Description
Factory Ford Explorer Workshop Manual (1995-2003)
This is the OEM dealer-level workshop software used by authorized Ford service centers to maintain and repair the second-generation Explorer across all trim levels sold in the US market, from base XL through Eddie Bauer and Limited editions.
Powertrain & Drive Coverage
| Component | Variants Covered |
|---|---|
| Petrol | 4.0L OHV V6, 4.0L SOHC V6 |
| Diesel | N/A |
| Transmissions | 4-speed automatic, 5-speed automatic |
| Drive | RWD, 4WD (shift-on-the-fly and Control Trac) |
| Model Years | 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003 |
| Badge Twins | Mercury Mountaineer (same platform) |
Common Explorer Repairs Covered
| System | Procedures |
|---|---|
| 4.0L SOHC Timing Chain | Timing chain tensioner replacement – a well-documented failure on the 4.0L SOHC; includes full chain, guide, and tensioner R&R procedures |
| Transfer Case | Control Trac 4WD transfer case service, motor replacement, and shift circuit diagnostics |
| Rear Axle | 8.8-inch rear differential seal, bearing, and limited-slip clutch pack service |
| Cooling System | Radiator and overflow tank replacement, thermostat R&R, coolant flush procedures with Ford-specified intervals |
Format & Delivery
Dealer software (NOT a PDF) – this is the same interactive OEM software platform used by Ford-authorized dealerships, featuring clickable wiring diagrams, circuit tracing, and searchable repair procedures. Compatible with Windows XP through Windows 11, plus Mac and Linux. Instant download; lifetime re-downloads.
Frequently Asked Questions
Is the notorious 4.0L SOHC timing chain failure covered in detail?
Yes. The 4.0L SOHC V6 timing chain tensioner and guide failure is one of the most common Explorer issues from this era. The software includes complete step-by-step procedures for replacing the chains, tensioners, and plastic guides on both cylinder banks, along with torque specifications and special tool requirements.
Does this cover the Mercury Mountaineer as well?
The Mercury Mountaineer shares the UN105/UN150 platform and the same powertrains as the Explorer during this generation. Many procedures, torque specs, and electrical diagrams are directly applicable, making this software a strong reference for Mountaineer repairs as well.
Are the 4WD transfer case and Control Trac system fully documented?
Yes. Both the manual-shift 4WD and the electronic Control Trac systems are covered, including transfer case disassembly, encoder motor replacement, vacuum actuator diagnostics, and shift circuit wiring schematics with connector pinouts.
What format is the manual?
This is dealer software, not a PDF. It runs as an interactive application on Windows (XP through 11), Mac, and Linux systems, providing the same diagnostic and repair capabilities used by Ford dealerships – including interactive wiring diagrams, DTC lookup, and component locators.
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