2003 Explorer Sport Trac XLT 4.0L 4WD Build/Maintenance thread

[parker_lansing]

Make/Model/Year​

Ford Explorer Sport Trac XLT 2003

Purchased March 30, 2023.

Reasons I bought this model: 4WD, keypad+remote, power rear window, bed auxiliary power, fold-down rear seats, fiberglass bed, 4 door, lots of space, comfortable interior, overhead compass/temp.

Goal

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I'm basing my vision for this vehicle on a similar model-year (2004-2009) South American (Argentinian) Ford Ranger XLS Double Cab.

Specifications​

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1st generation Sport Trac
XLT Premium package (but cloth seats instead of leather)
Color: Ford Black Ebony (UA) with light grey trim/interior
4.0L V6 gasoline engine
4WD
4.10 Conventional Rear Axle
front and rear disc brakes, ABS
automatic transmission

Premium features
premium audio system
rear audio controls with headphone jacks
Overhead Console (compass/temp display)
Power Driver Seat
Auto On/Off Headlamps
Front Tow Hooks (4x4 only)
Fog Lamps

History​

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Build Date: April 3, 2003. Routine maintenance at dealership since at least 2013.
Single owner from Virginia, until I bought it at 115,000 miles. It had sat on a used car lot for 9 months before I found it on AutoTrader (Freedom Auto Sales). Delivered sight-unseen in April 2023. The engine is super clean but was definitely torn apart at some point.

Maintenance and Repairs
April 2023: Replaced battery, removed factory running boards and front license plate bracket, replaced console mat insert, added cover to console lid
May 2023: Oil/filter change, patched tire
June 2023: Programmed two new OEM keys, fobs
July 2023: Full inspections/repair quotes from two places (Ford dealership, NAPA repair shop)
August 2023: Acquired parts for body/suspension lift and body mounts
September 2023: New front brakes/rotors. Replaced main ground strap (solved intermittent cold start)
October 2023: Replaced front sway bar links and frame bushings
November 2023: Replaced steering gear, outer tie rod ends, upper control arms, lower ball joints. Four wheel alignment. Replaced leaf springs. Bought used passenger side Sport Trac floor mat and NOS Sport Trac 01-05 All-Weather Rear Floor Mats (prairie tan)
December 2023: Replaced shocks with KYB. Replaced plugs, wires, air filter (solved rough idle/lurching after cold start). Replaced belt tensioner and serpentine belt (Continental Elite 4060865), (mostly fixed sluggish steering at low speeds)
January 2024: Replaced body mount bushings (Daystar KF04015BK kevlar/poly). Installed Torch Off-Road Leveling Lift Kit, new torsion adjustment nuts/bolts
February 2024: Krown Automotive rustproofing oil treatment. New wheels/tires: Performance Replicas/PR185/16.0X8/MATTE BLACK (5x), BF Goodrich All-Terrain T/A KO2 31.8"x9.3", Lug nuts (1/2" Thread Bulge Acorn 1.38" Lug Nuts Black 13/16" Hex)
March 2024: Replaced wiper blades with PIAA 97045 SI-Tech
April 2024: rebuild kit for gear selector, replaced turn signal switch, replaced cruise control buttons, touched up paint chips
May 2024: aftermarket kit to correct wheel camber after torsion lift, TSB seatbelt retraction issue, new wiper arms, replaced powered side mirrors, replace mirror adjustment switch, lubed window regulator rails with Fluid Film, replaced antenna mount cap (F65Z-18A927-AA), new spiral noise-reducing antenna, 3" Performance Accessories body lift
June 2024: installed YL1F-18C870-GA head unit (audiophile package with AUX for external CD changer), USA SPEC DF-FORD Adapter, IBR64 Bluetooth audio receiver, installed NOS hitch plate 1L5Z-17D826-AA, replaced broken driver/passenger body/frame ground straps, oil/filter change, tightened body mounts, fixed broken rear diff vent hose, NOS Sport Trac floor mats, AINOPE PD 36W USBC/USB charger
July 2024: Replace engine coolant thermostat housing and manifold gaskets, tinted front windows to match back and rear, replaced windshield
August 2024: Replace ignition switch and starter. Installed new seat belts 3L2Z78611B09AAB, 3L2Z78611B08AAB.
September 2024: Replace missing air intake bolts, extend hose, replace battery clamps.
October 2024: Replaced KYB front shocks with Rancho RS55374 to accommodate lift.

Planned Maintenance, Repairs, and Upgrades
replace firewall grommets
Addco 2612 (633) rear sway bar
LUND SunVisor II Rounded Visor cab visor, Sunvisor II Light Kit
detailing and/or repainting
window visors
Aries grill guard (accommodates tow hooks)
safari rack
replace Roof Molding: (left) 1L2Z-3551728-AAPTM, (right) 1L2Z-3551729-AAPTM
PCV metal upgrade
OEM amp/subwoofer
use CB antenna mount to run GPS, Satellite radio antennas
fix odometer advancing at idle / speed indicator bouncing

Scratched Ideas
- upgrade from 130A (1L2U-AB) to 200A Explorer V8 alternator (no need)
- transmission band adjustment (not needed yet)
- timing belt tensioner maintenance (apparently done by previous owner)
- upgrade front sway bar to Addco 733 (factory is good enough)
- swap in a 2004/05 digital dashboard panel (don't do this, they were problematic)
- swap 4.10 gearing for 4.56 for better mileage (only for 33"+ tires)
- upgrade to aftermarket exhaust (I prefer the quiet factory exhaust)
- replace power steering pump with same model year Explorer V8 (fixes cold weather issues)?
- Muth heated signal mirrors or tow mirror upgrade?

Parts on Hand
- license plate lamps
- Lower Bumper Billet Grille
- transmission oil pan - F69Z-7A194-BA
- bell housing -F7RZ-7976-AA
- door trim panel clips/tools
- 2003 Ford Explorer Sport Trac Shop Manual Set w/Electrical Wiring Diagrams
- 2x rear bumper cover pads 3L2Z-17B807-AAC
- Performance Accessories Gap Guards for 2001-2002 Sport Trac 2WD/4WD
- LUND cab visor, new add-on light package, new screw/cap set
- window visors
- NOS passenger (right) 1L2Z-3551729-AAPTM cab roof molding (Black Ebony)
- OEM Rear Sub Woofer Enclosure/Speaker/Amp

Parts For Sale

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Plus shipping
- F67Z-5B326-FB new driver's side torsion bar (Spring Code 1) ($180)
- F67Z-5B326-FA used passenger side torsion bar (Spring Code 1) ($180)
- 6L5Z-4B329-A (2x) torsion nuts ($24.80)
- -N811015-S101 (4x) Torsion bar isolator bolts for 2WD/4WD ($40)
- -N800442-S436 (2x) Body mount bolts (originally 4-pack, 2 remaining) ($20)
- 3L2T-18C868-BC head unit
- factory external SP-11CDS 10 disc CD changer/wiring harness (no cartridge)
- Manifold hex bolts x4 - W706216S309
- Air intake hex bolts x4 - W500214S437
- PCV hose - 1L5Z6A664FA
Free with shipping:
- radio antenna
- 2x factory front tow hooks
- cruise control buttons (new)
- Sport Trac "roof repair kit" for corner cab trim (black)
- steering wheel replacement leather kit (black) (new)
- 2003 Sport Trac owner's manual set with folio (new)
- passenger side floor mat (used)
- 2x factory windshield wiper arms (used)
- side mirrors (driver side doesn't adjust vertically but otherwise usable)

Up Next

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Planned Work
- replace burned out A/C panel bulbs
- inspect idler pulley and harmonic balancer for play
- replace all O2 sensors
- repair cracked rear bumper cover
- repaint exterior trim to stippled matte dark grey

Parts on Order
- AddCo 2612 (formerly 633) 1" rear sway bar
- fog lights L: 4L2Z15200CA; R: 4L2Z15200BA
- front bumper cover
- rear bumper cover 3L2Z-17K835-AABCP

Parts I'm Looking For
- NOS driver (left) 1L2Z-3551728-AAPTM cab roof molding (Black Ebony)
- Ford Ranger Tow Hooks
- rear bumper cover

 

[DILLARD000]

...2003​

...Sport Trac. ...4.0L V6 ...4WD
...bought it at 115,000 miles ...$7,500 ...on a used car lot for 9 months
...engine compartment is super clean ...looks new
...some hail damage (two small dents
...rear bumper cover is damaged ...hitch being dropped on it
...battery was not keeping a charge, so I replaced
...did an oil change ...filter looked like it hadn't been changed
...ground strap was falling apart, so I replaced
...did front brakes/rotors ...replaced the sway bar links and frame bushings
...removed the running boards
...surface rust at the seam on the interior bottom of the tailgate ...bolt-on points for the running boards
...Control arms and ball joints will be replaced
...Steering gear and outer tie rod ends have play, will have that work done ...along with a 4 wheel alignment
...passenger side window is very slow ...bought some Fluid Film for the track
...mirrors don't adjust in all directions via the toggle ...new toggle switch ...replace it when I have the door panels off
...cruise control buttons are unusable ...bought some aftermarket
...speedometer bounces around at idle ...suspect the instrument cluster
...cab mount insulators are all falling apart ...bought a 3" Performance Accessories body lift kit
...shocks are completely shot
...bought a used LUND SunVisor II Rounded Visor cab visor, and a new Sunvisor II Light Kit
...clear coat on the visor is peeling
...like to have the plastic trim repainted to a much darker shade of grey
...looking at buying some 16" aftermarket wheels ...31.5" BF Goodrich
...like to add an auxiliary input while still having a factory radio ...add a subwoofer and amp
...what lift kit combination will look good/balanced?
...truck has never seen a Michigan winter ...a few options ...Krown Automotive oil mist ...Ziebart undercoating

Welcome to the Herd; lots of friendly knowledgable folk in these forums.

Good looking "new" SportTrac !
2003 is likely the best year for Gen1 SportTracs; early production bugs had been worked out &
last year with pre-HybridElectronicControls\HEC; more reliable & easier to maintain than HEC.

Have a near identical older sibling here, 2001 SportTracJob2
now @260k+ Miles, owned since 2002 @10k Miles:
* Engin=V6~4.0L~SOHC, original
* Trans=5r55e, original
* 4WDTC=1354, original with newer 4x4ShiftMotor+4x4ConModul
* LimitedSlip 4.10 Rear + OpenSlip 4.10 Front Diffs, originals
* Front DiscBrakes + Rear DrumBrakes, 2002+Later has Rear DiscBrakes
Also considering doing a HandStipled FlatBlack repaint of this SportTracs lower body GrayPlastic trim;
did that a year ago to plastic trim on wifes car & it's holding up well.

Sounds like your getting a good start on maintenance\preservation\restoration.
NotoriousFailureItems & personal\preferredl Service Routines+Fixs:
* OilPressuized TimingTensioners; to avoid expensive TimingGuide damage
change Engin Oil+Filter every 4kMiles\6mths & renew these 2 Tensioners every 100kMiles\12Yrs.
* JunkPlastic ThermoStatHousing, replace with Aluminum version.
* JunkPlastic HeaterControlValve, renew every 100kMiles\12Yrs or replace with traditional Metal version.
* CoolantSystem: drain+flush Coolant & renew ThermoStat+RadCap & reverse HeaterHoses every 33kMiles\4yrs; inspect Hoses+Clamps+Radiator+Pump+PlasticFittings, renew as needed.
Consider upgrading JunkPlasticTanked 2Core Radiator to a 3or4Core AllAluminum version.
Consider deleting the PCVValve 5/16"CoolantHose WarmingLoop, a useless source of leaks.
* Renew 6 IgnitionPlugs+Wires & 3 OxygenSensors & PCVValve+HoseElbows every 100kMiles\12yrs.
* 5r55e Trans:
PanDrop+ValveBodyBoltRetorq+NewFilter+NewPanGasket+New5~7qts MerconV every 33kMiles\4yrs,
HandPump 3/4qt@DipTube+1/4qt@SteeringReservoir, fresh 1qt new MerconV every 4kMiles\6Mths.
Inspect the TransCooler Tubing+Hoses+Clamps for Cracks\Leaks.
* 1354 4WDTC:
Drain+Refill ATF every 33kMiles\4yrs, MerconLV.
Excercise ShiftMotor+ConMod once a month, drive a short distance in each mode 4WHi+4WLo.
* Diffs: Drain+Refill GearOIl every 33kMiles\4Yrs.
* Brake service every 50kMiles\6yrs, depending on habits\conditions.
* InstrumentCluster: clean, tighten electrical, renew Bulbs, lube Speedo+OdoMeter, every 100kMiles\12yrs.

Can't help with any recommendation on LiftKits or LargerTires;
Lived at 9kFt elevation for 20+ years; truck does well thru snow+ice on narrow mountain roads,
been full time running for 15+ years 254\70\16 MediumAggressive Mud+Snow Tires;
this notably improved low end torq & snow\ice traction, compared to
original factory 255\70\16 MildlyAgressive AllTerrain Tires. Keep a ToolBox~300Lbs in the bed.
Lifting & larger Tires can look good but may detract from drivability for snow\ice\towing?

Hopefully this helps:
Links to info on above items & more:
https://2001fordexplorersporttrac.fandom.com/Vehicle_Specs+Dimensions+Guideshttps://2001fordexplorersporttrac.fandom.com/Engine_Oilhttps://2001fordexplorersporttrac.fandom.com/Engine_Oil_Pan+Screenhttps://2001fordexplorersporttrac.fandom.com/Engine_Oil_PressureSwitch+Needlehttps://2001fordexplorersporttrac.fandom.com/Engine_Oil_Pressurized_TimingTensionershttps://2001fordexplorersporttrac.fandom.com/Engine_Belt_Serpentine+Tensioner+Idlerhttps://2001fordexplorersporttrac.fandom.com/Engine_Coolanthttps://2001fordexplorersporttrac.fandom.com/Engine_Coolant_Fan+Clutch+Pumphttps://2001fordexplorersporttrac.fandom.com/Engine_Coolant_Radiator+Caphttps://2001fordexplorersporttrac.fandom.com/Engine_Coolant_ThermoStathttps://2001fordexplorersporttrac.fandom.com/Engine_Coolant_HeaterValvehttps://2001fordexplorersporttrac.fandom.com/Engine_AirIntake_Filterhttps://2001fordexplorersporttrac.fandom.com/Engine_AirIntake_MAssFlowSensorhttps://2001fordexplorersporttrac.fandom.com/Engine_AirIntake_Throttlehttps://2001fordexplorersporttrac.fandom.com/Engine_AirIntake_IdleAutoControlValvehttps://2001fordexplorersporttrac.fandom.com/Engine_AirIntake_ExhaustGasRecirchttps://2001fordexplorersporttrac.fandom.com/Engine_AirIntake_PositiveCaseVenthttps://2001fordexplorersporttrac.fandom.com/Engine_AirIntake_Manifoldhttps://2001fordexplorersporttrac.fandom.com/Engine_Exhaust_OxygenSensorshttps://2001fordexplorersporttrac.fandom.com/Engine_Ignition_Plugs+Wires+CoilPackhttps://2001fordexplorersporttrac.fandom.com/Electrical_DashLampshttps://2001fordexplorersporttrac.fandom.com/Electrical_OnBoardDiagnosisPorthttps://2001fordexplorersporttrac.fandom.com/DriveTrain_Transmissionhttps://2001fordexplorersporttrac.fandom.com/DriveTrain_TransferCasehttps://2001fordexplorersporttrac.fandom.com/DriveTrain_Differentialshttps://2001fordexplorersporttrac.fandom.com/Mechanical_Suspensionhttps://2001fordexplorersporttrac.fandom.com/Mechanical_Brakeshttps://2001fordexplorersporttrac.fandom.com/Towing_Accessories

 

[parker_lansing]

Wow, you just answered questions I didn't even know I had! Thank you for all of this information. I was especially concerned about the timing chain issues - I've heard that if one fails it can junk the entire engine. I'll get this other work scheduled as well.

I do have one concern about reversing the heater hoses - if there really is some junk built up, wouldn't reversing the flow force that junk into the engine block? It seems to me that the safe bet (not knowing the history of the maintenance on my vehicle) would be to do the coolant drain/flush and replace the heater core as needed, instead of reversing the hoses.

 

[DILLARD000]

Or back flush the heater core with the hoses off.