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2002 Mercury Mountaineer

Factory specifications, fluid capacities, torque values, EPA fuel economy and the federal safety record for the 2002 Mountaineer.

Body SUV

Requiring 5.0 quarts of 5W-30 API engine oil, the 2002 Mercury Mountaineer is an SUV whose mechanical profile is unfortunately defined more by its powertrain failures than its routine upkeep. This model year anchors the very bottom of the Mountaineer's 1996–2010 reliability curve, accumulating 390 total owner complaints—predominantly in the Power Train category—alongside four separate recalls. Compared to the model's lowest complaint year of just three issues in 1996, the 2002 iteration represents the most problematic chapter in the vehicle's history, meaning researchers must weigh its significant powertrain vulnerabilities heavily when evaluating this specific model year.

Model year2010 2009 2008 2007 2006 2005 2004 2003 2002

Quick specs

Fluid capacities, tune-up values and fuel economy at a glance.

Engine oil capacity5.0 qtOEM · verified

Engine oil type5W-30 APIOEM · verified

Lug nut torque100 ft-lbsOEM · verified

Fitment & sizes

Replacement part sizes and factory part numbers — battery, bulbs, filters and belts.

From the factory this vehicle uses a BCI 65 · 650 CCA battery. Each part links to every other vehicle that shares it, so a part you already stock may fit more of your fleet than you'd expect.

Battery groupBCI 65 · 650 CCAOEM · verified

Tire sizeP245-70R16OEM · verified

Wheel / rim7 inOEM · verified

Service quick specs OEM factory data

Capacities, torques and tune-up values from the factory service manual.

This engine holds 5.0 qt of 5W-30 API engine oil, SYNTHETIC · 75W-140 · GL-5 in the differential, DOT 3 brake fluid. Torque lug nuts to 100 ft-lbs, the oil drain plug to 19.0 ft-lbs. The firing order is 1-3-7-2-6-5-4-8. Note the cylinder-head bolts finish on a torque angle (torque-to-yield) — they stretch permanently and should be replaced, not reused, during any head service.

Lubricants & capacities

Brake Fluid	DOT 3
Differential Gear Oil	SYNTHETIC · 75W-140 · GL-5
Differential Gear Oil Capacity	3.6 Pints Rear
Engine Oil	5W-30 · API
Engine Oil Capacity	5.0 qt
Engine Oil	5W-20 · API
Engine Oil Capacity	6.0 qt
Power Steering Fluid	ATF

Engine torques

Camshaft Bearing/Carrier Cap Bolts or Studs	11-12 ft-lbs
Intake Manifold to Engine Bolts	7.4 ft-lbs
Exhaust Manifold to Cylinder Head Bolts	16.0 ft-lbs
Intake Manifold to Engine Bolts	18.0 ft-lbs
Exhaust Manifold to Cylinder Head Bolts	15.0 ft-lbs
Main Bearings	67-74 ft-lbs
Engine Oil Pan Drain Plug	17.0-22.0 ft-lbs
Engine Oil Pan Drain Plug	19.0 ft-lbs

Chassis torques

Lug Nuts	100 ft-lbs
Transfer Case Fill Plug	4WD: 18.0, With AWD: 13.0 ft-lbs
Transfer Case Drain Plug	4WD: 18.0, With AWD: 13.0 ft-lbs
Rear Wheel Hub	203 ft-lbs
Front Wheel Hub	184 ft-lbs
Rear Wheel Hub	203 ft-lbs

Ignition

Cylinder Firing Order	1-4-2-5-3-6
Cylinder Firing Order	1-3-7-2-6-5-4-8
Curb Idle Speed (No Load)	MT: 850, AT: 710 rpm
Curb Idle Speed Variance (No Load)	MT: 50, AT: 40 rpm
Curb Idle Speed (No Load)	890 rpm
Spark Plug Manufacturer	Motorcraft
Spark Plug Gap	0.052-0.056 in
Spark Plug Torque	13.0 ft-lbs

Battery & A/C

Refrigerant	R134a
Refrigerant Capacity	Less auxiliary A/C, 1.88. With auxiliary A/C, 3.50. lbs
Oil Group	PAG
Oil Type	68
Oil Capacity	Less auxiliary A/C, 9.00. With auxiliary A/C, 13.00. oz
Standard BCI Group Number	65
Standard BCI Cranking Performance	650 cca
Standard BCI Group Number	65

Service checks

Pressure Test	13-18 psi
Radiator Cap Pressure Relief	13-18 psi
Thermostat Opening Temperature	183-190 °F
Key ON Engine OFF (KOEO)	30-45
Engine Oil Pressure	40-60 psi
Engine Oil Pressure RPM	2000 rpm
Engine Oil Pressure	20-45 psi
Engine Oil Pressure RPM	1500 rpm

Brakes

Brake Application	WITH REAR DISC / WITH STANDARD
Torque Caliper to Bracket	20 ft-lbs / 21-26 ft-lbs
Torque to Knuckle	80 ft-lbs / 73-97 ft-lbs
Minimum Pad Thickness	Front: 0.118; Rear: 0.118 in
Brake Application	WITH REAR DISC / WITH STANDARD
Rotor Max Parallel Variation	0.0002 in
Rotor Runout Limit	0.005 in
Rotor Discard at or Under	0.433 in / 0.965 in

Multi-step torque procedures OEM · verified

Connecting Rod (Large End) Bearings — tightening sequence 1 stages

15 ft. lbs., Step 2: 90

15 ft. lbs

Cylinder Head — tightening sequence 3 stages

Prep Do not reuse old bolts. Coat bolt threads with clean engine oil.

1	26.0 ft. lbs.	26 ft. lbs
2	90 degrees	90 degrees
3	90 degrees	90 degrees

Engine Flywheel Bolts — tightening sequence 1 stages

10 ft. lbs., Step 2: 52

10 ft. lbs

Factory maintenance schedule OEM · verified

Normal service, condensed from the factory interval matrix.

Under the factory schedule, replace the engine oil and filter every 5,000 mi; spark plugs every 100,000 mi; coolant every 50,000 mi. The big-interval services (every 50,000 mi for coolant, and the transmission fluid) are the ones owners most often skip — on a lower-mileage example, assume the original fluids are still in it and check them first.

Every 5,000 mi	Engine Oil (drain & refill) · Engine Oil Filter (replace) · Tire & Wheel Assembly (rotate)
Every 15,000 mi	Brake System (inspect) · Cabin Air Filter (replace) · Engine Coolant System (leak inspection) · Steering Linkage (inspect) · Suspension Ball Joint (inspect) · Suspension System (inspect)
Every 30,000 mi	Engine Air Filter Element (replace) · Exhaust System Heat Shield (inspect) · Fuel Filter (replace)
Every 50,000 mi	Engine Coolant System (drain, flush & refill)
At 100,000 mi	Engine Coolant System (drain, flush & refill)
Every 100,000 mi	Accessory Drive Belt (inspect) · PCV Valve (replace) · Spark Plugs (replace)
At 150,000 mi	Drive Axle Assembly (drain & refill) · Drive Belt (replace) · Wheel Bearing (replace)

Reliability & federal safety record

Owner-reported issues, recalls, investigations and service bulletins on record with NHTSA — an unfiltered look at what owners actually experience.

The 2002 Mercury Mountaineer generated 390 federal complaints, the highest single-year total across the entire 1996–2010 dataset and a dramatic increase from the 22 recorded for 2001. Although its four recalls match the 2001 count and remain below the nine seen in 1999, the 2002 model drew five investigations and 247 technical service bulletins, indicating elevated service activity without a proportional recall response. Complaint volume then falls to 152 in 2003 and generally moderates through the remainder of the decade, confirming 2002 as a pronounced outlier rather than the start of sustained high-volume reporting. Power Train led 2002 filings with 111 complaints, followed by Structure at 46, Engine & Engine Cooling at 28, and Suspension at 24, while the year also produced 17 crash and 7 fire complaints; the federal data does not specify root causes for these patterns. Because 2002 sits at the apex of the generation’s complaint curve with substantially higher owner-reported issues than the years immediately before and after it, this is not a favorable model year to purchase.

Open recalls

NHTSA campaigns

247

Service bulletins

Manufacturer communications

ODI investigations

Office of Defects Investigation

390

Owner complaints

17 involved a crash · 7 a fire

NHTSA crash-test rating federal NCAP · out of 5 stars

Rollover★★★★★

Owner complaints by model year NHTSA · this generation & adjacent

’96 ’97 ’98 ’99 ’00 ’01’02’03 ’04 ’05 ’06 ’07 ’08 ’09 ’10

Owner complaints filed with NHTSA, by component

All 390 complaints on record, top 8 components.

Power Train111

Structure46

Engine & Engine Cooling28

Suspension24

Visibility20

Air Bags17

Steering11

Vehicle Speed Control9

Source: NHTSA Office of Defects Investigation complaint database.

Recalls NHTSA · verified

Showing 2 of 4 campaigns on record for this vehicle.

07E104000Visibility:Glass, Side/RearReported 11/12/2007

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 VEHICLES MAY NOT… Remedy: SAFELITE WILL NOTIFY ITS RETAIL CUSTOMERS AND REPLACE THE GLASS FREE OF CHARGE. RETAIL CUSTOMERS CAN CONTACT SAFELITE TOLL FREE AT 1-888-843-2906. SAFELITE WILL NOTIFY ITS…

09V399000Vehicle Speed ControlReported 13/10/2009

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 MERCURY… Remedy: FORD WILL NOTIFY OWNERS THAT DEALERS WILL INSTALL A FUSED WIRING HARNESS IN LINE WITH THE SCDS. ON 1999-2003 WINDSTAR VEHICLES WITH A LEAKING SCDS, DEALERS WILL ALSO INSPECT THE…

Technical service bulletins NHTSA · verified

Showing 5 of 247 bulletins on record with NHTSA.

Bulletin	Date	Component	Summary
TSB 19-2026	2019-02-07	Structure	Some 2000 and newer Ford, Lincoln and Mercury vehicles equipped with aluminum body panels…
TSB 19-2026	2019-02-07	Structure	Some 2000 and newer Ford, Lincoln and Mercury vehicles equipped with aluminum body panels…
TSB-08-19-3	2009-05-01	Power Train	FORD: SOME VEHICLES MAY EXHIBIT OIL SEPARATION FROM THE INTERNAL LUBE FOUND IN THE…
07212	2007-10-01	Engine And Engine Cooling	SOME 1997-2008 VEHICLES EQUIPPED WITH A 4.6L 2V, 5.4L 2V, OR 6.8L 2V ENGINE--SPARK PLUG…
06216	2006-01-01	Power Train	LIMITED SLIP AXLE CHATTER, SHUDDER, BINDING SENSATION, OR VIBRATION DURING LOW SPEED…

Common OBD-II trouble codes

The most common OBD-II codes for this vehicle's emissions system. These are standardized SAE J2012 definitions, not vehicle-specific fault reports.

P0420

Catalyst system efficiency below threshold — Bank 1

P0300

Random / multiple cylinder misfire detected

P0171

System too lean — Bank 1

P0455

Evaporative emission system leak detected — large leak

P0128

Coolant thermostat below regulating temperature

P0442

Evaporative emission system leak detected — small leak

VIN tools

Decode factory build data for a specific vehicle by VIN.

VIN

Decode a VIN to confirm the transmission and build data for a specific Mountaineer. OEM

Build data

Plant, GVWR class, engine and body data for any 17-character VIN.

Recalls

Check open recall campaigns against a specific vehicle by VIN.

Vehicles with shared specs

Find every vehicle that shares this one's battery, bulbs, oil capacity, platform or parts.

Group 65 battery Vehicles taking 5.0 qt

Reference guides

Cross-vehicle references for the kinds of data on this page.

Vehicle recalls & TSBs OBD-II trouble codes Torque specifications Maintenance schedules Fluid capacities & specs

Frequently asked

How much oil does the 2002 Mountaineer take?

5.0 qt of 5W-30 API, per the factory manual.

Does the 2002 Mountaineer have open recalls?

NHTSA lists 4 recall campaign(s) for this model year. Check your specific vehicle by VIN.