A.J.'s 2002 Explorer XLS 5-speed | Ford Explorer Forums

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A.J.'s 2002 Explorer XLS 5-speed

96firephoenix

Well-Known Member
Joined
March 14, 2015
Messages
632
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55
City, State
Indianapolis, IN
Year, Model & Trim Level
2002 Ford Explorer XLT
I just wanted to start this thread for some basic issues/findings about my explorer...

First off: yes, it is a 5-speed manual. Yes I know how uncommon they are.

Second: I've got an issue with the shifter where sometimes it just won't go into gear. If I let off the clutch with the shifter in neutral, it will usually go in. This only happens in 1-2-3 and R, in that order of frequency. Most of the time it feels like there is something in the shifter. I'm thinking maybe a bad synchro, but engine and vehicle speed have little to no bearing on this issue.

Third: I think I may have an aftermarket sunroof. Does anyone know if there was a company doing those? There is a logo on the shade, can't quite read it without cleaning the 13 years of dirty hand gunk first... but the drains are 0% like the ones I've seen in the junkyards as far as fit and finish. they look like something that an idiot put together. It's also possible that it is just a replacement unit for a factory install. there is water damage to the headliner, but no leaks in heavy rain or in a carwash. There's no overhead console though, and all the ones in junkyards have them, and a switch that looks like the window switches. The switch I have is rather plain and doesn't look/feel like something ford made.

I can't really load pictures at the moment... I'm using the wife's laptop, and it doesn't handle much of anything, let alone uploading large jpegs

Repairs I've done so far: Replace rear bumper cover and taillights, replace headlight support and 1x headlight housing, replace RR window motor, brakes & tires all 4 corners (took to a shop)

Repairs it still needs: wheel bearings, parking brake cables, headliner, front bumper cover, paint job, running boards refinish

Modifications in progress: 2" bumper hitch with 7-blade RV plug from mountaineer, 4-flat retained with splices and carefulness; F-150 tow hooks (hooks and bumper hitch pending paint drying); BWM (when I get the wiring sorted for my own way)

Goodies that I want and need help finding: Brush guard that goes through fog lamp holes or the faux fog-lamp-blockoffs on the XLS bumper.

I'm by no means new to wrenching, or Fords, or wrenching on Fords. I've had 2 rangers, an escort and a pontiac firebird that I"ve done lots of work on...

Pictures added from early days of owning...

I've replaced the light housing and the support, but bumper cover is still broken.
11350639_10152829428490264_3649930699520461897_n.jpg


Broken rear bumper and mounty taillights (all the junkyard had):
11168589_10152829428445264_5186227188666690936_n.jpg


Back end after getting some Ex taillights and a bumper cover:
11350832_10152829428685264_5430320914833875318_n.jpg
 



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The first gen sport tracs or Rangers might be able to help more on the tranny issue. I believe the Rangers use the same transmission up to 2011.
 






The first gen sport tracs or Rangers might be able to help more on the tranny issue. I believe the Rangers use the same transmission up to 2011.
Posted over on TRS about this, and someone said to change tranny fluid... The shop I go to said they pulled some fluid out of the tranny, the xfer case and each diff and had it tested and it was ok...

thoughts on that?
 






I'd say they are very thorough! I don't think they do that around here.
 






I'd say they are very thorough! I don't think they do that around here.

I asked them to flush and replace, and they countered with a free inspect and top-off, flush and replace if needed. they save a pain in the ass, I save money.

one of the ford techs over there said it sounds like a slave cyl.... I think that may be the issue, but I'll check my clutch fluid level tomorrow, top off and monitor as needed...

other signs that i noticed tonight also point to a slave cyl issue... a light swooshing when parked in neutral that goes away when I push the clutch down.
 






just hooked up a junkyard remote to it. Trunk button pops the glass!

Life is a lot better now.
 






I just wanted to start this thread for some basic issues/findings about my explorer...

First off: yes, it is a 5-speed manual. Yes I know how uncommon they are.

Second: I've got an issue with the shifter where sometimes it just won't go into gear. If I let off the clutch with the shifter in neutral, it will usually go in. This only happens in 1-2-3 and R, in that order of frequency. Most of the time it feels like there is something in the shifter. I'm thinking maybe a bad synchro, but engine and vehicle speed have little to no bearing on this issue.

Third: I think I may have an aftermarket sunroof. Does anyone know if there was a company doing those? There is a logo on the shade, can't quite read it without cleaning the 13 years of dirty hand gunk first... but the drains are 0% like the ones I've seen in the junkyards as far as fit and finish. they look like something that an idiot put together. It's also possible that it is just a replacement unit for a factory install. there is water damage to the headliner, but no leaks in heavy rain or in a carwash. There's no overhead console though, and all the ones in junkyards have them, and a switch that looks like the window switches. The switch I have is rather plain and doesn't look/feel like something ford made.

I can't really load pictures at the moment... I'm using the wife's laptop, and it doesn't handle much of anything, let alone uploading large jpegs

Repairs I've done so far: Replace rear bumper cover and taillights, replace headlight support and 1x headlight housing, replace RR window motor, brakes & tires all 4 corners (took to a shop)

Repairs it still needs: wheel bearings, parking brake cables, headliner, front bumper cover, paint job, running boards refinish

Modifications in progress: 2" bumper hitch with 7-blade RV plug from mountaineer, 4-flat retained with splices and carefulness; F-150 tow hooks (hooks and bumper hitch pending paint drying); BWM (when I get the wiring sorted for my own way)

Goodies that I want and need help finding: Brush guard that goes through fog lamp holes or the faux fog-lamp-blockoffs on the XLS bumper.

I'm by no means new to wrenching, or Fords, or wrenching on Fords. I've had 2 rangers, an escort and a pontiac firebird that I"ve done lots of work on...

What transmission is it? I have this issue with the T5 in my mustang. I haven't fixed it yet but I have heard trying to change the fluid in the gearbox can fix it and possible synchro issues.
 






What transmission is it? I have this issue with the T5 in my mustang. I haven't fixed it yet but I have heard trying to change the fluid in the gearbox can fix it and possible synchro issues.

Its the Ford Mr55OD (I think) It's not the BW T5... I've got one of those in my 96 firebird, oddly enough.

That seems to be standard response though... I might do it on my own.
 






Just got it back from the shop. Had the parking brake cables replaced, rear wheel bearings replaced, and a broken rear spindle discovered and replaced (casting was cracked bad enough that it couldn't go back on, let alone shouldn't)

This 3-day weekend starts the inside cleaning and standard tune-up (plugs, wires, air, fuel filters, oil change).. I might pull off the running boards and re-paint them... not sure.

Went back and added pics from the first week... Yes, I ran Mounty tails on it for a couple of days.
 






Did plugs and wires/oil change... Found a broken coilspring up front...

If it's not one thing, its always another.
 






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