02 Explorer Nightmare

[Ranger J.]

Hi Folks,

I'm a former mechanic from various-make dealerships who is starting to get back into the field again after a two-decade hiatus, mainly for the purpose of servicing my own vehicles, because, frankly, I'm a little apprehensive about the apparent lack of diagnostic ability in the staff at my local Ford dealers.

Unfortunately, I've chosen to use a 2002 Explorer (the worst of the worst according to at least one website) to cut my teeth on. What's happening currently is that after I removed the hvac module to replace a mode door that had a broken lever, after getting the dash back together, the four wheel drive module died of natural causes, a diagnosis showed power/ground sources as they should be, and the new module cured the inactive dash selector switch. I think I'm missing the ground connection (G300) on the right A pillar because the instrument cluster goes through the "bulb test" mode and the odometer goes dark when the transmission is shifted into reverse and the "four wheel drive high" cluster indicator flashes ten times periodically. I'll get the ground condition diagnosed, as I more than likely caused it. My problem is that I can't find any information or chart that gives an accurate description of the self diagnostics behind the lamp operation (what code, if any, does the number of flashes indicate?)

My other question is, does anyone know if Ford sells any access to this information, as service manuals as I knew them are a thing of the past?

 

[1Aauto]

Thanks for joining,
Tony:wavey:

 

[Ranger J.]

To continue with my findings on the flashing 4wd lamps, malfunctioning 4wd selector switch and odometer blackout in reverse:

The the 4wd issues were remedied by replacement of both transfer case speed sensors along with the shift motor. During removal of the motor, the grounding eyelet fell off due to a metal fatigue crack in the eyelet itself. It could have been the cause of the loss of 4wd high and the flashing 4wdhigh indicator but I felt justified in replacing high mileage, twelve year old electronic items with shaky reputations, if for no other reasons than peace of mind and not having to navigate the web for specs. Etc. Etc. I did see the pictures that one of the members posted that dealt with shift motor issues, but elected to put this one aside to examine it later.

The selector switch on the left side of the transmission turned out to be the cause of the odometer going dark in reverse. This took some time to ferret out because the odometer was fine without the engine running, and the cluster would go through the bulb check when neutral was selected, as if the ignition key had been cycled off, then back on. These conditions occurred after I R and R'd the transmission, having a shop rebuild it. Condition went away with the switch disconnected. At this point, I got lazy and replaced it which fixed the problem. Getting the thing off the shift shaft required sawing the nut off by slicing it down one side,(heating it is naughty on the tranny). An attempt to wrench it nearly rounded off the flats on the shift arm which I welded and filed back into shape after hunting endlessly for a used one.(Ford wanted $125.00 for their's) The nut is a 14 MM./1.0 TPM on this unit at least, which Ford wants $8.99 plus shipping for and for which you get to wait around over the Christmas/ New Year holiday. Try looking one of THESE up.........on a Saturday afternoon! A web search by an astute local hardware store clerk revealed that BMX bicycles use this type of nut to secure the front wheel axle to the fork. Got the nut from a local bike shop that WASN'T closed for the winter. The odometer and cluster are now fine.

I took a long nap after that episode. Hey I'm 62!

J.R.

 

[fordysenior]

Hi Ranger J. -- I'm new to these forums, and they are very helpful. But I did receive a notice NOT to post tech questions in the "new member introduction" forum as you have done. The notice said they do not answer tech questions in that forum. Unless I'm wrong, you need to find your way to the exact section for your vehicle and post the questions. And by the way, I have a 2002 Explorer with 4.6 eng and four wheel drive with 120k miles on it -- it has been wonderful. I bought used with 26k back in 2004.

 

[Ranger J.]

Thanks Fordysenior, guess I'll move over to the 02-05 Explorer- stock section.
I got this vehicle after a lady crashed it into her mobile home while driving with a full-leg plaster cast on her right side. She'd had it fixed properly and the frame was untouched(the mobile home frame was a MESS) but the body shop boys forgot or couldn't figure out how to refill the non-dipstick transmission and she ran it until the fluid congealed enough to block the filter. I paid $1500 for it and wrung another year out of it by doing a couple of fluid/filter changes. This thing can do no wrong in the looks/fit/function categories but at 133,600 miles it's starting to show its teeth, particularly in fatigued electrical issues. Luckily for me, the body style at least is similar for a number of years hence because I really like the model and already want to upgrade few years. For now I'll continue to beat this one into submission!

 

[fordysenior]

Something to take note of, speaking of electrical issues. And you'll see it written up in the other section, one thread says something like "I'll bet you all have this issue". There is a wiring harness that goes over the oil filter drip bracket, at the backside of it. The wiring harness ends up laying against that bracket and ends up gouging and cutting it's way into the harness. It was happening to me, you might want to check that too.