Borg Warner 1354Type 2-Speed Planetary GearsLubricant Capacity (pt.) 3.0Gear Ratio — High Direct — 1.00:1Gear Ratio — Low Direct — 2.48:1Case Material Aluminum



CLUTCH SPECIFICATIONS

TECHNICAL SPECIFICATIONS

TransmissionsMANUAL TRANSMISSION SPECIFICATIONSMake/Type Mazda R1HD (5-Speed with O/D)Ratios (to 1):1st 3.402nd 2.053rd 1.314th 1.005th (OD) 0.79Reverse 3.40Lubricant Capacity (Pt.) 5.6Synchronizers — Gears 1,2,3,4,5

Gears: Material Carburized steelType — Helical 1st, 2nd, 3rd, 4th, 5th & reverse

Bearings:Mainshaft — Front Single row taper

— Center Single row taper— Rear Single row ball

Countershaft Gear — Front Single row roller— Center Single row roller— Rear Single row ball

Reverse Idler Gear — type Single row roller

AUTOMATIC TRANSMISSION SPECIFICATIONSMake Ford 5R55E 5 -Speed Automatic OverdriveModel 4x2/4x4Engine 4.0L (245) SOHC SEFI V-6Ratios (to 1):

1st 2.472nd 1.853rd 1.474th-(OD) 1.005th-(OD) 0.75Reverse 2.10

Converter 1.80Lubricant Capacity (pt.) 20.0Helical Gears AllOil Cooler WaterAuxiliary Cooler - 14 oz.(1)

(1) Additional Transmission Fluid required with Standard Aux. Trans. Oil Cooler.Oil

4x2/4x4Engine 4.0L (245) SOHC SEFI V-6Clutch Diameter (approx. in.): 10 (Hydraulic Actuation)Disc Type Segmented W/spring vibration damper/w/pre-damperLining Material Woven Non-AsbestosOutside Diameter (approx. in.) 10.00Inside Diameter (in.) 6.75Facing Area (sq. in.) 45.0Facing Thickness (in.) usable 138Pressure Plate make LukPilot Bearing Needle BearingRelease Bearing Lubed-For-Life, Self-Centering, Full Angular Contact



PAYLOAD/WEIGHT RATINGS

Option/Cargo Worksheet

Option Weight(Front/Total)(lbs.)

ENGINE/TRANSMISSION COMBINATIONS:4.0L (245) SOHC SEFI V-6 with 4x2/4x4 —w/ 5-Spd Automatic OD (U207)

(32/43)

4.0L (245) SOHC SEFI V-6 with 4x2/4x4 —w/ 5-Spd Automatic OD (P207)

(32/43)

Limited Slip Rear Axle (0/4)TIRES/WHEELS:

— P255/70R16 All-Terrain OWL (10/27)— 16x7 Bright Cast Alum. Whls (8/16)

GROUPS:Cloth Comfort Group (Sport Trac) (7/11)Cloth Comfort Group (Sport) (2/4)Leather Comfort Group (Sport Trac) (7/12)Leather Comfort Group (Sport) (4/10)Convenience Group (Sport) (6/12)Convenience group (Sport Trac) (6/8)Premium Sport Group (Sport Trac) 4x2,4x4 (68/113)Premium Sport Group (Sport) - 4x2Premium Sport Group (Sport) - 4x4

(58/86)(68/113)

OPTIONS:Cargo Cage (Sport Trac) (-2/14)Engine Block Heater (1/1)Moonroof - Power (15/32)Radio — AM/FM Premium Stereo/60 WattAmplifier/6-CD Player (Sport Trac)

(1/2)

Radio — AM/FM Premium Audiophile Stereo/290 Watt Amplifier/6-CD Player/Subwoofer(Sport)

(-1/17)

Radio — AM/FM Premium Pioneer UltimateStereo/400 Watt Amplifier/6-CD Player/Subwoofer (Sport Trac)

(13/25)

Tonneau Cover, Hard (Sport Trac) (-4/56)Sub-Total: Front/Total ____/____Sub-Total: From 1st Col. ____/____Line A) Total Actual OptionContent/Weight:

____/____



PAYLOAD/WEIGHT RATINGS

Cargo WorksheetTABLE "A" — MINIMUM CARGO CAPACITY RATINGPassenger Rating Minimum Cargo Capacity Rating(1)

No. Weight (lbs)4 (Sport) 600 1505 (Sport Trac) 750 150(1) In addition to passengers and maximum cargo capacity can be computed below.

MAXIMUM REGULAR PRODUCTION OPTION WEIGHT (LBS.)Model GVWR 4.0L (245) SOHC SEFI V-64x2 — 2 Dr Sport 4760 2314x2 — 4 Dr Sport Trac 5380 2474x4 — 2 Dr Sport 4920 2454x4 — 4 Dr Sport Trac 5560 270

Base Curb WeightsModel Front (lbs.) Rear (lbs.) Total (lbs.)Sport 4x2 — 2 Dr 1998 1771 3769Sport Trac 4x2 — 4 Dr 2240 1851 4091Sport 4x4 — 2 Dr 2145 1818 3963Sport Trac 4x4 — 4 Dr 2410 1900 4310



SPECIAL APPLICATIONSTrailer Towing InformationNOTE: Refer to the TRAILER TOWING SECTION in this book.

Documents

2002 Explorer Sport/Sport Trac