2002 Ford Explorer
Problems, recalls and owner-reported issues
Power train is the leading concern among 3,613 owner complaints filed for this model year. This is the highest complaint count among 26 Explorer model years with reports.
Of the 2002 reports, 163 involved a crash and 71 involved a fire. 213 people were injured and 6 people died.
What owners report most often
Recalls and investigations
Vehicle speed controlOct 13, 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 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.
A VEHICLE FIRE COULD OCCUR WITH OR WITHOUT THE ENGINE RUNNING.
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.
Campaign 09V399000 on NHTSA.gov
Exterior lighting, headlightsMay 11, 2009
DOPE, INC. IS RECALLING 42,540 COMBINATION CORNER AND BUMPER LAMP ASSEMBLIES OF VARIOUS PART NUMBERS SOLD FOR USE AS AFTERMARKET EQUIPMENT FOR VARIOUS PASSENGER VEHICLES. THESE HEADLAMPS FAIL TO CONFORM TO THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 108, "LAMPS, REFLECTIVE DEVICES, AND ASSOCIATED EQUIPMENT." THESE LAMPS DO NOT CONTAIN THE REQUIRED AMBER SIDE REFLECTORS.
DECREASED LIGHTING VISIBILITY MAY RESULT IN A VEHICLE CRASH.
DOPE, INC. WILL NOTIFY OWNERS AND OFFER A FULL REFUND FOR THE NONCOMPLIANT COMBINATION LAMPS. THE SAFETY RECALL BEGAN ON JULY 28, 2009. OWNERS MAY CONTACT DOPE, INC. AT 1-626-272-1798.
Campaign 09E025000 on NHTSA.gov
Exterior lightingApr 7, 2009
SABERSPORT IS RECALLING 16,270 COMBINATION CORNER AND BUMPER LAMP ASSEMBLIES OF VARIOUS PART NUMBERS SOLD FOR USE AS AFTERMARKET EQUIPMENT FOR VARIOUS PASSENGER VEHICLES. THESE HEADLAMPS FAIL TO CONFORM TO THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 108, "LAMPS, REFLECTIVE DEVICES, AND ASSOCIATED EQUIPMENT." THESE LAMPS DO NOT CONTAIN THE REQUIRED AMBER SIDE REFLECTORS.
DECREASED LIGHTING VISIBILITY MAY RESULT IN A VEHICLE CRASH.
SABERSPORT WILL NOTIFY OWNERS AND OFFER A FULL REFUND FOR THE NONCOMPLIANT COMBINATION LAMPS. THE SAFETY RECALL BEGAN ON MAY 11, 2009. OWNERS MAY CONTACT SABERSPORT AT 1-909-598-7589.
Campaign 09E012000 on NHTSA.gov
Visibility, glass, side/rearDec 11, 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 BREAK INTO SMALL PIECES AS EXPECTED OF TEMPERED GLASS AND FAILS TO CONFORM TO FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 205, "GLAZING MATERIALS."
IN THE EVENT OF A VEHICLE CRASH, THE OCCUPANT(S) MAY BE SERIOUSLY INJURED BY SHATTERED GLASS.
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 WHOLESALE CUSTOMERS AND REIMBURSE WHOLESALE CUSTOMERS FOR CURRENT INVENTORY AND AT A SPECIFIED RATE FOR REPLACING THEIR CUSTOMER'S GLASS. WHOLESALE CUSTOMERS CAN CONTACT SAFELITE'S WHOLESALE DIVISION, SERVICE AUTOGLASS TOLL FREE AT 1-888-246-6298. THE RECALL BEGAN ON JANUARY 15, 2008.
Campaign 07E104000 on NHTSA.gov
Exterior lightingMay 24, 2006
CERTAIN CK MOTORSPORTS COMBINATION HEADLIGHTS, CLEAR CORNER, BUMPER, AND SIDE MARKER LIGHTS SOLD AS REPLACEMENT LAMPS FOR USE ON THE PASSENGER VEHICLES LISTED ABOVE. SOME COMBINATION LAMPS THAT ARE NOT EQUIPPED WITH AMBER SIDE REFLECTORS FAIL TO CONFORM TO FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 108, LAMPS, REFLECTIVE DEVICES, AND ASSOCIATED EQUIPMENT.
WITHOUT THE AMBER REFLECTORS, THE VEHICLE WILL BE POORLY ILLUMINATED, POSSIBLY RESULTING IN A VEHICLE CRASH WITHOUT WARNING.
CK MOTORSPORT WILL NOTIFY OWNERS AND REPLACE THE NONCOMPLIANT LAMPS FREE OF CHARGE. THE RECALL BEGAN ON JULY 1, 2006. OWNERS MAY CONTACT CK MOTORSPORT AT 1-909-610-7211.
Campaign 06E049000 on NHTSA.gov
Exterior lightingMar 23, 2006
CERTAIN PRO-A MOTORS CORNER LAMPS, TURN SIGNALS, AND HEADLIGHTS SOLD AS REPLACEMENT LAMPS FOR USE ON CERTAIN PASSENGER VEHICLES LISTED ABOVE. SOME COMBINATION LAMPS THAT ARE NOT EQUIPPED WITH AMBER SIDE REFLECTORS FAIL TO CONFORM TO FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 108, LAMPS, REFLECTIVE DEVICES, AND ASSOCIATED EQUIPMENT.
WITHOUT THE AMBER REFLECTORS, THE VEHICLE WILL BE POORLY ILLUMINATED, POSSIBLY RESULTING IN A VEHICLE CRASH WITHOUT WARNING.
PRO-A MOTORS WILL NOTIFY OWNERS AND OFFER TO REPURCHASE THE LAMPS. THE RECALL BEGAN ON APRIL 3, 2006. OWNERS MAY CONTACT PRO-A MOTORS AT 323-838-2988.
Campaign 06E026000 on NHTSA.gov
Structure, body, hatchback/liftgate, hinge and attachmentsSep 13, 2004
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.
IF THE HINGE SHOULD FRACTURE, THERE IS A POTENTIAL FOR THE GLASS TO FALL AND ULTIMATELY BREAK AND PERSONAL INJURIES COULD OCCUR.
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.
Campaign 04V442000 on NHTSA.gov
StructureMar 7, 2003
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.
THIS OVERHEATING CONDITION CAN CAUSE THE RUNNING BOARD TO MELT OR CAUSE A FIRE.
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.
Campaign 03V094000 on NHTSA.gov
Tires, sidewallMay 24, 2001
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.
OVER TIME, THE TIRE COULD FAIL, INCREASING THE RISK OF A CRASH.
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.
Campaign 01V171000 on NHTSA.gov
Visibility, glass, side/rearApr 10, 2001
THIS IS NOT A SAFETY RECALL IN ACCORDANCE WITH THE SAFETY ACT. HOWEVER, IT IS DEEMED A SAFETY IMPROVEMENT CAMPAIGN BY THE AGENCY. VEHICLE DESCRIPTION: 2002 FORD EXPLORER AND MERCURY MONTAINEER SPORT UTILITY VEHICLES. THE BRACKETS CONNECTING THE LEFT CYLINDERS TO EACH SIDE OF THE LIFTGATE GLASS COULD ROTATE OUT OF POSITION IF EITHER THE URETHANE BOND OR TORQUE ARE NOT SUFFICIENT.
ROTATION OF THE BRACKETS COULD POTENTIALLY CAUSE THE LIFT CYLINDERS TO DETACH FROM THE GLASS OR, IN SOME CASES, COULD POTENTIALLY CAUSE THE LIFTGATE GLASS TO BREAK. EITHER CONDITION IS MOST LIKELY TO OCCUR WHEN THE GLASS IS BEING CLOSED.
FORD DEALERS WILL INSPECT THE VEHICLES FOR THE POSITION OF BOTH THE LEFT AND RIGHT LIFTGATGE GLASS LIFT CYLINDER BRACKETS. IF THE BRACKETS ARE IN THE PROPER POSITION, THE BRACKET RETAINERS WILL BE TIGHTENED TO A HIGHER TORQUE. IN CASES WHERE THE BRACKET IS NOT PROPERLY POSITION, THE BRACKET MUST BE RE-ALIGNED.
Campaign 01I010000 on NHTSA.gov
Representative owner complaints: electrical system
179 reports, newest first. Show all
Electrical system, May 1, 2008
DOOR AJAR LIGHT STAYS ON AND CAUSES DOME LIGHTS TO FLASH ON AND OFF AND CHIME WHILE DRIVING. CAR ALARM GOES OFF RANDOMLY FOR NO APPARENT REASON. HAVE TALK TO FORD THEY TELL ME I NEED TO BRING IT IN WHILE THIS IS ALL HAPPENING SO THEY CAN FIGURE OUT WHAT'S GOING ON. CAR NEVER SEEMS TO DO IT AT A TIME I CAN TAKE IT IN. *TR
Electrical system, Apr 17, 2008
DOOR AJAR LIGHT AND ALARM ARE COMING ON INTERMITTENTLY . ALSO THE ANTI-THEFT ALARM WILL GO OFF FOR NO REASON. *TR
Electrical system, Feb 28, 2008
AT 110,000 MILES BOTH REAR PASSENGER WINDOWS STOPPED WORKING. A TRIP TO THE DEALER SAID BOTH WINDOWS NEEDED NEW CABLES AND IT WOULD COST $1,000. WINDOWS WON'T GO UP OR DOWN. *TR
Suspension, Electrical system, Exterior lighting, Feb 21, 2008, fire
2002 FORD EXPLORER CAUGHT FIRE. CONSUMER STATED THAT THE VEHICLE CAUGHT FIRE WHILE HIS MOTHER WAS VISITING HIS SISTER IN A DIFFERENT STATE. NO ATTEMPT WAS MADE TO REPAIR HER VEHICLE AND RENTAL COST THEM $600.00 OUT OF POCKET. *KB PRIOR TO THE FIRE, THE CONSUMER ASKED THE MECHANIC TO INSPECT THE VEHICLE, BECAUSE WARNING LIGHTS WERE COMING ON AND GOING OFF INTERMITTENTLY. THE CONSUMER HAD A LIST OF DOCUMENTATION RELATING TO ELECTRICAL ISSUES. THE VEHICLE HAD TO GET A JUMP SEVERAL TIMES, THE VEHICLE WOULD HESITATE WHEN FIRST STARTING UP. THE BRAKE LIGHTS WERE STUCK, THE DEALER REPLACED THE BRAKE PEDAL SWITCH. THE CRUISE CONTROL WAS INOPERABLE SO THE DEALER REPLACED THE BRAKE LIGHT SWITCH. THE ALTERNATOR AND WHEEL BEARINGS WERE REPLACED. *JB
Fuel system, Gasoline, Electrical system, Jan 9, 2008
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 ALMOST 30 DAYS AND THIS CAR WAS RETURNED TO ME WITH THIS POTENTIALLY FATAL DEFECT STILL UNDIAGNOSED. NONE OF THE AFOREMENTIONED DEALERSHIPS COULD DETERMINE THE TRUE UNDERLYING PROBLEM. AT THE TOYOTA DEALERSHIP A BRAND NEW STARTER WAS INSTALLED BECAUSE OF A NO START CONDITION SHOWING NO POWER TO THE STARTER AND BLOWN FUSES FOR THE INJECTORS, FUEL PUMP, AND THE COMPUTER. THE SAME DEFECT SHOWED ITSELF ONE DAY LATER AFTER TRAVELING OVER 70 MILES WITH NO SIGN OF FAILURE. *TR
Electrical system, Jan 4, 2008
FORD RECALL#05S28 (SPEED CONTROL DEACTIVATION SWITCH). POSSIBLE UNDERHOOD FIRE IF NOT REPAIRED. NOTIFIED IN AUG. 2007 IT IS NOW JAN. 2008 AND THE CONDITION HAS NOT BEEN CORRECTED. *CN
Electrical system, Nov 26, 2007, fire
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. *TR
Electrical system, Nov 16, 2007
TL*THE CONTACT OWNS A 2002 FORD EXPLORER. THE CONTACT STATED THAT THE VEHICLE ALARM SOUNDS THROUGHOUT THE NIGHT WHILE THE VEHICLE IS PARKED AND SHUT OFF. WHILE DRIVING, THE DOORS LOCK AND UNLOCK, THE CEILING LIGHTS FLICKER ON AND OFF, AND THE DOOR AJAR BUZZER CHIMES INTERMITTENTLY. THE DEALER HAS NOT BEEN NOTIFIED. THE CURRENT MILEAGE WAS APPROXIMATELY 150,000 AND FAILURE MILEAGE WAS APPROXIMATELY 147,0000.
Electrical system, Oct 19, 2007, fire
WAS USING THE 4 WHEEL DRIVE IN WHEN THE ENGINE STARTED SMOKING AND THE ENGINE COMPARTMENT CAUGHT ON FIRE, THEN THE CAB STARTED BURNING AND THEN THE WHOLE CAR CAUGHT ON FIRE AND EXPLODED.
Electrical system, Oct 1, 2007
IN TWO DIFFERENT OCCASIONS I HAD TO JUMP START THE 2002 FOR EXPLORER, I DID A BATTERY LOAD TEST AND IT WAS FINE ALSO CHECK IT WHILE THE VEHICLE WAS RUNNING AND ALL THE READINGS APPEARED CORRECT AND WAS CHARGING OK. *TR
Power train, Electrical system, Visibility, Tires, Sep 17, 2007
AFTER OWNING FOR A WEEK AND A HALF, HAD TO HAVE THE G EARS IN THE REAR END REPLACED. LATER INFORMED THAT THE TIRES WERE NOT EVENLY WORN WHICH WAS CAUSING THE REAR END TO POP. AFTER REPLACING THE TIRES, THE FOUR WHEEL DRIVE WOULD NOT WORK. THE 4 X 4 MODULE AND THE WIRING NEED TO BE REPLACED, COSTING $1000.00. THAT IS NOT INCLUDING THE DRIVER WINDOW SWITCH NEEDING TO BE REPLACED AS WELL AS THE WINDOW REGULATOR. NOW THERE IS AN ELECTRICAL PROBLEM COMING FROM THE DASH. UNABLE TO FIGURE OUT WHAT IT IS YET. *JB
Electrical system, Aug 22, 2007
TL*THE CONTACT OWNS A 2002 FORD EXPLORER SPORT TRAC. THE CONTACT STATED THAT THE SPEEDOMETER DISPLAYS 10 MPH, EVEN IF THE VEHICLE IS TRAVELING AT HIGHER SPEEDS. THE DEALER STATED THAT THE COMPONENTS WERE OPERATING NORMALLY AND THEY MAY BE ABLE TO PLACE A SPEEDOMETER CLUSTER ON THE VEHICLE. THE VEHICLE WAS PURCHASED FROM A PRIVATE PARTY. THE SPEED WAS UNKNOWN. THE CURRENT MILEAGE WAS 99,679 AND THE FAILURE MILEAGE WAS UNKNOWN.
Electrical system, Equipment, May 14, 2007
THE KEY IGNITION SWITCH KEEPS ON GETTING GROUND AND HAD TO DISCONNECT THE BATTERY TO PULL THE KEY OUT OF THE IGNITION SWITCH. THIS WILL BE THE THIRD TIME I HAVE TO REPLACE THE SWITCH. *AK
Electrical system, Apr 15, 2007
RATTLE OR THUMMING SOUND FROM REAR OF INSTRUMENT PANEL SOUNDS LIKE SPEDOMETER CABLE NOT LUBRICATED. SOUND CHANGES IN FREQUENCY AND VOLUME WITH SPEED OF VEHICLE. *AK
Electrical system, Apr 6, 2007
2002 EXPLORER HAS 83,500 MILES. DISCOVERED THAT THE 4X4 SYSTEM WOULD NOT ENGAGE. GANLEY FORD REPLACED THE CONTROL MODULE THAT COMMUNICATES WITH THE 4X4 SYSTEM AT A TOTAL COST OF $577.00. THE PART ALONE WAS $293.00. EXPLANATION AS TO WHY THE BALANCE OF THE LABOR WAS SO HIGH WAS "THE CONTROL MODULE IS DIFFICULT TO REACH UP UNDER THE DASH". WHY IS THAT MY PROBLEM? I HAD ALSO PURCHASED THE GOLD PLAN WARRANTY AND THIS PART WAS NOT COVERED. FORD'S GOLD PLAN IN MY OPINION IS USELESS. I WILL NEVER PURCHASE ANOTHER FORD PRODUCT AGAIN! *AK
Electrical system, Mar 30, 2007, fire
I WAS DRIVING WHEN MY CAR START SMOKING, WHEN I STOPPED IT CAUGHT ON FIRE. THE CAR IS TOTALED. THE FIRE ORIGINATED AT THE ENGINE COMPARTMENT NEAR THE SPARK PLUGS. *JB
Electrical system, Feb 26, 2007
DIGITAL ODOMETER DISPLAY NUMBERS DO NOT LIGHT UP MAKING IT IMPOSSIBLE TO VIEW CUMULATIVE MILEAGE AND USE OF TRIP COMPUTER AND COMPASS DOES NOT WORK. *NM
Suspension, Power train, Electrical system, Feb 7, 2007
I HAVE A 2002 FORD EXPLORER. WHEN IT STARTED TO GET VERY COLD, MY EXPLORER, THAT I JUST BOUGHT, STARTED TO NOT WANT TO GO INTO GEAR. IT WOULD GRIND AND SLIP. THERE WAS A CLICKING SOUND COMING FROM UNDER THE DASH. IT WAS FROM THE COMPUTER THAT RUNS THE 4 WHEEL DRIVE. THE 4 LOW BUTTON WOULD JUST KICK IN BY ITS SELF. THEN IT WOULD NOT GO INTO GEAR. AFTER A WHILE OF TRYING TO GET IT INTO GEAR IT WOULD GO. IT WOULD ONLY ACT UP WHEN IT WAS VERY COLD OUT (10 TO -5 DEGREES) IT DID THIS TO ME FOR ABOUT A WEEK AND THEN IT JUST STUCK INTO 4 LOW AND NOW WON'T COME OUT. THERE WAS A SMELL THIS LAST TIME OF BURNING ELECTRICAL WIRE AND SMOKE. NOW MY EXPLORER WON'T DRIVE AND HAS A ELECTRICAL SMOKE SMELL STUCK IN IT. I NOW HAVE TO HAVE IT TOWED TO A FORD DEALER TO GET IT FIXED. IT ALSO MAKES A REALLY LOUD POPPING SOUND WHEN I GO TO TURN OR HIT A BUMP. SOUND COMES FROM THE FRONT OF THE EXPLORER DRIVERS SIDE. *JB
Electrical system, Feb 4, 2007
VEHICLE IS A 2002 FORD SPORT TRAC WITH APPROX 42K MILES. BEGAN WITH RAPID FLASHING OF LEFT TURN SIGNAL. REAR TURN AND BRAKE LAMP WERE INOPERABLE. REPLACING BULB HAD NO EFFECT. FOUND POSITIONING STEERING COLUMN TO A HIGHER TILT POSITION CORRECTED MALFUNCTION. REMOVED STEERING COLUMN COVER AND FOUND 4 WIRES PULLED OUT OF CONNECTOR ON MULTI-FUNCTION (TURN SIGNAL SWITCH). WIRES MOVE IN AND OUT AS COLUMN IS MOVED THROUGH TILT RANGE. WIRES OUT AT BOTTOM OF TILT AND IN AT TOP OF TILT RANGE. REMOVED CONNECTOR PART # E6DB-14489-DA. 3 CONNECTOR PIN RETAINERS FELL OUT AND WERE RECOVERED. A FOURTH WAS FOUND TO BE IN THE CONNECTOR BUT NOT RETAINING IT'S PIN. CONNECTOR MUST BE REPLACED TO CORRECT PROBLEM. ALSO THE WIRING HARNESS IS SECURED ABOVE THE TILT PIVOT POINT OF THE STEERING COLUMN. I BELIEVE THE HARNESS IS SECURED WITH INSUFFICIENT SLACK TO PREVENT EXCESSIVE STRESS ON THE CONNECTOR AT THE LOWER POSITIONS OF THE STEERING COLUMN TILT RANGE. I BASE THIS ON THE FACT THAT THE 3 PINS WITH BROKEN RETAINERS ARE ON THE TOP ROW OF THE CONNECTOR AND WOULD BE THE MOST STRESSED IN A LOWER POSITION OF THE STEERING WHEEL. ALSO I HAVE OVER 20 YEARS OF AIRCRAFT ELECTRONICS EXPERIENCE AS AN AVIONICS TECHNICIAN AND FULLY UNDERSTAND PROPER WIRE ROUTING PROCEDURES. DIGITAL PICTURES OF THE CONNECTOR ARE AVAILABLE. *JB
Fuel system, Gasoline, Power train, Electrical system, Visibility, Structure, Jan 3, 2007
AT 74000 MILES OUR TRANSMISSION WENT OUT COMPLETELY WHILE WE WERE ON VACATION! THE DEALERSHIP WHERE WE BOUGHT THE VEHICLE, SAID THAT "WE WERE THE ONLY ONE'S WHO HAVE HAD THIS PROBLEM" (YEAH RIGHT!) IT COST US $6000 OUT OF OUR POCKET TO FIX. AT 86000 MILES THE REAR WINDOW CRACKED RIGHT BELOW THE WINDOW. FORD AND THE DEALERSHIP REFUSES TO FIX IT. AGAIN, STAYTON FORD TOLD US THAT,"WE WERE THE ONLY PEOPLE WHO HAVE HAD THIS PARTICULAR ISSUE." AT AROUND 85000, 95000 AND 105000 MILES, THE REAR SEALS LEAKED. WE WERE PROMISED EACH TIME THAT THEY WOULD LAST "FOR AT LEAST 50000 MILES." WE WERE ALWAYS A FEW MILES AWAY FROM GETTING THEM REPLACED FOR FREE SINCE THEY'RE LIMITED WARRANTY IS ONLY GOOD FOR 10000 MILES. AT 111000 MILES THE ELECTRICAL SYSTEM WENT "HAYWIRE." EVEN WHEN ALL OF THE DOOR AND HATCH ARE CLOSED, THE DOME LIGHT CONTINUES TO GO ON AND OFF (MAKING IT HARD TO DRIVE AT NIGHT) BECAUSE IT SENSES THAT A "DOOR IS A JAR." SOMETIMES, THE KEY PAD THAT'S LOCATED ON THE DRIVERS SIDE WINDOW SETS OFF THE ALARM WHEN WE PUSH THE FIRST NUMBER ON THE KEY. TOTALLY UNRELIABLE VEHICLE THAT I'M AFRAID TO DRIVE! *NM
Electrical system, Nov 13, 2006
UPON INSPECTION OF THE WIRING JUST ABOVE THE OIL FILTER DRAIN SHROUD DURING ROUTINE MAINTENANCE THERE WAS A WIRE HARNESS FOUND WITH EXPOSED WIRES. THE THREE WIRES WERE ENCASED IN ONE BUNDLE BUT ARE SUPPOSED TO BE ISOLATED. IT APPEARS THAT THE HARNESS HAS BEEN RUBBING AGAINST THE UPPER EDGE OF THE OIL DRAIN SHROUD SINCE THE VEHICLE WAS BUILT. THIS BUNDLE OF WIRES SHOULD BE CHECKED AND REPAIRED ON ALL 2002 FORD EXPLORERS. THERE IS THE POSSIBILITY OF A FIRE. *NM
Engine and engine cooling, Power train, Electrical system, Nov 6, 2006
DT*: THE CONTACT STATED WHILE ACCELERATING, THE VEHICLE VIBRATED AND A NOISE WAS HEARD. THE VEHICLE WAS TAKEN TO THE DEALER FOUR TIMES WHERE THE TRANSMISSION CONVERTER WAS REPLACED TWICE, HOWEVER THE PROBLEM RECURRED. ALSO, WHILE THE CONTACT WAS CHANGING THE OIL IT WAS NOTICED A WIRE FROM THE BATTERY WAS BARE. THE CONSUMER STATED THE TRANSMISSION IS STILL NOT SHIFTING PROPERLY AND DURING ACCELERATION, THE VEHICLE STILL VIBRATES. UPON INSPECTION THE 02 SENSOR WAS FOUND DAMAGED. THE SENSOR WAS COVERED IN GLUE AND WRAPPED AROUND TO THE TRANSMISSION MOUNT. UPDATED 12/01/06. *JB
Engine and engine cooling, Power train, Electrical system, Tires, Nov 5, 2006
ONGOING SHIFTING AND SLIPPING WITHIN THE TRANSMISSION. ALSO A LOUD SHRILL AT THE END OF THE ACCELERATION. THE TRANSMISSION CONVERTER HAS BEEN REPLACED MULTIPLE TIMES AND THE TRANSMISSION LEAKED OUT FLUID AT HIGHWAY SPEED. AFTER THE REPAIR OF A STRIPPED TRANSMISSION LINE CONNECTOR AND A PILE OF GLUE TO FIX A BROKEN ELECTRICAL CONNECTOR THE VEHICLE WAS RETURNED TO SERVICE BY THE DEALERSHIP AND THE WARRANTY COMPANY. THE CONVERTERS ARE "REMANUFACTURED" WHICH HAVE BEEN KNOWN TO FAIL. THE GLOB OF GLUE ON THE ELECTRICAL CONNECTOR WILL BE REVIEWED BY THE STATE AS TO THE PROPER REPAIR PROCEDURE. A LAW SUIT MAY FOLLOW DUE TO SEPARATE REPAIRS INCLUDING A TIRE WITH A NAIL, WHERE A NEW TIRE WAS PURCHASED AND A USED ON WAS INSTALLED (BF GOODRICH). THE TIRE WAS ALSO NOT BALANCED AND WAS OFF BY 1.5 OZ. THERE WAS ALSO A GASKET REMOVED FROM THE COOLING SYSTEM THAT CAUSED ANTIFREEZE TO SPILL OUT ONTO THE ENGINE. THE COOLING SYSTEM HAD BEEN SERVICED TWO MONTHS PRIOR AND WAS NEVER LEAKING UNTIL THE DAY THE VEHICLE WAS RETURNED. THERE WAS ALSO THE DISCOVERY OF THE POSITIVE ELECTRICAL HARNESS TO THE STARTER HAVING EXPOSED WIRES DUE TO THE OIL FILTER DRAIN HOUSING MADE OF PLASTIC RUBBING AGAINST THE WIRES. THERE ARE THREE WIRES EXPOSED AND THERE MAY BE THE POTENTIAL FOR FIRE. *NM
Electrical system, Oct 17, 2006, fire
EXPERTS DETERMINED THAT THE RIGHT SIDE OF THE LEFT FRONT DRIVERS SEAT SUFFERED AN ELECTRICAL FAULT, RESULTING IN A FIRE WHICH TOTALED THE VEHICLE. HOWEVER, THE INTERIOR CABIN FIRE WAS EXTINGUISHED, PRESERVING THE REMAINDER OF THE SEAT AND ADJACENT CENTER CONSOLE BURN AREA. OCCUPANTS WERE ABLE TO ESCAPE THE VEHICLE AND AVOID PERSONAL INJURY. A YEAR AND A HALF LATER, FORD STILL REFUSES TO ACCEPT RESPONSIBILITY FOR THE MALFUNCTION, AND THE CASE IS IN LITIGATION. *NM
Electrical system, Aug 8, 2006
BOUGHT MY 2002 FORD EXPLORER NEW. AT 90000 MILES, THE MILEAGE GAUGE WENT OUT AND FORD DEALERSHIP TOLD ME IT WOULD COST $600 TO REPAIR. MY LOCAL REPAIR SHOP TOLD ME THAT THIS PROBLEM IS COMMON WITH FORD EXPLORERS AND EXPEDITIONS OF THE SAME YEAR. *NM