Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
2008 Ford Explorer 4WD V6-4.0LFACTORY OEM SERVICE PROCEDURE
Piston, Engine
Piston
Diameter
Coded standard 100.380-100.400 mm (3.952-3.9528 in)
Coded 0.5 100.880-100.900 mm (3.971-3.972 in)
Coded 1.0 101.390-101.400 mm (3.991-3.992 in)
Clearance-to-cylinder bore 0.030-0.050 mm (0.0012-0.002 in)
Ring end gap
Top 0.200-0.450 mm (0.008-0.018 in)
Bottom 0.40-0.60 mm (0.016-0.024 in)
Ring groove width
Top 1.23-1.25 mm (0.0484-0.0492 in)
Bottom 1.52-1.54 mm (0.0598-0.0606 in)
Oil ring 3.01-3.03 mm (0.1185-0.1193 in)
Ring width
Top 1.175-1.190 mm (0.0463-0.0469 in)
Bottom 1.475-1.490 mm (0.0581-0.0587 in)
Ring-to-groove clearance
Top 0.040-0.075 mm (0.0016-0.0030 in)
Bottom 0.030-0.065 mm (0.0012-0.0026 in)
Pin bore diameter 23.958-23.976 mm (0.943-0.944 in)
Piston Pin
Diameter
Red 23.994-23.997 mm (0.9446-0.9448 in)
Blue 23.997-24.000 mm (0.9448-0.9449 in)
Length 72.0-72.8 mm (2.835-2.866 in)
Fit-to-piston 0.01-0.016 mm (0.0004-0.0006 in)
Clearance-to-connecting rod 0.01-0.016 mm (0.0004-0.0006 in)
Diameter
Coded standard 100.380-100.400 mm (3.952-3.9528 in)
Coded 0.5 100.880-100.900 mm (3.971-3.972 in)
Coded 1.0 101.390-101.400 mm (3.991-3.992 in)
Clearance-to-cylinder bore 0.030-0.050 mm (0.0012-0.002 in)
Ring end gap
Top 0.200-0.450 mm (0.008-0.018 in)
Bottom 0.40-0.60 mm (0.016-0.024 in)
Ring groove width
Top 1.23-1.25 mm (0.0484-0.0492 in)
Bottom 1.52-1.54 mm (0.0598-0.0606 in)
Oil ring 3.01-3.03 mm (0.1185-0.1193 in)
Ring width
Top 1.175-1.190 mm (0.0463-0.0469 in)
Bottom 1.475-1.490 mm (0.0581-0.0587 in)
Ring-to-groove clearance
Top 0.040-0.075 mm (0.0016-0.0030 in)
Bottom 0.030-0.065 mm (0.0012-0.0026 in)
Pin bore diameter 23.958-23.976 mm (0.943-0.944 in)
Piston Pin
Diameter
Red 23.994-23.997 mm (0.9446-0.9448 in)
Blue 23.997-24.000 mm (0.9448-0.9449 in)
Length 72.0-72.8 mm (2.835-2.866 in)
Fit-to-piston 0.01-0.016 mm (0.0004-0.0006 in)
Clearance-to-connecting rod 0.01-0.016 mm (0.0004-0.0006 in)
Factory Service Tools
Use the Manual With the Right Hardware
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When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.
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