A/C compressorAir filterAlternatorBall jointBatteryBlower motorBrake caliperBrake drumBrake padsBrake rotorParking brake shoesLight bulbClutch kitControl armCooling fanCV axleEngine / transmission mountExhaust / mufflerFuel injectorFuel pump moduleCooling part (generic)Drivetrain part (generic)Engine part (generic)Fuel part (generic)Maintenance item (generic)Sensor (generic)Steering part (generic)HeadlightCoolant hoseIgnition coilOxygen (O2) sensorOil filterRadiatorSerpentine beltSide mirrorSpark plugStarter motorStrut / shock absorberSway bar linkTail lightThermostatTie rod endTiming chainU-jointWater pumpWheel hub & bearingWiper blade
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2002-2005 Ford Explorer
Photo: IFCAR, public domain, cropped, Wikimedia Commons

Ford Explorer 2002–2005 Parts

3rd generation (U152) · 4.0L 6-cyl, 4.6L 8-cyl · RWD / 4WD

  • 70 common parts
  • 3 with factory part numbers
  • 10 recall campaigns
  • 6,227 NHTSA complaints
Price links search Amazon for Ford Explorer 2003. Confirm fitment for your engine and drive.

Engine 6

Cooling 7

Fuel 4

Ignition 4

Brakes 10

Suspension 7

Steering 3

Electrical 5

Exhaust 5

Drivetrain 9

Body & Lighting 5

Filters & Maintenance 5

Icons are generic illustrations made for this site and do not show the exact part. Parts that depend on engine, drive or powertrain are marked using EPA data for this generation; confirm fitment with your VIN before ordering. Factory part numbers are shown as a reference when available; confirm the number with your old part or VIN before ordering. Price links search by part name and vehicle.

About the 2002–2005 Explorer

Overview

The 3rd generation (U152) Ford Explorer covers the 2002–2005 model years in the US. The EPA lists 2 powertrains for this generation: 4.0L 6-cyl (2002–2005) and 4.6L 8-cyl (2002–2005). Drive types: RWD / 4WD. Transmissions: 5-speed automatic, 5-speed manual.

The parts list above covers items commonly replaced on these vehicles, grouped by system.

Engines & specs
EngineYearsDriveTransmissionEPA MPG
4.0L 6-cyl2002–2005RWD / 4WD5-speed automatic, 5-speed manualRWD: 13–15 city / 19–20 hwy / 15–17 comb.
4WD: 13–14 city / 18–19 hwy / 15–16 comb.
4.6L 8-cyl2002–2005RWD / 4WD5-speed automaticRWD: 13 city / 18 hwy / 15 comb.
4WD: 13 city / 17–18 hwy / 14–15 comb.

Flex-fuel (E85) versions are listed by the EPA for 2002–2005. Source: U.S. EPA / DOE fueleconomy.gov vehicle data.

Common problems reported to NHTSA
Mention in complaint2002200320042005
Transmission problems1,009 / 3,295224 / 1,131353 / 1,30465 / 497
Brake problems302 / 3,29594 / 1,131114 / 1,30449 / 497
Steering problems188 / 3,29552 / 1,13161 / 1,30424 / 497
Airbag warning or airbags170 / 3,29555 / 1,13142 / 1,30415 / 497
Stalling or loss of power81 / 3,29546 / 1,13181 / 1,30428 / 497
Check-engine light109 / 3,29547 / 1,13131 / 1,30436 / 497
Suspension noise or failure104 / 3,29529 / 1,13128 / 1,3046 / 497

Owner complaints filed with NHTSA (6,227 for 2002–2005), counted by words in the complaint text. One complaint can mention several issues; the second number is all complaints for those years.

YearRecallsComplaintsTop components in complaints
2002103,295Power Train:Automatic Transmission, Power Train, Suspension:Rear
200371,131Power Train:Automatic Transmission, Structure:Body, Power Train
200441,304Power Train:Automatic Transmission, Structure:Body, Power Train
20053497Structure:Body, Power Train, Power Train:Automatic Transmission

Source: NHTSA (U.S. National Highway Traffic Safety Administration) recalls and complaints data, retrieved November 2026.

Recalls (10 campaigns)
  • Visibility: Glass, Side / Rear (2002, NHTSA 01I010000)
    THIS IS NOT A SAFETY RECALL IN ACCORDANCE WITH THE SAFETY ACT.
  • Tires: Sidewall (2002, NHTSA 01V171000)
    VEHICLE DESCRIPTION: SPORT UTILITY VEHICLES.
  • Structure (2002–2003, NHTSA 03V094000)
    CERTAIN PICKUP TRUCK, VAN, AND MINI VAN CONVERSIONS EQUIPPED WITH SOUTHERN COMFORT BUILT RUNNING BOARDS THAT CONTAIN CERTAIN COURTESY LIGHTS MANUFACTURED BY AMERICAN TECHNOLOGY COMPONENTS, INC.
  • Structure: Body, Hatchback / Liftgate (2002–2003, NHTSA 04V442000)
    ON CERTAIN SPORT UTILITY VEHICLES, THE LIFTGATE GLASS STRUT MAY BECOME DISENGAGED OR THE HINGE MAY FRACTURE ALLOWING THE GLASS TO FALL AND POSSIBLY BREAK.
  • Exterior Lighting (2002–2005, NHTSA 06E026000)
    CERTAIN PRO-A MOTORS CORNER LAMPS, TURN SIGNALS, AND HEADLIGHTS SOLD AS REPLACEMENT LAMPS FOR USE ON CERTAIN PASSENGER VEHICLES LISTED ABOVE.
  • Exterior Lighting (2002–2005, NHTSA 06E049000)
    CERTAIN CK MOTORSPORTS COMBINATION HEADLIGHTS, CLEAR CORNER, BUMPER, AND SIDE MARKER LIGHTS SOLD AS REPLACEMENT LAMPS FOR USE ON THE PASSENGER VEHICLES LISTED ABOVE.
  • Visibility: Glass, Side / Rear (2002–2005, NHTSA 07E104000)
    CERTAIN CURVED TEMPERED REPLACEMENT GLASS MANUFACTURED BY HANGZHOU SAFETY GLASS LTD AND SUPPLIED TO SAFELITE BY AUTO TEMP INC., IDENTIFIED AS DOT-430, AND SOLD FOR USE ON CERTAIN DOMESTIC AND FOREIGN …
  • Exterior Lighting (2002–2003, NHTSA 09E012000)
    SABERSPORT IS RECALLING 16,270 COMBINATION CORNER AND BUMPER LAMP ASSEMBLIES OF VARIOUS PART NUMBERS SOLD FOR USE AS AFTERMARKET EQUIPMENT FOR VARIOUS PASSENGER VEHICLES.
  • Exterior Lighting: Headlights (2002–2004, NHTSA 09E025000)
    DOPE, INC. IS RECALLING 42,540 COMBINATION CORNER AND BUMPER LAMP ASSEMBLIES OF VARIOUS PART NUMBERS SOLD FOR USE AS AFTERMARKET EQUIPMENT FOR VARIOUS PASSENGER VEHICLES.
  • Vehicle Speed Control (2002, NHTSA 09V399000)
    FORD IS RECALLING MODEL YEARS 1995-2003 WINDSTAR, 2000-2003 EXCURSION DIESEL, 1993-1997 AND 1999-2003 F-250 SD THROUGH F-550 SD DIESEL, 1992-2003 E-150 THROUGH E-550, 1995-2002 EXPLORER, 1997 AND 2002…

Source: NHTSA. Check open recalls for your vehicle with its VIN at nhtsa.gov/recalls.