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: power train
1,575 reports, newest first. Show all
Power train, Dec 22, 2006
MY 2002 FORD EXPLORER HAS A REAR DIFFERENTIAL WHICH HAS WORN OUT. THE VEHICLE BOARDS ONLINE ARE FILLED WITH COMPLAINTS REGARDING THIS PARTICULAR PROBLEM, IF THERE IS ANY RELIEF AVAILABLE BY FORD FOR THIS PROBLEM, I WOULD LIKE TO BE MADE AWARE. *NM
Power train, Dec 16, 2006
02 FORD EXPLORER, REAR DIFFERENTIAL CHATTERS AT LOW RPM/ LOW SPEEDS, HOWLS AT HIGHER SPEEDS. OUT OF WARRANTY, ONLY 4 YEARS OLD. FORD SAID IT WAS HARMONIC VIBRATION, WOULD BE FINE. *NM
Power train, Dec 1, 2006
I HAVE A 2002 FORD EXPLORER. MY COMPLAINT IS HAVING THIS CAR FOR ONLY 2 YEARS AFTER BUYING IT FROM THE RANCHO SANTA MARGARITA FORD DEALER, NOW THE CAR HAS A TRANSMISSION PROBLEM. I HAVE LOOKED UP A LOT OF COMPLAINTS REGARDING THIS PARTICULAR PROBLEM WITH 2002 FORD EXPLORER. AND THEY ALL HAVE THE SAME PROBLEMS AS MINE.. AND WE GET STUCK WITH $4K FOR A NEW TRANSMISSION. I THINK THEY SHOULD HAVE A RECALL ON THIS VEHICLE BECAUSE IT'S A COMMON PROBLEMS WITH THIS PARTICULAR VEHICLE.. CONSUMERS SHOULDN'T BE PAYING $4K FOR A NEW TRANSMISSION AFTER ONLY 4 YEARS HAVING THE VEHICLE..SOME PEOPLE COMPLAINTS EVEN HAPPENS AFTER 2 YEARS BUYING THE VEHICLE. I THINK YOU SHOULD INVESTIGATE THIS PROBLEM AND MAKE SURE FORD COMPANY IS NOT MAKING MONEY FROM CONSUMERS THROUGH REPAIRS OF A NEW TRANSMISSION. *JB
Power train, Nov 30, 2006
PURCHASED VEHICLE FROM CROSSROADS FORD , RALEIGH NC JUNE 24,06 WHILE DRIVING IN TRAFFIC NOV 22,06 CHECK TRANSMISSION APPEARED ON MESSAGE CENTER, ODO LIGHT STARTED FLASHING, CHECK ENGINE LIGHT ILLUMINATED AND VEHICLE WOULD NOT SHIFT GEARS. THE VEHICLE WOULD NOT INCREASE SPEED WHILE ENGINE RPM WERE INCREASING. VEHICLE GAVE NO PRIOR WARNING OF IMPENDING PROBLEM FROM JUN TO NOV AND HAD BEEN DRIVEN LOCALLY FOR THE PERIOD OF OWNERSHIP. TOOK VEHICLE TO THE LOCAL FORD DEALER CLOSE TO MY HOME I WAS INFORMED THAT AFTER DIAGNOSTIC TESTING AND REFERRING TO FORD TSB THE TRANSMISSION NEEDED TO BE REPLACED. CALLED FORD CUSTOMER SERVICE, THEY INFORMED ME THAT IT WAS AN UNFORTUNATE SITUATION, BUT THERE WAS NOTHING THEY COULD DO FOR ME AND TO CALL THE DEALER WHERE I PURCHASED THE VEHICLE. CALLED CROSSROADS FORD AND LEFT A MESSAGE FOR MIKE BEVAN (SERVICE ADVISOR) HE FAILED TO RETURN MY CALLS. MY HUSBAND CALLED MIKE BEVAN AND WAS ABLE TO SPEAK WITH HIM, MIKE INFORMED MY HUSBAND THAT THERE WAS NOTHING THEY COULD DO AND IF WE WOULD BRING THE VEHICLE TO HIM THEY WOULD LET US KNOW THE COST TO REPLACE THE TRANSMISSION. I DID SOME RESEARCH ONLINE AND WAS SURPRISED AT THE LARGE NUMBER OF OWNERS LISTED ON CARREVIEW.COM WITH THE SAME SITUATION. IF THIS HAPPENED ON THE HIGHWAY ANOTHER VEHICLE COULD HAVE REAR ENDED MY VEHICLE CAUSING DAMAGE AND INJURY. *NM
Power train, Nov 29, 2006
I OWN A 2002 FORD EXPLORER XLT. I BOUGHT IT NOVEMBER OF 2004 WITH 40,000 MILES ON IT. IT NOW HAS 80,000 MILES ON IT AND SLIPS WHILE SHIFTING FROM 2ND TO 1ST GEAR AND I ALSO HEAR A WHINING NOISE IN THE REAR END. IT JERKS AND SLIPS CONSISTENTLY. THE OVERDRIVE OFF LIGHT IS FLASHING, AND THE SERVICE ENGINE LIGHT IS ON. THE CAR SAYS "CHECK TRANSMISSION" ON THE INSTRUMENT CLUSTER. I CALLED 4 FORD DEALERS AND WAS TOLD THERE WAS NOTHING THEY COULD DO. THIS IS LOW MILEAGE TO HAVE TO REPLACE THE TRANSMISSION. IT IS A KNOWN PROBLEM FOR THESE CARS, AND FORD DOESN'T CARE. I AM STUCK WITH THE CAR THAT CANNOT BE SAFELY DRIVEN NOW. OWNERS OF THESE CARS NEED HELP TO GET FORD TO ISSUE A RECALL. *JB
Power train, Nov 26, 2006
WITH VEHICLE STOPPED, WHILE SHIFTING GEAR LEVER UNDER STEERING WHEEL FROM DRIVE TO PARK, THE GEAR LEVER BROKE RENDERING THE GEAR LEVER HANDLE USELESS WITH TRANSMISSION BETWEEN PARK AND REVERSE AS INDICATED BY THE INDICATOR. A CAST CYLINDRICAL PART LINKED TO GEAR LEVER BROKE. HAD VEHICLE TOWED TO DEALER TO BE REPAIRED. *NM
Power train, Nov 21, 2006
TRANSMISSION NEEDS REPLACING IN A 2002 FORD EXPLORER, 81,000 MILES. *NM
Power train, Structure, Nov 11, 2006
WELL....HERE IS THE 2ND COMPLAINT THAT I'M FILING ON MY VEHICLE. I PURCHASED MY EXPLORER BRAND NEW WITH ONLY 10 MILES. I THOUGHT I WOULD GET THE BRAKES CHECKED SINCE I HAD 68,000 MILES ONLY TO FIND OUT THE REAR DIFFERENTIAL WAS BAD AND NEEDING REPAIR. FORD DROPPED THE BALL ON THAT!!! NOW I DISCOVERED THAT THE REAR PANEL HAS CRACKED. I WILL NEVER BUY ANOTHER FORD AGAIN!!! THERE NEEDS TO BE A CLASS ACTION LAWSUIT FILED AGAINST THEM!!! *JB
Power train, Nov 10, 2006
11/7/03 AT 20,272 MILES UNIT IN FOR REAR AXLE WHINE DEALER REPLACED THE DRIVE SHAFT BUT REAR AXLE WHINE NOT FIXED. 11/13/04 AT 34269 MILES VEHICLE TAKEN TO DEALER FOR REAR END HOWL AGAIN REPLACED REAR DIFFERENTIAL UNIT. NEXT MORNING WIFE WENT TO TAKE CHILD TO DAY CARE AND VEHICLE WOULD NOT GO OVER 35 MPH WITHOUT RESISTANCE. HAD TOWED TO THE DEALER AND THE WAS TOLD A FAULTY DIFFERENTIAL UNIT. PUT THE OLD ONE BACK IN AND REORDERED ANOTHER REAR DIFFERENTIAL UNIT AND PUT THE NEW UNIT IN ON 11//17/04 AT 34,291 MILES. WHEN THE SERVICE RECORDS STATE FOUND BAD BEARING IN THE UNIT. 6/12/06 REAR END AXLE SEAL LEAKING REPLACED THE REAR END WHINE WAS STILL EVIDENT. 6/12/06 AT 62,31 MILES REAR AXLE SEAL LEAK REPAIRED. 11/09/06 AT APPROX 68,000 MILES TRANSMISSION HAS FAILED. REFERENCE TSB#16898 REAR AXLE WHINE AND TSB#03254. HAVE SEEN A LOT OF COMPLAINTS ABOUT THESE TRANSMISSION FAILURES ON LINE FOR THE 2002 FORD EXPLORER'S. LEADS ME TO BELIEVE THAT THE REAR END WHINING IS BINDING THE TRANSMISSIONS AND CAUSING THEM TO FAIL. ALSO SEE TSB#06216, TSB#18466, TSB#18423. *JB
Suspension, Power train, Nov 9, 2006
A WHINING SOUND COMES FROM THE FRONT END END OF THE VEHICLE, UPON FIRST INSPECTION BY A MECHANIC A BAD TIRE WAS FOUND AND BLAMED ON THE NOISE. AS IT WAS BEARABLE AT HIGHWAY SPEEDS, WE IGNORED IT TRUSTING THE DIAGNOSIS. WE PLANNED ON PURCHASING TIRES SOON AND BELIEVED THE PROBLEM WOULD BE SOLVED. NEW TIRES WERE PURCHASED AND AN ALIGNMENT DONE AND THE SAME SOUND CAME FROM THE FRONT END MOST NOTICEABLY 45-65 MPH. NOW WE ARE TOLD IT IS A WHEEL BEARING AND THE COST FOR THE PARTS ALONE IS $350.00 NOT TO MENTION THE $55/HR. LABOR. WE ALREADY HAD THE REAR END REPLACED FOR NOISE AND NOW WE ARE TOLD THAT A DANGEROUS SITUATION INVOLVING ANOTHER PART OF THE DRIVETRAIN IS LOOMING. THIS IS UNACCEPTABLE AND I WOULD HOPE THAT FORD WOULD ACKNOWLEDGE THE PROBLEM THAT THE VEHICLES HAVE AND REMEDY IT. I HAVE HEARD OF THIS HAPPENING TO VEHICLES WITH FAR LESS THAN MY 65,000 MILES AND THESE PARTS WERE BUILD TO LAST A WHOLE LOT LONGER AS THEY WERE SUPPOSED TO BE SEALED AND MAINTENANCE-FREE, INSTEAD THEY FAIL TOO OFTEN AND COST A FORTUNE. I BELIEVE THIS WILL BE MY LAST FORD PRODUCT IF I DO NOT RECEIVE SOME SORT OF SATISFACTORY RESPONSE FROM FORD. *NM
Power train, Nov 9, 2006
DT*: THE CONTACT STATED WHILE ATTEMPTING TO PUT THE GEAR SHIFTER INTO PARK, THE SHIFTER DETACHED FROM THE COLUMN. THE VEHICLE WAS TOWED TO A DEALERSHIP, WHERE THE GEAR SHIFTER WAS REPLACED.
Power train, Nov 6, 2006
TRANSMISSION OUT. *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
Power train, Nov 3, 2006
MY 2002 FORD EXPLORER XLS, 85,000 MILES, STARTED WITHOUT WARNING TO FLASH THE O/D LIGHT AND THE TRANSMISSION FAILED. *JB
Power train, Nov 1, 2006
I HAVE A 2002 FORD EXPLORER WITH 52,000 MILES ON IT AND THE REAR DIFFERENTIAL IS STARTING TO WHINE VERY LOUD. THE WHINING STARTED AT ABOUT 30K MILES. IT HAS THE 3.73 LIMITED SLIP DIFFERENTIAL. I HAVE TALKED TO OTHER EXPLORER OWNERS AND THEY TOLD ME ABOUT THIS SITE TO FILE A COMPLAINT AS THIS SEEMS TO BE A GROWING PROBLEM
Power train, Oct 27, 2006
2002 FORD EXPLORER - OVERDRIVE LIGHT FLASHING, TRANSMISSION HAS DIFFICULTY SHIFTING. WINDS UP TO EXCESSIVE RPM'S BEFORE SHIFTING. VEHICLE HAS ONLY 57,000 MILES. *NM
Power train, Oct 25, 2006
TRANSMISSION SHIFTS HARD BOTH IN/OUT OF PARK AS WELL AS BETWEEN GEARS. CYLANOID REPLACED TWICE WITHIN 2 YEARS. LOUD WHINE IN REAR ASSEMBLY/AXLE FLUID LEAK. NHTSA RELECTS NUMEROUS COMPLAINTS/SERVICE BULLETINS ON THIS ISSUE.
Power train, Oct 25, 2006
VEHICLE MAKES A WHINNING SOUND FROM THE REAR DRIVE SHAFT WHEN ACCELLARATING OVER 35 MPG.
Power train, Oct 24, 2006
DT*: THE CONTACT STATED WHILE DRIVING 60 MPH ON THE HIGHWAY, THE OVERDRIVE LIGHT ILLUMINATED, AND THE VEHICLE OPERATED AT A REDUCED SPEED. IT WAS DRIVEN TO THE DEALER FOR INSPECTION, WHO DETERMINED THE AUTOMATIC TRANSMISSION NEEDED TO BE REPLACED. AFTER THE REPLACEMENT, THE PROBLEM PERSISTED. THE VEHICLE WAS TAKEN BACK TO THE DEALER WHO DETERMINED THE AUTOMATIC TRANSMISSION NEEDED TO BE REPLACED AGAIN. THE MANUFACTURER WAS ALERTED.
Power train, Oct 23, 2006
I NOTICED A FLUID LEAK FROM THE REAR AXLE OF MY 2002 FORD EXPLORER AND TOOK IT TO THE DEALER FOR DIAGNOSIS. IT TURNED OUT THAT BOTH THE LEFT AND RIGHT REAR AXLE SEALS HAD FAILED. THE VEHICLE HAD ONLY 75K MILES ON IT WHEN THE LEAK BEGAN. I DOUBLE CHECKED THE RECOMMENDED SERVICE SCHEDULE TO SEE IF I HAD MISSED SOMETHING BUT THEY DO NOT RECOMMEND THAT THE REAR AXLE FLUID BE CHANGED UNTIL 150K MILES. SO THIS IS NOT A CASE OF OWNER NEGLECT. AFTER SOME DISCUSSION AT THE DEALER SERVICE CENTER THEY INFORMED ME THAT THIS REPAIR IS FAIRLY COMMON ON EXPLORERS, MOUNTAINEERS AND AVIATORS AND THAT THE REPAIR KIT HAS A NEWLY DESIGNED SEAL. IF THERE IS A NEWLY DESIGNED SEAL AVAILABLE, THIS STRONGLY SUGGESTS THAT THE ORIGINAL SEALS ARE INSUFFICIENT. THIS IS ALSO PROVEN BY THE FACT THAT BOTH SEALS FAILED, NOT JUST ONE. THE COST OF THE REPAIR WAS QUOTED AT $490 ($380 OF WHICH WAS LABOR COST). THIS IS TOO MUCH TO ASK A CONSUMER TO PAY FOR A PART THAT WAS UNDER DESIGNED AND NOT PROPERLY TESTED PRIOR TO BEING PUT INTO PRODUCTION. THEREFORE, I BELIEVE THESE REAR AXLE SEAL PARTS SHOULD BE RECALLED AND THE OEM SHOULD BE FORCED TO REIMBURSE VEHICLE OWNERS FOR REPAIR COSTS. I ALSO NOTICED THAT THERE ARE TSB'S REGARDING EXPLORER, MOUNTAINEER, AND AVIATOR VEHICLES THAT MAY HAVE BEEN FILLED WITH THE WRONG REAR AXLE FLUID AT TIME OF PRODUCTION BUT HAVE NO WAY TO GET MORE INFORMATION ON THIS TO SEE IF MY VEHICLE IS AFFECTED. I WOULD BE INTERESTED IN ANY INFORMATION NHTSA MAY HAVE. *NM
Power train, Oct 19, 2006
VEHICLE O/D LIGHT BEGAN TO FLASH. STOPPED VEHICLE AND TRIED TO GET IT TO GO OFF - WON'T GO OFF. STARTED HOME AND VEHICLE SHIFTED "VERY HARD" INTO 3 OR 4TH GEAR. TOOK TO DEALERSHIP THE NEXT AVAILABLE DAY - TRANS MISSION NEEDS PRESSURE SOLENOID, VALVE BODY AND OTHER PARTS - $2000 WORTH OF REPAIRS. VEHICLE IS 4 YEARS OLD AND HAS 75,000. NOW TAKING TO ANOTHER DEALER TO GET RESOLVED. CALLED FORD - WILL DO NOTHING ABOUT IT. ADVISED THEM OF THE MULTIPLE NTSB COMPLAINTS, SAID WE KNOW NOTHING ABOUT RECURRING PROBLEMS WITH VEHICLE.
Power train, Oct 17, 2006
OVERDRIVE LIGHT FLASHES LEADING TO TRANSMISSION FAILURE ON MY 2002 FORD EXPLORE XLT. *NM
Power train, Oct 10, 2006
2002 FORD EXPLORER - TRANSMISSION WENT OUT AT 63,884 MILES - NO WARNING - JUST WENT OUT. AFTER REVIEWING SO MANY COMPLAINTS ON THE INTERNET IT APPEARS THAT THERE IS A MAJOR DEFECT IN THIS PARTICULAR ENGINE. FORD NEEDS TO DO SOMETHING ABOUT THIS. THIS WILL DEFINITELY BE MY LAST FORD PRODUCT. *NM
Power train, Oct 9, 2006
O/D LIGHT FLICKER. ON RESTART WENT AWAY. DEALER INDICATED THERE WAS INTERNAL TRANSMISSION DAMAGE. TRANSMISSION COULD NOT BE REBUILT NEEDED TO BE REPLACED. WHILE IN SHOP THEY DISCOVERED PROBLEMS WITH THE REAR END AS WELL. CAR HAS 72,000 MILES AND NEEDS TRANSMISSION AND NEW REAR END. I WAS SHOCKED. *JB