2002 Ford MUSTANG Workshop Service Repair Manual

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🏷️ Basic Information Identification Make: Ford Model: Mustang Year: 2002 Generation Generation Code: Fourth Generation (SN95) / New Edge Design Codes Platform Code: DEW98 👋 Introduction Market Position Positioning: The 2002 Ford Mustang represented the culmination of the 'New Edge' design phase of the SN95 generation, offering a blend of retro styling cues with modern performance and technology for its era. It was positioned as an accessible American sports coupe and convertible, appealing to a wide range of enthusiasts. Competitive Analysis Competitors: Key competitors included the Chevrolet Camaro, Pontiac Firebird, and to a lesser extent, front-wheel-drive sports coupes like the Honda Prelude and Toyota Celica. The Mustang differentiated itself with its rear-wheel-drive platform and classic V8 muscle car heritage. Key Features Design: Aggressive 'New Edge' styling with sharper lines, revised headlights, taillights, and aerodynamic enhancements. Engine Options: Choice of a fuel-efficient 3.8L V6 or a potent 4.6L V8, with the 'Performance Improvement' (P.I.) version of the 4.6L offering increased horsepower and torque. Performance Variants: Available in standard GT trim (4.6L V8) and the highly desirable SVT Cobra (4.6L supercharged V8). Chassis: Rear-wheel-drive platform with a robust independent front suspension and a solid rear axle, tuned for a balance of handling and ride comfort. Body Styles: Offered in both coupe (Pony) and convertible body styles. 📋 Manual Details Coverage Areas Coverage: Single-year specific OEM repair and service Page Count Estimated Pages: Approximately 2000-2500 (typical for a full workshop manual, actual PDF size may vary) Manual Type Type: Workshop Service Repair Manual Language Language: English Format Format: Digital (PDF) 📖 Manual Coverage Systems Covered Engine Mechanical: V6 (3.8L), V8 (4.6L SOHC & P.I.) - Diagnosis, repair, overhaul, timing, lubrication, cooling, fuel delivery, emission controls Engine Electrical: Ignition system, starting system, charging system, PCM (Powertrain Control Module), sensors, actuators, wiring diagrams Transmission Manual: BorgWarner T-5 (4.6L V8), Tremec TR-3650 (4.6L V8 P.I.) - Diagnosis, repair, overhaul, clutch system, shift linkage Transmission Automatic: 4R70W (V6 & 4.6L V8) - Diagnosis, repair, overhaul, torque converter, valve body, electronic controls Drivetrain: Rear axle, drive shafts, universal joints, half shafts, limited-slip differential (if equipped) Suspension: Front independent (MacPherson strut), rear solid axle, springs, shock absorbers, bushings, alignment specifications Steering: Power steering system, steering column, steering rack/gearbox, tie rods, power steering fluid Brakes: Front disc (ABS available), rear disc, hydraulic system, brake fluid, parking brake, ABS module and sensors Wheels Tires: Wheel specifications, tire size recommendations, lug nut torque, balancing Exhaust System: Exhaust manifolds, catalytic converters, mufflers, pipes, hangers, emissions control components Fuel System: Fuel tank, fuel pump, fuel injectors, fuel lines, fuel pressure regulator, evaporative emissions system Cooling System: Radiator, coolant, thermostat, water pump, cooling fan, hoses, heater core HVAC: Air conditioning system, heater core, blower motor, controls, refrigerant, cabin air filter Electrical Body: Lighting, wipers, horn, power windows, power locks, mirrors, seats, interior trim, exterior trim Body And Frame: Chassis structure, body panels, doors, hood, trunk, bumpers, glass replacement, rust repair Restraints: Airbag system, seat belts, SRS module diagnosis and replacement Diagnostic Tools: OBD-II (On-Board Diagnostics II) information, DTC (Diagnostic Trouble Code) interpretation, scan tool usage Procedures Included Maintenance: Oil change, filter replacement, fluid checks and changes, belt inspection and replacement, spark plug replacement, air filter replacement Repair: Engine component replacement (e.g., alternator, starter, water pump), transmission rebuild/replacement, brake caliper/rotor replacement, suspension component replacement, exhaust system repair Troubleshooting: System diagnosis based on symptoms, electrical circuit tracing, mechanical component failure analysis Installation: Component replacement, accessory installation, sensor replacement Specifications: Torque specifications for all fasteners, fluid capacities, electrical specifications, diagnostic parameters Technical Depth Depth: Comprehensive DIY and Professional Level - Covers basic maintenance to complete engine and transmission overhauls, detailed electrical diagnostics, and bodywork repair. 📊 Manual Specifications File Format Format: PDF File Size Mb: Around 100 MB (as stated, actual size may vary based on PDF optimization) Print Quality Quality: High-resolution, suitable for printing individual pages or sections. Binding Type Binding: N/A (Digital PDF) Paper Type Paper: N/A (Digital PDF) ⚙️ Engine Specifications Primary Engine Engine Code V6: 3.8L 'Essex' OHV V6 (Naturally Aspirated) Engine Displacement V6 Liters: 3.8 Engine Displacement V6 Ci: 232 Engine Bore V6 Mm: 96.8 Engine Stroke V6 Mm: 83.3 Engine Compression Ratio V6: 9.4:1 Engine Horsepower V6 Hp: 190 Engine Torque V6 Lbft: 220 Engine Redline V6 Rpm: 5800 Engine Options Engine Code V8 Gt: 4.6L 'Modular' SOHC V8 (Naturally Aspirated - P.I. upgrade) Engine Displacement V8 Liters: 4.6 Engine Displacement V8 Ci: 281 Engine Bore V8 Mm: 90.2 Engine Stroke V8 Mm: 90.0 Engine Compression Ratio V8 Gt: 9.4:1 (P.I. heads increased this) Engine Horsepower V8 Gt Hp: 260 (with P.I. heads) Engine Torque V8 Gt Lbft: 302 (with P.I. heads) Engine Redline V8 Gt Rpm: 6500 Engine Code V8 Cobra: 4.6L Supercharged 'Inconel' SOHC V8 (Terminator) Engine Horsepower V8 Cobra Hp: 320 Engine Torque V8 Cobra Lbft: 335 Performance Acceleration...

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Description

🏷️ Basic Information

Identification

Make:

Model:

Mustang

Year:

Generation

Generation Code:

Fourth Generation (SN95) / New Edge Design

Codes

Platform Code:

DEW98

👋 Introduction

Market Position

Positioning:

The 2002 Ford Mustang represented the culmination of the 'New Edge' design phase of the SN95 generation, offering a blend of retro styling cues with modern performance and technology for its era. It was positioned as an accessible American sports coupe and convertible, appealing to a wide range of enthusiasts.

Competitive Analysis

Competitors:

Key competitors included the Chevrolet Camaro, Pontiac Firebird, and to a lesser extent, front-wheel-drive sports coupes like the Honda Prelude and Toyota Celica. The Mustang differentiated itself with its rear-wheel-drive platform and classic V8 muscle car heritage.

Key Features

Design:

Aggressive 'New Edge' styling with sharper lines, revised headlights, taillights, and aerodynamic enhancements.

Engine Options:

Choice of a fuel-efficient 3.8L V6 or a potent 4.6L V8, with the 'Performance Improvement' (P.I.) version of the 4.6L offering increased horsepower and torque.

Performance Variants:

Available in standard GT trim (4.6L V8) and the highly desirable SVT Cobra (4.6L supercharged V8).

Chassis:

Rear-wheel-drive platform with a robust independent front suspension and a solid rear axle, tuned for a balance of handling and ride comfort.

Body Styles:

Offered in both coupe (Pony) and convertible body styles.

📋 Manual Details

Coverage Areas

Coverage:

Single-year specific OEM repair and service

Page Count

Estimated Pages:

Approximately 2000-2500 (typical for a full workshop manual, actual PDF size may vary)

Manual Type

Type:

Workshop Service Repair Manual

Language

Language:

English

Format

Format:

Digital (PDF)

📖 Manual Coverage

Systems Covered

Engine Mechanical:

V6 (3.8L), V8 (4.6L SOHC & P.I.) - Diagnosis, repair, overhaul, timing, lubrication, cooling, fuel delivery, emission controls

Engine Electrical:

Ignition system, starting system, charging system, PCM (Powertrain Control Module), sensors, actuators, wiring diagrams

Transmission Manual:

BorgWarner T-5 (4.6L V8), Tremec TR-3650 (4.6L V8 P.I.) - Diagnosis, repair, overhaul, clutch system, shift linkage

Transmission Automatic:

4R70W (V6 & 4.6L V8) - Diagnosis, repair, overhaul, torque converter, valve body, electronic controls

Drivetrain:

Rear axle, drive shafts, universal joints, half shafts, limited-slip differential (if equipped)

Suspension:

Front independent (MacPherson strut), rear solid axle, springs, shock absorbers, bushings, alignment specifications

Steering:

Power steering system, steering column, steering rack/gearbox, tie rods, power steering fluid

Brakes:

Front disc (ABS available), rear disc, hydraulic system, brake fluid, parking brake, ABS module and sensors

Wheels Tires:

Wheel specifications, tire size recommendations, lug nut torque, balancing

Exhaust System:

Exhaust manifolds, catalytic converters, mufflers, pipes, hangers, emissions control components

Fuel System:

Fuel tank, fuel pump, fuel injectors, fuel lines, fuel pressure regulator, evaporative emissions system

Cooling System:

Radiator, coolant, thermostat, water pump, cooling fan, hoses, heater core

HVAC:

Air conditioning system, heater core, blower motor, controls, refrigerant, cabin air filter

Electrical Body:

Lighting, wipers, horn, power windows, power locks, mirrors, seats, interior trim, exterior trim

Body And Frame:

Chassis structure, body panels, doors, hood, trunk, bumpers, glass replacement, rust repair

Restraints:

Airbag system, seat belts, SRS module diagnosis and replacement

Diagnostic Tools:

OBD-II (On-Board Diagnostics II) information, DTC (Diagnostic Trouble Code) interpretation, scan tool usage

Procedures Included

Maintenance:

Oil change, filter replacement, fluid checks and changes, belt inspection and replacement, spark plug replacement, air filter replacement

Repair:

Engine component replacement (e.g., alternator, starter, water pump), transmission rebuild/replacement, brake caliper/rotor replacement, suspension component replacement, exhaust system repair

Troubleshooting:

System diagnosis based on symptoms, electrical circuit tracing, mechanical component failure analysis

Installation:

Component replacement, accessory installation, sensor replacement

Specifications:

Torque specifications for all fasteners, fluid capacities, electrical specifications, diagnostic parameters

Technical Depth

Depth:

Comprehensive DIY and Professional Level - Covers basic maintenance to complete engine and transmission overhauls, detailed electrical diagnostics, and bodywork repair.

📊 Manual Specifications

File Format

Format:

File Size Mb:

Around 100 MB (as stated, actual size may vary based on PDF optimization)

Print Quality

Quality:

High-resolution, suitable for printing individual pages or sections.

Binding Type

Binding:

N/A (Digital PDF)

Paper Type

Paper:

N/A (Digital PDF)

⚙️ Engine Specifications

Primary Engine

Engine Code V6:

3.8L 'Essex' OHV V6 (Naturally Aspirated)

Engine Displacement V6 Liters:

Engine Displacement V6 Ci:

Engine Bore V6 Mm:

Engine Stroke V6 Mm:

Engine Compression Ratio V6:

9.4:1

Engine Horsepower V6 Hp:

Engine Torque V6 Lbft:

Engine Redline V6 Rpm:

Engine Options

Engine Code V8 Gt:

4.6L 'Modular' SOHC V8 (Naturally Aspirated - P.I. upgrade)

Engine Displacement V8 Liters:

Engine Displacement V8 Ci:

Engine Bore V8 Mm:

Engine Stroke V8 Mm:

Engine Compression Ratio V8 Gt:

9.4:1 (P.I. heads increased this)

Engine Horsepower V8 Gt Hp:

260 (with P.I. heads)

Engine Torque V8 Gt Lbft:

302 (with P.I. heads)

Engine Redline V8 Gt Rpm:

Engine Code V8 Cobra:

4.6L Supercharged 'Inconel' SOHC V8 (Terminator)

Engine Horsepower V8 Cobra Hp:

Engine Torque V8 Cobra Lbft:

Performance

Acceleration 0 60 V8 Sec:

Approx. 5.4-6.0 seconds (GT), Approx. 4.8-5.2 seconds (Cobra)

Fuel System

Fuel Type:

Unleaded Gasoline

Fuel Octane Rating:

91+ Octane Recommended for GT/Cobra, 87 Octane Minimum for V6

Fuel Delivery:

Multi-port Electronic Fuel Injection (EFI)

Fuel Pump Type:

In-tank electric

Emissions

Emission Controls:

Catalytic converters, EGR (Exhaust Gas Recirculation), PCV (Positive Crankcase Ventilation), EVAP (Evaporative Emission Control)

🔧 Transmission

Standard

Transmission Std V6:

4-speed Automatic (4R70W)

Transmission Std V8:

5-speed Manual (BorgWarner T-5 for non-P.I. 4.6L, Tremec TR-3650 for P.I. 4.6L)

Optional

Transmission Opt V6:

5-speed Manual (optional on some V6 models)

Transmission Opt V8:

4-speed Automatic (4R70W) available on GT

Transmission Std Cobra:

6-speed Manual (Tremec TR-3650)

Transmission Opt Cobra:

N/A (Manual only for Cobra)

Features

Transmission Fluid Type:

Mercon V Automatic Transmission Fluid (for 4R70W), Manual Transmission Fluid (weight varies by manufacturer, e.g., Synchromesh or 75W-90)

Transmission Fluid Capacity Auto:

Approx. 10.2 quarts (9.6 liters) for 4R70W (dry fill)

Transmission Fluid Capacity Manual:

Approx. 2.3 quarts (2.2 liters) for T-5, 2.8 quarts (2.6 liters) for TR-3650

Clutch System:

Hydraulically actuated dry single-plate clutch (manual transmissions)

📐 Dimensions

Exterior

Length In:

191.0

Width In:

Height In:

53.1 (Coupe), 53.5 (Convertible)

Wheelbase In:

101.3

Front Track In:

Rear Track In:

Ground Clearance In:

Approx. 5.0

Wheel Bolt Pattern:

4x114.3 mm (4 on 4.5 inch)

Wheel Size Standard:

16-inch (V6, base GT), 17-inch (GT Premium, Cobra)

Tire Size Standard V6:

P205/55R16

Tire Size Standard Gt:

P225/55R16 (standard), P245/45ZR17 (optional/performance)

Tire Size Standard Cobra:

P275/40ZR17 (Rear), P245/45ZR17 (Front)

Weights

Curb Weight V6 Coupe Lbs:

Approx. 3200-3300

Curb Weight Gt Coupe Lbs:

Approx. 3350-3450

Curb Weight Cobra Coupe Lbs:

Approx. 3600-3700

Gross Vehicle Weight Rating Gvwr Lbs:

Approx. 4400-4600 (varies by model)

Cargo

Trunk Volume Cu Ft:

Approx. 10.3 (Coupe)

Trunk Volume Cu Ft Convertible:

Approx. 8.7 (Convertible, with top up)

🛡️ Safety Features

Ratings

NHTSA Frontal Driver Rating 2002:

4 out of 5 stars (Good)

NHTSA Frontal Passenger Rating 2002:

4 out of 5 stars (Good)

NHTSA Side Driver Rating 2002:

N/A (Not tested extensively for side impact in this era for this specific model)

IIHS Frontal Offset Rating:

Acceptable (for SN95 platform generally)

Active Features

Anti-lock Braking System (ABS) - Standard on Cobra, optional on GT and V6.

Traction Control:

Traction control system (TCS) available on GT and standard on Cobra.

Limited Slip Differential:

Optional on GT, standard on Cobra (Torsen or Dana differential).

Passive Features

Airbags:

Driver and front passenger airbags.

Seatbelts:

3-point inertia-reel seatbelts with pretensioners.

Anti Theft:

SecuriLock immobilizer system standard on all models.

Fog Lights:

Standard on GT and Cobra, optional on V6.

💡 Technology Features

Infotainment

Audio System:

Factory AM/FM stereo with CD player (single-disc or optional 6-disc changer), cassette player available on some models. Upgraded Mach 460 audio system with amplifier and subwoofer.

Display:

Basic digital clock and radio display. No central touchscreen infotainment system.

Driver Assistance

Cruise Control:

Standard cruise control.

Parking Assistance:

N/A (No factory rear parking sensors or backup cameras).

Connectivity

Connectivity Options:

No Bluetooth or USB connectivity from the factory. Aftermarket solutions are common.

Other Tech

Instrument Cluster:

Analog gauges with tachometer, speedometer, fuel level, and coolant temperature. Oil pressure gauge on GT/Cobra. Warning lights for various systems.

🔧 Maintenance

Service Intervals

Oil Change Interval Miles:

Every 5,000 to 7,500 miles (or 6-12 months), depending on driving conditions and oil type used.

Engine Air Filter Replacement Miles:

Every 15,000 to 30,000 miles, or as needed based on inspection.

Cabin Air Filter Replacement Miles:

Every 15,000 to 20,000 miles, or annually.

Spark Plug Replacement Miles V6:

Approx. 100,000 miles (if using long-life spark plugs, refer to manual for specific type).

Spark Plug Replacement Miles V8:

Approx. 100,000 miles (if using long-life spark plugs, refer to manual for specific type).

Coolant Flush Interval Miles:

Every 30,000 to 50,000 miles (or 3-5 years).

Transmission Fluid Change Auto Miles:

Every 30,000 to 60,000 miles, especially under severe driving conditions.

Transmission Fluid Change Manual Miles:

Every 50,000 to 100,000 miles.

Brake Fluid Flush Miles:

Every 2-3 years, regardless of mileage.

Serpentine Belt Inspection Miles:

Inspect every 15,000 miles, replace as needed or approximately every 60,000-100,000 miles.

Fluid Specifications

Engine Oil Type V6 V8:

SAE 5W-30 API SN or higher

Engine Oil Capacity V6 Quarts:

4.5 (with filter)

Engine Oil Capacity V8 Quarts:

5.0 (with filter)

Coolant Type:

Motorcraft Premium Engine Coolant (Yellow) or equivalent (50/50 mix of antifreeze and distilled water)

Power Steering Fluid Type:

Mercon V or equivalent

Brake Fluid Type:

DOT 3

Known Issues

Common Issues:

Ignition coil pack failure (especially on 4.6L), rear main seal leaks, intake manifold gasket leaks (on some earlier 4.6L versions), fuel pump failures, rear axle seal leaks, sagging rear springs.

Svt Cobra Specific Issues:

Clutch slave cylinder failures, fuel pump upgrades often recommended, potential for intercooler issues on earlier models.

📚 Vehicle History

Brand Heritage

Ford History:

Ford Motor Company, founded by Henry Ford, revolutionized automotive manufacturing with the assembly line and is one of the oldest and largest automotive manufacturers globally.

Model Evolution

Mustang Heritage:

The Mustang, first introduced in 1964, created the 'pony car' class and has been a cultural icon of American automotive design and performance for decades. The 2002 model is part of the SN95 generation, which ran from 1994-2004, with the 'New Edge' redesign occurring in 1999.

Sn95 Generation Context:

The SN95 generation was a significant departure from the Fox-body Mustang, featuring more rounded, aerodynamic styling. The 1999 redesign ('New Edge') sharpened the styling and improved performance, particularly with the introduction of the P.I. heads for the 4.6L V8 and the upgraded SVT Cobra.

Production

Manufacturing Location:

Dearborn, Michigan, USA (Dearborn Assembly Plant) and potentially Flat Rock, Michigan, USA (Romeo Engine Plant for Cobras).

Production Volume 2002:

Approximately 196,170 total Mustangs produced for the 2002 model year.