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
Engine and engine cooling, Power train, Air bags, Aug 10, 2005
APRIL 04 PURCHASED 2002 FORD EXPLORER; JUST OVER 60,000 MILES. NO LONGER UNDER WARRANTY;SOLD AS IS. DAY AFTER PURCHASE, NOTICED KNOCKING SOUND. RETURNED TO DEALER. STATED SOUND COMING FROM THE REAR AC. REPAIRED, DID NOT HEAR AFTER REPAIR. APPROXIMATELY ONE WEEK AFTER PURCHASE, NOTICED DELAY IN GEARS ENGAGING WHEN GOING FROM PARK TO DRIVE , PARK TO REVERSE ALSO GEAR SHIFT SEEMED TO BE LOOSE. RETURNED TO DEALER; TOLD IT WAS NORMAL FOR THIS MODEL. ADVISED TO KEEP IN OVERDRIVE. LATE JULY 2004, NOTICED DELAY SEEM TO BE GETTING LONGER AND JERKING SUDDENLY WHEN FINALLY ENGAGED. WHILE DRIVING ,OD LIGHT FLASHED ON AND OFF ERRATICALLY. PROBLEM WITH OD LIGHT INTERMITTENT. SPOUSE TOOK THE CAR TO THE DEALER; TOLD THAT IT WASN'T UNDER WARRANTY, BUT WE COULD MAKE A SERVICE APPOINTMENT. SPOUSE TOOK THE VEHICLE TO A SHOP HAD DONE BUSINESS IN THE PAST. THOUGHT THAT IT COULD NEED TRANSMISSION FLUID. CHECKED FLUID LEVELS NOT DEFICIENT. PROBLEMS CONTINUED; HAD THEM LOOK AT IT A COUPLE OF MONTHS LATER. COULD NOT DETERMINE PROBLEM, ADVISED TO TAKE TO A TRANSMISSION SPECIALIST IF CONTINUED. PROBLEM PERSISTED. SEEMED TO GET WORSE AS THE WEATHER TURNED COLDER. LATE DECEMBER 04, DELAYS IN ENGAGING GEARS WORSENED; NOW MAKING A LOUD CLUNKING NOISE AND LUNGES WHEN ENGAGES, OD LIGHT FLASHED ERRATICALLY ON A FREQUENT BASIS AND ENGINE SERVICE LIGHT ON AND GEAR SHIFT SEEMED TO BE COMING OUT. JANUARY 2005, SPOUSE TOOK THE VEHICLE TO A TRANSMISSION SHOP FOR DIAGNOSTIC. TRANSMISSION SHOT. REBUILT AT A COST OF $2900. FOUND OUT THAT THE VEHICLE HAD BEEN REPAIRED TWICE BEFORE, WHILE UNDER WARRANTY FOR THE SAME PROBLEMS DESCRIBED. ITS OBVIOUS FROM THE NUMBER OF COMPLAINTS THAT THIS IS A KNOWN DESIGN DEFECT. WHEN A COMPANY SELLS DEFECTIVE PRODUCTS THEY SHOULD BE HELD LIABLE, ESPECIALLY WHEN THEY DO SO KNOWINGLY. I STOPPED MAKING PAYMENTS ON THIS JUNK AND WILL NOTIFY THE LENDER SO THAT THEY AND FORD CAN FIGHT IT OUT. ANY OWNER WHO WISHES MAY CONTACT ME AT 703-998-5510. *JB
Power train, Aug 9, 2005
I HAVE RECEIVED ONLY ONE RECALL NOTICE ON MY 2002 FORD EXPLORER RELATING TO PROBLEMS WITH THE TAILGATE WINDOW. TONIGHT, AFTER EXPERIENCING PROBLEMS THAT CAUSED THE AUTOMATIC TRANSMISSION TO JUMP TO A HIGHER RATE OF A MARKEDLY HIGHER RATE OF REVOLUTION, I WAS INFORMED BY THE DEALERSHIP THAT I HAD TRANSMISSION PROBLEMS. THESE PROBLEMS COST OVER $815 TO REPAIR. THE DEALERSHIP ALSO HAD TO REPLACE A SOLENOID SWITCH ON TWO DIFFERENT OCCASIONS IN THE AUTOMATIC TRANSMISSION. I QUICKLY LOOKED AT THE VEHICLE RECALL DATABASE TO SEE IF OTHERS HAD EXPERIENCED THE PROBLEMS I EXPERIENCED. I WAS SURPRISED TO SEE A LARGE NUMBER OF RECALLS THAT I FAILED TO RECEIVE ANY NOTIFICATION FOR. I AM FILING THIS TO REQUEST: (I) FORD TO REQUIRE DEALERSHIPS TO NOTIFY CONSUMERS PERSONALLY IN WRITING OF RECALLS...IF NHTSA OR THE MANUFACTURER DEEMS AN ISSUE IMPORTANT ENOUGH TO ISSUE A RECALL NOTICE, SHOULDN'T THE DEALER BE REQUIRED TO DELIVER WRITTEN NOTIFICATION TO THE CONSUMER? IT IS AN UNFAIR AND DECEPTIVE TRADE PRACTICE TO DO LESS THAN THIS, ESPECIALLY AFTER THE CONSUMER HAS FAILED TO RECEIVE THE BENEFIT OF HIS OR HER PURCHASE AND MAY BE RISKING OF DANGER TO HIMSELF OR OTHERS; AND II. NHTSA TO INVESTIGATE THE AUTOMATIC TRANSMISSION FAILURES DESCRIBED ABOVE. THE CAR LITERALLY "JUMPS" INTO A MUCH HIGHER RATE OF REVOLUTION AND ACCELERATION REQUIRING THE DRIVER TO IMMEDIATELY HIT THE BRAKES. IT'S TOO DANGEROUS, ESPECIALLY IN CITY TRAFFIC OR IN AREAS WHERE SMALL CHILDREN ARE PLAYING. *JB
Power train, Aug 5, 2005
2002 FORD EXPLORER [XXX] TRANSMISSSION NOT SHIFTING PROPERLY. REAR END NOISY AT 40 MPH. NOT REPAIRED. *JB UPDATED 07/19/2012 *JS INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)
Power train, Aug 1, 2005
THE EVENTS LEADING UP TO THE FAILURE OF MY VEHICLE IN THE MIDDLE OF A BUSY INTERSTATE WAS THAT THE OVERDRIVE LIGHT STARTED TO FLASH WHICH IN TURN WOULD TRIGGER THE CHECK ENGINE LIGHT. THE FAILURE WAS A SHOT TRANSMISSION AT ONLY 60,000 MILES. A PROBLEM THAT FORD MOTOR COMPANY KNOWS ABOUT FROM THE HUNDREDS OF TECH BULLETIN'S I'VE READ. THE VEHICLE WAS TAKEN INTO ADAMSON FORD IN BIRMINGHAM,ALA. AND WAS DIAGNOSED AS HAVING TROUBLE CODES,P0733,P0735,P0775 AND A FAULTY POWERTRAIN CONTROL MODULE. AFTER RECEIVING MY CAR AND ALMOST $800.00 LATER,THE SAME THING HAPPENED AGAIN. THE OVERDRIVE LIGHT STARTED BLINKING TRIGGERING THE CHECK ENGINE LIGHT. AFTER RETURNING TO THE DEALER WHOM THEN INFORMS ME THAT I WOULD HAVE TO BUY A REMANUFACTURER TRANSMISSION AT OVER $2200,00 PLUS LABOR. I CAN'T AFFORD THIS AND NOW I'M STUCK WITH A LATER MODEL CAR THAT I CAN'T USE, AND A HIGH CAR NOTE. I WILL NEVER BUY ANOTHER FORD AGAIN PERIOD. *JB
Power train, Jul 29, 2005
1) BEGAN WITH WHIRLING NOISE COMING FROM REAR END, ENDED WITH A LEAKING REAR END COMPONENT. BOTH REAR END PINION SEALS REPLACED,NEW SYNTHETIC OIL ADDED AND RE-PACKED WITH ALL NEW GASKETS.(NEW SEALS WERE ORDERED DIRECTLY FROM FORD) I WAS TOLD THAT THESE PARTICULAR PARTS WERE NOT AVAILABLE IN AFTERMARKET. *NM
Power train, Jul 25, 2005
BOUGHT FORD EXPLORER (2002) USED FROM TOYOTA DEALER. DROVE FINE FOR OVER 6 MONTHS. BEGINNING IN MARCH (2005), UPON ACCELERATION (ESP. ON HILLS), VEHICLE LURCHES/SHUDDERS AS IT GAINS SPEED. HAVE TAKEN IT TO 3 DIFFERENT FORD DEALERS, WITH NO RESOLUTION (INITIALLY SAID THAT MY NEW TIRES WERE 1/4-INCH DIFFERENT IN SIZE...TIRES WERE REPLACED AND PROBLEM CONTINUED). CONTINUOUS LURCHING FINALLY FRIED THE GEM MODULE (AND FRONT/REAR SPEED SENSORS). FORD STILL DID NOT HAVE AN ANSWER. TOOK IT TO REPUTABLE LOCAL MECHANIC WHO DETERMINED THAT IT WAS NOT THE TIRES, NOR SENSORS, BUT A PROBLEM WITH "SLOP" IN THE TRANSFER CASE. THIS SLOP MADE THE 4X4 AUTO SENSE SLIPPAGE AND COMPENSATE, BUT MORE SLOP MEANT MORE SLIPPAGE AND MORE COMPENSATION, HENCE THE REPEATED LURCHING FEELING. GRAPHICAL ELECTRICAL CHART INDICATED THAT 4X4 WAS ENGAGING AND DISENGAGING APPROXIMATELY 40X A SECOND. AFTER-MARKET WARRANTY WOULDN'T COVER REPAIR AT LOCAL MECHANIC, SO BROUGHT CAR TO FORD DEALER (6TH TIME), WHO "THINK" PROBLEM IS IN THE TRANSFER CASE.
Power train, Jul 24, 2005
DIFFERENTIAL FAILED; REPAIRED UNDER ORIGINAL FACTORY NEW VEHICLE WARRANRTY. DIFFERENTIAL FAILED AGAIN, 9000 MILES LATER, WHEN VEHICLE WAS OUT OF ORIGINAL WARRANTY. DEALER WANTS $825.00 TO REPLACE THE EXACT SAME PARTS AGAIN IN THE DIFFERENTIAL.
Power train, Jul 22, 2005
VEHICLE MADE INCREASINGLY LOUD NOISE AT RIGHT REAR WHEEL AREA. SOUNDED LIKE AIRPLANE TAKE-OFF OR TUNNEL SOUND AT REAR WHILE DRIVING. NOISE INCREASED ON WIDE TURNING ROADS AS IF SOME KIND OF PRESSURE EXERTED ON RIGHT REAR WHEEL. THOUGHT IT MIGHT BE TIRE PRESSURE PROBLEM. BEFORE HAVING TIRE CHECKED THE VEHICLE BECAME NEARLY IMPOSSIBLE TO DRIVE ON A STRAIGHT-AWAY AT 25 MPH WITH SERIOUS NOISE IN THE REAR THAT SOUNDED LIKE SOMETHING WOULD FALL APART SOON. FORTUNATELY I WAS VERY CLOSE TO A AUTO SERVICE CENTER IN A 25 MPH AREA. CAR COULD NO LONGER BE USED. THE RIGHT REAR HUB BEARING ASSEMBLY WAS REPLACED. THE OTHER 3 WERE CHECKED AND WERE FINE. I DO NOT HAVE ANY OF THE PARTS.
Power train, Jul 19, 2005
REAR AXLE HAS HAD RECURRENT LEAKS. THESE WERE REPAIRED 3 TIMES UNDER WARRANTY. ON THE FOURTH OCCASSION THE DEALER REPLACED THE AXLE. THIS WAS ALSO DONE UNDER WARRANTY. PROBLEM WAS FIRSTED NOTED AT JUST UNDER 30,000 MILES. AXLE REPLACEMENT WAS AT 58,OOO MILES
Power train, Jul 9, 2005
TWO INSTANCES OF WHINING NOISE AT 50+ MPH AND FLUID LEAKAGE FROM REAR AXLE SEAL 2002 FORD EXPLORER LIMITED. THE FIRST ONE CAUSED LOSS OF CONTROL WHEN ACCELERATING ON HIGHWAY; RESULTING IN COMING TO REST WITHIN INCHES OF CONCRETE BARRIER AFTER JERKING ACROSS SEVERAL LANES. DIFFICULT TO DETERMINE SINCE REAR TRANSAXLE FLUID LEAKS DOWN DRIVE SHAFT TO BRAKE ASSEMBLY. I ONLY NOTICE BECAUSE I PERFORM A MONTHLY INSPECTION OF THE UNDERCARRIAGE. NOTICED SIGNIFICANT CORROSION OF BRAKE ASSEMBLY WHERE FLUID IS RUNNING INTO THE WHEEL ASSEMBLY. ONLY WHEN LEAK IS SIGNIFICANT WILL FLUID DRIP ONTO SURFACE BELOW REAR AXLE. DEALER NOTED FORD ENGINEERS ARE AWARE OF PROBLEM BUT EXPECT THE CONSUMER TO PAY FOR REPAIRS. FIRST REPLACEMENT OF REAR AXLE SEALS AT 39000 MILES; SECOND AT 50000 MILES. THESE SEALS SHOULD LAST LONGER. SECOND INSTANCE HAD VIBRATION WHEN ENGAGING THE VEHICLE IN REVERSE AND OUD WHINING NOISE/ VIBRATION FROM REAR; THEN FLUID LEAKAGE. THIS IS A MAJOR SAFETY ISSUE FOR THE FORD EXPLORER. SEVERAL WORK COLLEAGUES HAD THE REAR AXLE SIEZE DUE TO LUBRICANT LOSS WITH SIMILIAR SYMPTOMS, ALMOST CAUSING SERIOUS ACCIDENT. MY DEALER ACKNOWLEDGES (BILL ESTES, BROWNSBURG, IN) THAT MANY EXPLORERS (2002-2005) HAVE THIS PROBLEM AND FORD MOTOR COMPANY ENGINEERS ARE EVALUATING; AS A DEALER THERE IS NOTHING THEY CAN DO. FORD HAS NOT INDICATED A FIX OTHER THAN TO CHECK FLUID LEVEL, REPLACE REAR AXLE SEALS, AND/OR THE REAR UNIT. THIS IS A SIGNIFICANT HAZARD SINCE IN MOST CASES THE VEHICLE OWNER WILL NOT KNOW THERE IS A PENDING FAILURE DUE TO THE FLUID LEAKING DOWN THE REAR AXLE DRIVE SHAFT TOWARD THE BRAKE/WHEEL ASSEMBLY. THE WHINING NOISE WILL INCREASE AS FLUID LEVEL DECREASES WITH RISK FAILURE AND LOSS OF CONTROL. THIS PROBLEM IS FAR MORE COMMON THAN REPORTED DUE TO THE DIFFICULT NATURE OF OBSERVATION OF LEAKAGE. ONE HAS TO CRAWL UNDER THE REAR TRANSAXLE AND CAREFULLY INSPECT THE TWO AXLE SEALS TO LOOK FOR SIGNS OF CORROSION AND FLUID LEAKAGE.
Power train, Tires, Jul 8, 2005
2002 4X4 EXPLORER LIMITED WITH V8. AT 7390 MILES (3/12/03, INVOICE # W40836) TWO ISSUES; THE TRANSMISSION NEVER SHIFTED PROPERLY AND IT STARTED LEAKING FLUID EVERYWHERE. TWO WEEKS LATER THE DEALER ADMITTED THEY DIDN''T KNOW THE CAUSE AND REPLACED THE TRANSMISSION WITH A NEW ONE. ENGINE SEVERELY OVERHEATED (INVOICE 3W47852). AT 20K MILES THE TRUCK WILL ONCE IN A WHILE STOP (AS IF I HIT SOMETHING) AS I START TO BACK OUT OF THE GARAGE - PROBLEM DISCOVERED AT 31K BRAKE JOB - REAR SHOES ON PARKING BRAKE BROKE LOOSE ON DRIVERS SIDE (BOTH) AND ONLY ONE ON PASSENGER SIDE. LOOSE SHOE ON PASS. SIDE WOULD WEDGE WITH GOOD ONE AND LOCK UP WHEELS WHEN MOVING SLOW. LOT'S OF ARGUMENTS AND FORD FINALLY REPLACED SHOES (4/25/05 INVOICE # 99323). AT 26K (11/05, NO INVOICE) ONE TIRE WENT FLAT AND UPON INSPECTION BY A TIRE SHOP, THAT TIRE AND A SECOND TIRE HAD TREAD SEPARATION - RUNNING GOODYEAR''S. FORD QUICKLY REPLACED BOTH TIRES WITHOUT ANY QUESTIONS. AT 29K, MY FAMILY AND I MOVED FROM MI TO GA. EACH TIME I STOPPED FOR GAS THE EXPLORER SOUNDED LIKE THE FRONT END WAS GRINDING METAL TO METAL ON THE GEARS. THE 4X4 WAS IN AUTO FOR THE TRIP AND ONCE I GOT BACK ON THE HIGHWAY ABOVE 20 MPH THE NOISE WENT AWAY. HOWEVER, IT CONTINUED TO SHIFT POORLY AND IT STARTED TO SURGE (SHAKE) OR THUMP LIKE SOMETHING WAS CATCHING IN THE DRIVE TRAIN EVERY TIME I WOULD LET OFF THE GAS PEDAL AND ALLOWED THE TRUCK TO DECELERATE WITHOUT BRAKING. EVEN AFTER NEW BRAKES AND ROTORS, THE PROBLEM GOT WORSE AND WORSE - NOW AT 34K, (5/30/05, INVOICE # W50821) THE TRUCK IS IN THE DEALERSHIP FOR THE 3RD TIME ON THIS ISSUE. THE FIRST TIME, THEY REPLACED THE "MODULE-TRANSFER SH" WHICH DID PRETTY MUCH ELIMINATE THE SHIFTING ISSUE. THEY ALSO REPLACE THE "DRIVE SHAFT FLANGE PER SSM 16824" WHATEVER THAT MEANS. BUT A MAJOR PROBLEM IN THE DRIVE TRAIN STILL EXISTS AND IT STILL UNRESOLVED. HERE'S MY POINT, FORD HAS A MAJOR DRIVE TRAIN PROBLEM WITH THE REDESIGNED 2002 EXPLORER.
Power train, Jul 4, 2005
DRIVE TRAIN AND REAR AXLE HAVE PERSISTENT SHUDDER AND BINDING WHEN SHIFTING GEARS 2-3 AND UPON ACCELERATION DEALERSHIP HAS BEEN NOTIFIED AND WILL NOT RESOLVE PROBLEMS THAT HAVE BEEN ID'D W/ SERVICE BULLETINS FOR THE 5355-RW ASSEMBLY AND THE REAR-GEAR LUBRICANT RATIO MIX-UP INTHE SEALED REAR HOUSING EVEN THOUGH THEY HAVE REC'D PROTOCAL FROM MFG. ON THE PROCEDURE AND/OR REPLACEMENT PARTSAS BEING AVAILABLE SINCE MAR 2001 THIS HAS BEEN NOTED IN OTHER COMPLAINTS THAT HAVE RESULTED IN SEVERE DAMAGE DONE TO THE REAR AXLE AND WHEEL COMPONENTS BUT THEY DO NOT SEE THIS AS A PROBLEM WHEN IN FACT IT CAN RESULT IN VEHICLE FAILURETHAT MAY RESULT IN INJURY OR EVEM DEATH. I PERSONALLY SEE THIS AS BLATANT NEGLIGENCE ON THE DEALERAND MFG. PART OF RESOLVING THIS ISSUE. MY EXPLORER EXHIBITED TROUBLE SINCE JULY'04 AND WAS MFGD. IN THE TIME FRAME THAT A DEFECT WAS BROUGHT TO FORD'S ATTENTION IN THIS MATTER. WHAT DO THEY WANT A CERTAIN NUMBER OF DEATHS OR INJURIES?
Power train, Jul 1, 2005
RIGHT REAR AXLE AND BEARING
Power train, Jun 26, 2005
REAR END ON MY 2002 FORD EXPLORER IS ROARING AND LEAKING FLUID.
Power train, Jun 24, 2005
THE REAR SEAL ON THE AXLE ASSEMBLY HAD TO BE REPLACED 5 TIMES ON THE CONSUMERS 2002 FORD EXPLORER. *JB THE CONSUMER REQUESTED REIMBURSEMENT. *SC *JB
Power train, Jun 21, 2005
MY HUSBAND AND I PURCHASED A 2002 FORD EXPLORER XLT AROUND MID JULY/EARLY AUGUST 2002. IN AUGUST OF 2003 I NOTICE THAT MY CAR WAS EXPERIENCING SOME CLUNKING IN THE TRANSMISSION. I DON'T KNOW THE FULL DETAIL OF THAT PROBLEM BUT THEY GAVE ME AN EXTRA 5 YEAR WARRENTY ON MY VEHICLE. LAST YEAR MY FAMILY AND I TOOK A TRIP TO FLORIDA AND MY CAR WOULD GET THIS LOUD ROARING SOUND AT 45 MILES PER HOUR. WHEN WE RETURNED FROM MY TRIP I CALLED TO COMPLAIN ABOUT IT. THEY ASKED ME TO BRING IT TO THEM BUT THEY SAID THAT IT WAS MY TIRES. MY HUSBAND REPLACED THE TIRES HOPING THAT THIS WOULD RESOLVED THE PROBLEM. (EVEN BEFORE THIS PROBLEM BECAUSE THEY REQUESTED US TOO). A WEEK LATER MY HUSBAND AND I WENT TO TEXAS AND THE SOUND GOT WORSE. UPON RETURNING FROM OUR TRIP I WAS TOLD THAT IT WAS MY AXEL. MY FAMILY AND I COULD HAVE BEEN KILLED BECAUSE OF THEIR MISTAKE. I 'VE HAD MY FRONT AND REAR WHEEL BEARINGS, AXEL, AXEL BOOT, HUBS BEARINGS, EMERGENCY BRAKE (WHICH THEY SAY WAS SPLIT) REPLACED. I STILL HEAR A PROBLEM WITH MY TRANSMISSION BUT THEY KEEP TELLING ME THAT MY CAR IS SAFE TO RIDE IN. I DO NOT FEEL SAFE IN THIS VEHICLE. I'VE GONE TO THE ATTORNEY GENERAL, FILED A COMPLAINT FOR ABITRATION. MY (PREPAID) ATTORNEY HAS EVEN SENT THEM TWO LETTERS ADVICING THEM TO TAKE THIS SITUATION SERIOUSLY. THEY NEVER REPLIED BACK TO ME OR MY ATTORNEY. I'M FORD PLAN AND I REALLY THOUGHT THAT I WOULD BE TREATED WITH A LITTLE MORE RESPECT. I WANT THEM TO BE RESPONSIBLE AND SEE THAT THEY SOLD ME A "LEMON". I REALLY NEED SOME HELP. THANK YOU.
Power train, Jun 20, 2005
THE "O/D" LIGHT OF MY 2002 FORD EXPLORER LIT UP WITHOUT WARNING WHILE I WAS TURNING. ENGINE "REVVED" BUT DIDN'T ACCELERATE. ONCOMING CARS SWERVED TO AVOID ME. THIS WAS AN UNSAFE SITUATION, AS I EXPECTED THE VEHICLE TO FUNCTION PROPERLY. I TOOK THE CAR TO THE DEALER AND WAS TOLD THE TRANSMISSION HAD TO BE TOTALLY REBUILT, FOR $2,400, SINCE I WAS 4000 MI OUT OF WARRANTY, EVEN THOUGH <3 YEARS. I ASKED THE SERVICE MANAGER IF FORD WOULD COVER IT. THE ZONE PERSON, ADVISED NO. I PHONED CUSTOMER ASSISTANCE, AND WAS TOLD THERE WERE DEALER/FIELD DISCRETIONARY FUNDS TO PAY FOR REPAIRS OUTSIDE OF WARRANTY, BUT ONLY FOR "LOYAL" CUSTOMERS. I WAS TOLD THAT I SHOULD HAVE PURCHASED THE VEHICLE NEW AND HAD MY MAINTENANCE DONE AT THE DEALER. I ASKED WHAT MAINTENANCE SHOULD BEEN DONE ON THE TRANSMISSION. I WAS TOLD THAT THERE WAS NONE. I SPOKE WITH A GENTLEMAN IN THE QUALITY DEPARTMENT AT A LOCAL TRANSMISSION PLANT, WHO SAID THIS WAS A COMMON FAILURE, BUT THAT FORD WOULDN'T OFFER ANY HELP BECAUSE "MONEY IS TIGHT". HE SAID THAT THE BANDS IN MY TRANSMISSION HAD BEEN SUPERCEDED TWICE DUE TO THIS PROBLEM, AND A TECH BULLETIN EXISTED, EXPLAINING THIS TO DEALERSHIPS. I READ MANY OTHER COMPLAINTS ON THIS WEBSITE! I FAIL TO UNDERSTAND WHY FORD HONORS A SECRET WARRANTY FOR "LOYAL" CUSTOMERS YET OFFERS NO RECOURSE FOR CUSTOMERS WHO WERE PUT IN THE SAME UNSAFE SITUATION, JUST BECAUSE THEY BOUGHT THE VEHICLE USED. I HAD THE REPAIR DONE AT AN INDEPENDENT REPAIR FACILITY. FORD ADVISES THEY WILL NOT TAKE ANY FINANCIAL RESPONSIBILITY BECAUSE THE REPAIR WAS DONE AT AN INDEPENDENT. I AM ONE OF MANY CONSUMERS WHO MUST DRIVE IN A DEFECTIVE AND DANGEROUS VEHICLE, DUE TO THIS TRANSMISSION PROBLEM. IT FAILED ME ONCE WITHOUT WARNING, I PAID $1,200 FOR REPAIR, AND APPROACH INTERSECTIONS WITH TREPIDATION DUE TO THE POSSIBILITY OF MY TRANSMISSION UNEXPECTEDLY SLIPPING AGAIN. I WOULD WELCOME CONTACT AT 248.808.1279 TO DISCUSS RESOLUTION OF THIS DANGEROUS ISSUE.
Power train, Jun 15, 2005
THE GEAR SHIFTER BROKE OFF WHILE SHIFTING FROM PARK TO REVERSE. THE SHIFTER COMPLETELY SNAPPED OFF THE ASSEMBLY RENDERING THE 2002 FORD EXPLORER COMPLETELY INOPERABLE. MILEAGE WAS ONLY 56,000 MILES AND BEEN DRIVEN FOR ONLY 4 YEARS. THE CAR HAS TO BE TOWED TO THE DEALER'S LOCATION. THE DEALER REPLACED THE STEERING COLUMN ASSEMBLY (PART # FMC4L2Z 3C 529 DA) AT A COST OF $706.20 TO THE VEHICLE OWNER.
Suspension, Power train, Jun 15, 2005
DT: PROBLEM WITH BACK END, TOOK VEHICLE TO THE DEALER,AND DEALER SAID THEY FIXED AXLE, THEN, TOOK BACK VEHICLE TO THE DEALER, AND THEY FIXED HUB, AND REPLACED THE REAR WHEEL BEARINGS. IN LAST 3 MONTHS VEHICLE HAS BEEN IN SHOP 3 TIMES. CURRENTLY, IN THE SHOP. WENT TO GET OIL CHANGE LAST FRIDAY, AND MECHANIC NOTICED OIL WAS LEAKING FROM THE AXLE. CURRENTLY VEHICLE IN SHOP TRYING TO FIGURE OUT WHAT WAS WRONG WITH IT. THIS HAPPENED BEFORE. THEY GAVE CONSUMER AN EXTRA 5 YR WARRANTY BECAUSE OF THE TRANSMISSION, AND THIS WAS 8 MONTHS AFTER PURCHASING THE VEHICLE. DEALERSHIP KEPT SAYING VEHICLE WAS SAFE EVEN THOUGH DIDN'T KNOW WHAT WAS WRONG WITH IT. *AK
Power train, Jun 14, 2005
DT: GEAR SHIFT BROKE OFF. CONSUMER SAID SHIFTER BROKE OFF AND LANDED IN HIS LAP. CONSUMER WAS SHIFTING INTO GEAR WHEN THIS HAPPENED. NO PREVIOUS PROBLEMS. VEHICLE IS SERVICED REGULARLY. CONSUMER HAD HIGHTECH AUTO CENTER FIX PROBLEM, THEY REPLACED THE WHOLE COLUMN. FORD REFUSED TO DO REPAIRS, SAID WARRANTY EXPIRED. *AK
Power train, Jun 13, 2005, crash
DT: CONSUMER STATES THAT TRANSMISSION WENT FROM PARK TO DRIVE. WHILE SHE WAS AT HER DAUGHTER'S SCHOOL SHE STEPPED OUT OF THE VEHICLE TO TALK TO SOMEONE AND THE CAR JUMPED FROM PARK TO DRIVE AND HIT ANOTHER VEHICLE. ALSO THE TRANSMISSION WENT OUT. SHE HAD SEVERAL OTHER PROBLEMS WITH THIS VEHICLE. SHE WAS NEVER NOTIFIED ANYTHING FROM FORD ABOUT ANY TYPE OF PROBLEM. THE SERVICE DEPARTMENT PRINTED OUT A TSB FOR HER, INCLUDING THE FOLLOWING NUMBERS; TRANSMISSION: 03-25-4 DATED 12-22-03, AND GEAR SELECTOR:04-22-12 DATED 11-15-04. THE VEHICLE IS REGULARLY MAINTAINED.*AK
Power train, Jun 2, 2005
THE CONSUMER EXPERIENCED A CLUNKING NOISE WHICH THE DEALER REPORTED ORIGINATED FROM THE DRIVESHAFT. SOME OF THE DRIVE SHAFT MOUNTING BOLTS WERE MISSING AND SOME WERE LOOSE. THE DEALER REPAIRED THE MOUTNING BOLTS. THERE WAS NO WARNING OF THE DRIVESHAFT HAVING MISSING BOLTS. *AK *TT THE CONSUMER FELT THAT THE DEALER SHOULD HAVE REPLACED THE ORIGINAL BOLTS THAT HAD COME LOOSE. THE CONSUMER ALSO FELT THAT FORD SHOULD COVER THE COST OF REPAIRS. *SC *JB
Power train, Jun 1, 2005
WAS DRIVING ON A HIGHWAY WHEN THE OD LIGHT STARTED FLASHING THEN THE TRANSMISSION FAILED COMPLETELY. HAVING NEW TRANSMISSION INSTALLED. MANY OTHER THINGS HAVE FAILED TOO. THREE WEEKS PRIOR SHIFT LEVER BROKE OFF IN MY HANDS WHEN I SHIFTED FROM PARK TO REVERSE. HAVE CHANGED RIGHT REAR BEARING WHICH "BLEW OUT". THE 4 WHEEL DRIVE QUIT WHILE THE TRUCK WAS STILL UNDER WARRANTY. WHEN I FIRST GOT THE TRUCK AND COMPLAINED TO THE DEALER ABOUT THE WAY THE TRANSMISSION WORKED HE GAVE ME A PRINTOUT FROM FORD STATING THE TRANSMISSION WAS PROGRAMMED TO ADJUST TO THE DRVERS STYLE OF DRIVING.
Power train, Jun 1, 2005
LOUD THUMPING NOISES COMING FROM FRONT END OF 2002 FORD EXPLORER. FORD SAYS THEY ARE NORMAL. IT DIDN'T DO THIS WHEN WE BOUGHT IT. ALSO THERE IS A LOUD WHINING NOISE COMING FROM THE REAR END. REAR END HAS BEEN REPLACED ONCED. PROBLEM DISAPPEARED FOR ABOUT 10K MILES AFTER IT WAS REPLACED. WIFE IS AFRAID TO DRIVE THE CAR AS WE HAVE THREE NEWBORN BABIES.
Power train, Jun 1, 2005
I NOTICED SOME VIBRATION/SHUTTERING WHEN ACCELERATING IN THE REAR END OF MY 2002 EXPLORER IN APRIL, 2005. THE LOCAL DEALER'S SERVICE DEPARTMENT DIAGNOSED THE PROBLEM AS NEEDING TO REPLACE THE CLUTCH PACK FOR THE REAR AXLE (WHICH THEY SAID WOULD CAUSE SHUTTERING WHEN TURNING) AND TO REPLACE THE TIRES. I PUT NEW TIRES ON THE REAR WHICH DID NOTHING FOR THE SHUTTERING AND IN ADDITION I COULD NOW HEAR A LOUD HUMMING UPON DECELARATION FROM SPEEDS OVER 50 MPH APPROXIMATELY. THE DEALER'S SERVICE DEPT. RECHECKED IT AND TOLD ME IN ADDITION TO THE CLUTCH PACK, I ALSO NEEDED TO REPLACE THE RING AND PINION AT A TOTAL COST OF OVER $1,500.00. THE ODOMETER READING ON THE INITIAL SERVICE DATE WAS 43893 MILES (WARRANTY EXPIRED AT 36000). I SUBSEQUENTLY HAD A INDEPENDENT REPAIR SHOP LOOK AT IT AND THEY TOLD ME THEY COULDN'T FIND ANYTHING WRONG WITH IT. I'M NOT SURE WHAT TO DO AS I DON'T WANT TO HAVE MY WIFE DRIVING A VEHICLE THAT IS A POTENTIAL DANGER, BUT I DON'T WANT TO UNNECESSARILY SPEND $1500.00.