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 for keyless entry, power rear window, auxiliary power in the bed, folding rear seats, fiberglass bed, 4 door, lots of space, interior is more comfortable than Gen2, compass/temp on overhead console. I would have liked a sun/moonroof, but I'm planning on adding a rack anyway. I also would have preferred leather seats, but after looking at the condition of some other interiors, I reconsidered.

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). I had it delivered sight-unseen in April 2023. The engine compartment is super clean, everything looks new - no cracked hoses, wires, fluid spots, or visible repairs (other than the negative battery terminal being replaced). The body is in excellent condition.

Remaining Issues discovered after delivery
- hood has hail damage, chips in the paint, light scrapes on sides
- surface rust at seam on interior bottom of tailgate, and at bolt-on points for running boards
- warped cab trim pieces
- side mirrors don't respond to the controls in some directions
- passenger side window is slow to roll down
- missing original Sport Trac driver side floor mat

Maintenance and Repairs
April 2023: Replaced battery (wouldn't hold charge). Removed factory running boards and front license plate bracket. Replaced console mat insert, added cover to console lid.
May 2023: Oil/filter change. Patched driver side rear tire.
June 2023: Programmed two additional OEM keys and key 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 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.

Planned Maintenance, Repairs, and Upgrades
upgrade rear sway bar to Addco 633
upgrade front sway bar to Addco 733
install LUND SunVisor II Rounded Visor cab visor, Sunvisor II Light Kit
detailing and/or repainting
install window visors
add Aries grill guard (accommodates tow hooks)
add safari rack
upgrade to aftermarket exhaust
replace Roof Molding: (left) 1L2Z-3551728-AAPTM, (right) 1L2Z-3551729-AAPTM
PCV metal upgrade
add aux input to factory radio, subwoofer, amp
use existing CB antenna mount to run GPS, Satellite radio antennas

Not Sure Yet
- swap 4.10 gearing for 4.56 for better mileage (only for 33"+ tires?)
- Is it possible to swap in a 2005 digital dashboard panel?
- replace power steering pump with same model year Explorer V8 (fixes cold weather issues)
- replace alternator w/Explorer V8 alt?
- replace side mirrors with Muth heated signal mirrors or tow mirror upgrade

Parts on Hand
- door trim panel clips / tools
- mirror adjustment control
- hitch plate 1L5Z-17D826-AA (NOS)
- Performance Accessories 2001-2005 Sport Trac 3" Body Lift Kit # 70023
- Performance Accessories Gap Guards for 2001-2002 Sport Trac 2WD/4WD
- cruise control buttons
- LUND cab visor, new add-on light package, new screw/cap set
- 2003 Ford Explorer Sport Trac Shop Manual Set w/Electrical Wiring Diagrams
- Black Ebony touch-up paint pen
- window visors
- NOS passenger (right) 1L2Z-3551729-AAPTM cab roof molding (Black Ebony)
- OEM Rear Sub Woofer: Enclosure, Speaker, Amp
- factory stereo with external CD changer (missing cartridge)
- IBR64 Bluetooth audio receiver
- Blackberry Music Gateway (bluetooth)

Parts For Sale

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Local pick-up only
- original running boards and bolts (surface rust)
Plus shipping
- F67Z-5B326-FB new driver's side torsion bar (Spring Code 1) ($140.40)
- F67Z-5B326-FA used passenger side torsion bar (Spring Code 1) ($132.55)
- 6L5Z-4B329-A (2x) torsion nuts ($24.80)
- -N811015-S101 (4x) Torsion bar isolator bolts for 2WD/4WD ($32.76)
- -N800442-S436 (2x) Body mount bolts (originally 4-pack, 2 remaining) ($10.09)
- Sport Trac "roof repair kit" for corner cab trim (black) (free)
- steering wheel replacement leather kit (black) (free)
- 2003 Sport Trac owner's manual set with folio (new condition) (free)

Up Next

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Planned Work
- replace burned out bulbs in A/C panel
- use Fluid Film to lubricate/clean window tracks
- replace side view new mirror controls
- tint front windows to match rear
- find a replacement hitch plate
- repair cracked rear bumper cover and missing hitch plate
- repaint plastic trim to stippled matte dark grey
- body lift (3" Performance Accessories body lift)
- fix seatbelt retraction issue
- replace worn cruise control buttons
- inspect wheel bearings, idler pulley and harmonic balancer for play
- troubleshoot odometer advancing at idle and speed indicator bouncing around
- play in gear indicator, can point to P instead of N
- timing belt tensioner maintenance
- replace all O2 sensors
- transmission band adjustment

Parts on Order
- Ford Ranger Tow Hooks
- 2x rear bumper cover pads 3L2Z-17B807-AAC
- 2x windshield wiper arms 6L5Z-17526-A

Parts I'm Looking For
- NOS driver (left) 1L2Z-3551728-AAPTM cab roof molding (Black Ebony)
- NOS passenger (right) F67Z-5B326-FA torsion bar (low priority)
- updated Addco 633 rear sway bar
- rear sway bar links, bushings, brackets for Addco 633 1" sway bar

Things I Need to Check
- check if 130W or 200W alternator
- check part number for Power Steering pump

 

[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.