KnownCarProblems2002 Ford Explorer Problems and Recalls
Owners filed 3,295 complaints with NHTSA about the 2002 Ford Explorer, most often about the transmission (46% of complaints, typically around 80,000 miles). It is the most complained-about Explorer model year since 2000 and has 4 recalls.
Most common 2002 Ford Explorer problems
Transmission
1,502 complaints · 46%Half of these problems showed up before 80,000 miles. Parts named most often: automatic transmission, driveline, axle assembly, transfer case (4-wheel drive).
High pitch whinning noise in rear end of 2002 Ford Explorer. Dealer says rear differential gears have defect and I have to pay $1200. Because warranty expired!
Ford Explorer rear end had high pitch noise: mechanic had to place a new rear end in the vehicle: four wheel drive locked into low gear and would not release: replaced control switch but 4x4 high light blinks.
Body and structure
486 complaints · 15%Half of these problems showed up before 66,500 miles. Parts named most often: body, frame and members.
The rear liftgate window shattered into pieces. Consumer reached to close the window and it moved approx. Six inches when it shattered. Pe04045.pco glass shattered when closing. Will ck. Dob and design version.
The liftgate bracket cracked and the glass shattered. When this occurred driver was standing against the liftgate, and sustained cuts from the pieces of glass. Recall 01i01000 was issued for this component, but this vehicle was not included in the recall due to VIN. Pe04045.pco
Suspension
422 complaints · 13%Half of these problems showed up before 80,000 miles. Parts named most often: rear, front.
On new years eve 2005-2006 the wheel bearing on the driver's rear broke while I had my family with me. The wheel bearing had to be replace. The vehicle is a 2002 Ford Explorer xlt v6 with 80000 mi. On it. No warranty. On 5/21/06 while driving interstate speeds, the passenger rear wheel bearing broke and steering wheel…
Major noise from rear end escalated quickly requiring service. Independent service garage diagnosed and replaced right rear wheel hub assembly and left rear tie rod. This was the third of the four wheel hubs replaced on this vehicle between 70,000 and 86,000 actual odometer miles. The other two were both the fronts.…
Engine
212 complaints · 6%Half of these problems showed up before 89,500 miles. Parts named most often: engine, exhaust system, cooling system.
: the contact stated while driving the vehicle 25-35 MPH, there was a sound like an explosion coming from the engine. The vehicle was towed to a garage where the garage determined a spark plug had blown out. The dealership determined this was a very common problem with these vehicles. The dealership also informed the…
Spark plug blew out of cylinder head while driving under normal conditions, could have caused fire had to replace the cylinder head instead of a tap kit to avoid metal shavings ruining the engine.
Air bags
162 complaints · 5%Half of these problems showed up before 73,500 miles. Parts named most often: frontal, side/window, on-off switch assembly.
There was an accident. Hit another car at about 40 miles an hour and the front drivers and passenger airbags did not deploy. There were two injured. The frame wasn't bent and the engine was okay. What saved the passengers was an add-on bumper guard I had on the front. Truck was towed to a Ford dealership and the…
- the contact owns a 2002 Ford Explorer. The airbag warning light remained illuminated. The dealership informed the contact the driver's front seat pretentioner upgrade harness needed to be replaced. The dealership made the repair. The airbag warning light no longer illuminated. The current mileage was 73,000. Update…
Steering
155 complaints · 5%Half of these problems showed up before 92,000 miles. Parts named most often: column, rack and pinion, hydraulic power assist system, steering wheel/handle bar.
My steering column shifter broke while trying to put the vehicle in park. It was stuck in reverse so I had to take the column apart and figure how to change gears and get my keys out. Found out this has happened to numerous people with this steering column/gear shift. Why make two things that have nothing to do with…
Pulling out of a neighbor's driveway, my shift rod cracked off and dangled, leaving the truck immobile. Nothing had preceded this. Due to towing fees, I contacted a local mechanic who was able to bring it to his shop, a mile away, vs. To Ford, which would have required a $200 flatbed tow. This provider tried for 3…
Speed control
152 complaints · 5%Half of these problems showed up before 65,000 miles. Parts named most often: accelerator pedal, cruise control, cables, linkages.
Repeat failure of brake light switch, cruise control won't disengage when brake pedal depressed ,an unsafe situation. Also intermittent inability to shift out of park and brake lights not operating.
When applying the brakes to disengage the cruise control vehicle would speed more instead of disengaging. Disengaged the cruise control using the hand button. Dealer changed the brake lamp switch.
Electrical
148 complaints · 5%Half of these problems showed up before 93,500 miles. Parts named most often: wiring, ignition, 12v/24v/48v battery, instrument cluster/panel.
On 11/22/2007 my 2002 Ford Explorer burned, it is a total loss. The fire originated inside the center console. Vehicle was running when smoke first appeared, engine was immediately shut off. Flames erupted within 3-5 minutes from the time smoke first appeared.
This 2002 Ford Explorer eddie bauer abruptly stops while driving at any speed without any notice or indication that the ignition will fail to keep the car running. This car has been to two Ford dealerships and one reputable and established independent automotive repair shop. This car was at a toyota dealership for…
Complaints are owner reports to NHTSA, not verified defects. One complaint can name several components, so shares add up to more than 100%.
2002 Ford Explorer recalls
Speed control: vehicle speed control
Risk: A vehicle fire could occur with or without the engine running.
Fix: 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 ABS control module connector and repair as necessary. Repairs will be completed free of charge. The safety recall began on october 27, 2009. Owners may contact ford at 1-888-222-2751.
Full defect summary
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 mountaineer, 1995-1997 and 2001-2003 ranger, and 1994 f53 vehicles equipped with the texas instruments speed control deactivation switch (scds). The scds may leak internally and then overheat, smoke, or burn.
Body and structure: hinge and attachments
Risk: If the hinge should fracture, there is a potential for the glass to fall and ultimately break and personal injuries could occur.
Fix: Dealers will have the liftgate glass strut brackets and glass hinges replaced. For the vehicles built from august 1, 2000 through march 3, 2002, the dealers will replace the hinges and liftgate strut bracket. On vehicles built from march 3, 2002 through june 23, 2003, the dealers will only replace the hinges. The recall began on september 30, 2004. A postcard was sent to owners on december 27, 2004, advising them that parts are now available. Owners should contact ford at 1-800-392-3673.
Full defect summary
On certain sport utility vehicles, the liftgate glass strut may become disengaged or the hinge may fracture allowing the glass to fall and possibly break.
Body and structure: structure
Risk: This overheating condition can cause the running board to melt or cause a fire.
Fix: Dealers will replace the wiring harness on these running boards. Owner notification began march 7, 2003. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact southern comfort at 1-800-745-6096.
Full defect summary
Certain pickup truck, van, and mini van conversions equipped with southern comfort built running boards that contain certain courtesy lights manufactured by american technology components, inc. These units contain a courtesy light or lights that might overheat when the wire harness is exposed to excessive moisture and road salt.
Wheels and tires: sidewall
Risk: Over time, the tire could fail, increasing the risk of a crash.
Fix: Dealers will inspect the tires and, if any slices are found, the cut tires will be replaced. Owner notification began june 7, 2001. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact ford at 1-800-392-3673.
Full defect summary
Vehicle description: sport utility vehicles. The right side tires may have horizontal cuts on the edge of the tread that could have occurred during vehicle assembly.
Recall repairs are free at any franchised dealer. Enter your VIN at nhtsa.gov/recalls to see which recalls are still open on your car.
NHTSA defect investigations
Vehicle rollaway allegations
Summary
This investigation is being closed based on several considerations.by the most inclusive counting of all alleged rollaway incidents (I.e., counting all alleged rollaway incidents and assuming a singular failure mechanism), the incident rate is low, however during ea09-013, odi identified a number of different failure mechanisms in 180 incidents related to the alleged defect.the highest rate for any particular failure mechanism, the failure of the automatic transmission parking system, was 4.4/100k.the next-highest failure rate was for the bsi system, at 3.4/100k.for all identified failure mechanisms there has been a drastically declining trend including very few incidents occurring in recent
Vehicle rollaway allegations
Summary
In response to an information request (ir) letter sent by the office of defects investigation (odi), ford stated consumer reports of higher than expected efforts when shifting into and out of park could be a result of a groove being worn into the swing arm ramp of the steering column. The swing arm is a component bolted to the steering column that assists in shifting through the transmission gears.an engineering evaluation conducted by ford of returned steering columns found the groove could be created over time if consumer shift more quickly from the drive or reverse to park than the brake shift interlock (bsi) solenoid pin retracts after the brake pedal is applied. In november of 2004, for
Spark plug ejection from cylinder head
Summary
On september 6, 2005, odi received a petition requesting that the agency investigate allegations of engine spark plug ejection in certain model year 1997 through 2004 ford vehicles with triton v-8 and v-10 engines.odi received a total of 474 non-duplicative complaints on the subject vehicles where the complainant, or the dealer repairing the vehicle, reported that a spark plug detached from the cylinder and/or ejected from the engine.as of december 8, 2005, odi is not aware of any allegations where the alleged defect resulted in a loss of vehicle control, a crash, an injury, or a fatality in any of the 10,319,810 subject vehicles.in addition, odi is aware of only two incidents where the vehi
Stuck engine throttle
Summary
On july 7, 2005, the office of defects investigation (odi) opened a preliminary evaluation to investigate alleged stuck throttle complaints in certain model year (my) 2002 ford explorer and mercury mountaineer vehicles equipped with the standard available 4.0l sohc v6 engine.at that time, odi was aware of 15 complaints that alleged stuck engine throttle causing unwanted vehicle acceleration and 1 alleged crash as a result.six complainants reported that throttle control cable replacement remedied the alleged stuck throttle condition.additionally, odi was aware of a technical service bulletin issued by the manufacturer that referred to an accelerator cable design change.odi sent a letter to th
Rear liftgate glass assembly
Summary
Complaints report failure of the rear liftgate glass support while the operator is opening or closing the glass.the falling glass can strike the operator or bystander.the injuries reported are bruises to the head, neck or back, cuts to the face, arm or hand.on september 9, 2004, ford notified the agency that it will recall approximately 955,732 my 2002 and 2003 ford explorer and mercury mountaineer vehicles to replace the liftgate glass strut brackets and/or hinges.see NHTSA recall 04v442 for details. This investigation is closed.
Mis-assembled airbag clockspring
Summary
In july 2001, ford issued a special service message announcing that some air bagclockspring devices may produce noise when the steering wheel is turned full left or right.ford was aware that some clocksprings may have been improperly installed.the improper installation may also cause an open circuit and the air bag warning light to illuminate.starting with vehicles produced in september 2001, ford adding length to the clockspring wire to reduce the likelihood of damage from improper installation.odi's investigation revealed 32 comlaints (vehicle built prior to sept. 2001) of warning light but no crashes, injuries, lawsuits or claims.a safety defect has not been identified at this time and fu
Inoperative air bag system
Questions about the 2002 Ford Explorer
- What are the most common problems with the 2002 Ford Explorer?
- By NHTSA owner complaints: transmission (1,502 complaints, typically around 80,000 miles); body and structure (486 complaints, typically around 66,500 miles); suspension (422 complaints, typically around 80,000 miles).
- How many recalls does the 2002 Ford Explorer have?
- 4 recalls listed by NHTSA, the latest from October 13, 2009 (speed control). Check your VIN at nhtsa.gov/recalls to see which ones are still open on your car.
- Is the 2002 a bad year for the Ford Explorer?
- It is the most complained-about Explorer model year since 2000, with 3,295 complaints. Complaint counts are not adjusted for how many cars were sold, so popular years collect more of them, and the newest years have had less time to.