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: suspension
445 reports, newest first. Show all
Suspension, Apr 21, 2006
DT*: THE CONTACT STATED WHILE TRAVELING 30 MPH, THE REAR PASSENGER SIDE TIRE BEGAN TO WOBBLE. THE VEHICLE WAS PULLED OVER AND THE CONTACT NOTICED THE WHEEL BEARINGS IN THE ROAD. THE VEHICLE WAS DRIVEN TO AN INDEPENDENT REPAIR SHOP WHERE THE WHEEL BEARING AND HUB WAS REPLACED.
Suspension, Power train, Apr 17, 2006
THREE INSTANCES OF WHINING NOISE AT 50+ MPH AND FLUID LEAKAGE FROM REAR AXLE SEAL 2002 FORD EXPLORER. THE FIRST ONE CAUSED LOSS OF CONTROL WHEN ACCELERATING ON HIGHWAY. DIFFICULT TO DETERMINE SINCE REAR TRANSAXLE FLUID LEAKS DOWN DRIVE SHAFT TO BRAKE ASSEMBLY. I 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 30000 MILES; SECOND AT 460000 MILES AND THE THIRD AT 62000 MILES. THESE SEALS SHOULD LAST LONGER. SECOND INSTANCE HAD VIBRATION WHEN ENGAGING THE VEHICLE IN REVERSE AND LOUD WHINING NOISE/ VIBRATION FROM REAR; THEN FLUID LEAKAGE. MY DEALER ACKNOWLEDGES 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. *NM
Suspension, Apr 4, 2006
2002 FORD EXPLORER REAR COIL SPRING WAS DEFECTIVE, CONSUMER WANTS TO BE REIMBURSED. *TS *NM
Suspension, Service brakes, Hydraulic, Mar 20, 2006
2002 EXPLORER REAR COIL SPRINGS BROKE AT 76,000 MILES. *TS THE FRONT BRAKE PADS WERE REPLACED. *JB
Suspension, Power train, Mar 19, 2006
REAR END HUM AND LEAK BACK TIRE WAS LOOSE DUE TO REAR WHEEL BEARINGS DETERIORATING, TOOK IT APART AND BEARINGS FELL APART. THERE WAS NO GREASE ON THEM. THIS '02 EXPLORER HAS 30,000 MILES ON IT. *JB
Suspension, Wheels, Mar 16, 2006
I OWN A 2002 FORD EXPLORER, WITH 69.000 MILES ON IT. IN THE LAST FEW MONTHS I HAVE HAD TO REPLACE EVER WHEEL BEARING ON MY CAR, THE WHEEL HAVE COME LOOSE, AND THE BEARING WERE SCRAPING. THE COST FOR THE BEARING AND THE LABOR WAS OVER $1,400 , I AM ALSO HAVE TO REPLACE MY TIRES BECAUSE OF THIS, WHEN I CONTACTED FORD ON THIS MATTER, THERE COMMIT WAS "THAT IS YOUR PROBLEM IT IS OUT OF WARRANTY, THERE IS NO REASON ALL 4 WHEEL BEARING WOULD HAVE GONE BAD WITH NO MORE MILES THAN THERE IS ON THE CAR. MY CONCERN IS THAT THE NEXT PERSON MAY NOT KNOW IN TIME THAT THERE IS FLAW IN THE BEARINGS AND MAY HAVE A WHEEL COME OFF. THIS SHOULD BE A VERY BIG SAFETY CONCERN. THIS COULD CAUSE SOMEONE THERE LIFE. I HOPE I CAN GET SOMEONE TO LISTEN BEFORE IT IS TO LATE AND CAUSES A CHILD'S LIFE. THANK YOU. *JB
Suspension, Mar 10, 2006
FUNNY THING, MY EXPLORER ONLY HAS 30,000 MILE, THERE WAS NO EVENT, ONE DAY IT WAS FINE THE NEXT DAY COME THE WHINE AND GRIND. *JB
Suspension, Feb 20, 2006
AFTER 60,000 MILES TWO WHEEL BEARINGS NEEDED REPLACEMENT. *NM
Suspension, Power train, Feb 15, 2006
I BROUGHT THIS SUV LAST YEAR AT BILL HEARD CHEVROLET DEALERSHIP. EVEN THOUGH THIS WAS A NEW VEHICLE. WHEN I WENT TO THE DEALERSHIP THEY TOLD ME THAT I COULD PAY THIS CAR IN THREE YEARS BUT IN REALITY IT WAS FIVE YEARS. I SIGNED ALL THE PAPERWORK I HAD TO BUT THEY DIDN'T GIVE ME ANY PAPERS WHEN I LEFT. HOWEVER WHEN I WENT TO APPLY TO BUY ANOTHER CAR THEY DIDN'T ACCEPT MY APPLICATION BECAUSE THEY TOLD ME THAT I WAS ALREADY BEING FINANCE A CAR FOR FIVE YEARS. THIS CAR HAS HAD MANY PROBLEMS LIKE THE TRANSMISSION WOULD JUST MAKE REALLY LOUD NOISES WHEN I DROVE THE SUV; THE TRANSMISSION WAS SIMPLY NOT FUNCTIONING PROPERLY. WHEN I DROVE THE CAR 60 MPH OR MORE THE VEHICLE WOULD JUST START VIBRATING. I CONTACT THE DEALERSHIP TO MAKE A COMPLAINT BUT THEY SIMPLY JUST IGNORE MY COMPLAINT. *NM
Suspension, Feb 9, 2006
DT*: THE CONTACT STATED WHILE DRIVING AT SPEEDS OF 20MPH OR MORE THERE WAS A ROARING NOISE COMING FROM THE REAR END OF THE VEHICLE. INITIALLY THE CONTACT SUSPECTED THE TIRES NEEDED REPLACED. THE VEHICLE WAS INSPECTED BY AN INDEPENDENT TIRE REPAIR SHOP. THE REPAIR SHOP MECHANIC SUGGESTED THE VEHICLE SHOULD BE INSPECTED BY AN AUTHORIZED DEALER BECAUSE IT WAS DETERMINED THERE WERE NO PROBLEMS WITH THE TIRES. THE MECHANIC SUGGESTED THE NOISE COULD POSSIBLY BE ASSOCIATED WITH THE REAR SUSPENSION. UPDATED 7/13/2006 - *NM
Suspension, Power train, Jan 29, 2006
ON JANUARY 16, 2006 WHILE DRIVING ON THE HIGHWAY I NOTICED A SHAKING FEELING UNDER THE DRIVER'S SIDE FLOOR. THERE WAS ALSO LOUD NOISE. I SLOWED DOWN AND CONTINUED TO DRIVE. ON SATURDAY, JANUARY 21, 2006 I BROUGHT FORD EXPLORER 2002 TO A FORD DEALER FOR THEM TO DRIVE AND TAKE A LOOK. THE RESULT WAS VEHICLE ALL OVER THE ROAD, WAS UNSTABLE AND NEEDED ALL 4 WHEEL BEARINGS, UPPER REAR BALL JOINTS. REPLACED. NOT SAFE TO DRIVE FOR VERY LONG, MUST GO SLOW AND A $3,000 APPROXIMATE COST TO REPAIR. I CONTACTED FORD TO COMPLAIN AND TO SEE IF THEY COULD HELP OUT BY REDUCING THE COST OF FIXING IT FOR FREE. THEIR RESPONSE WAS SORRY BUT THEY COULD NOT HELP. I CANNOT SEE HOW FORD CAN TELL ME THERE WAS NOTHING THEY COULD DO WHEN EVERY MECHANIC I HAVE SPOKEN TO SAID IT WAS UNHEARD FOR ALL 4 WHEEL BEARINGS TO GO AT THE SAME TIME, ESPECIALLY WITH ONLY 73,000 MILES ON THE TRUCK. I DRIVE MY 6 YEAR OLD SUN TO SCHOOL, LEFT TO FORD I'M SUPPOSED TO TAKE MY CHANCES WITH HIS SAFETY WHILE DRIVING ONE OF THEIR POORLY MADE VEHICLES. ALL THIS AFTER I HAD TO REPLACE THE TRANSMISSION IN OCTOBER WHEN THAN WENT WHILE I WAS ON VACATION IN NEW HAMPSHIRE.*AK
Suspension, Power train, Dec 5, 2005
I BOUGHT MY EXPLORER BRAND NEW IN MAY 2002. I HAVE HAD PROBLEMS WITH THE REAR END DIFFERENTIAL TWICE, REAR END SENSOR, AND MY LATEST PROBLEM IS THE REAR END SEALER (PINION). ALL WITHIN 3 YEARS OF OWNING THE VEHICLE. *JB
Suspension, Dec 2, 2005
2002 FORD EXPLORER BOTH REAR COIL SPRINGS BROKE. *JB
Suspension, Nov 28, 2005
1) COULD HEAR HIGH PITCH NOISE WHILE DRIVING. 2) JACKED UP REAR OF EXPLORER AND REAR WHEEL(S) COULD WOBBLE ON THE AXLE. 3) BY 70,000 MILES, BOTH LEFT AND RIGHT REAR WHEEL BEARINGS HAVE NOW FAILED AND HAVE BEEN REPLACED BY A FORD DEALER. I NOW HAVE 77000 MILES ON THE EXPLORER AND I AM BEGINNING TO HEAR THE HIGH PITCH SOUND AGAIN. *JB
Suspension, Nov 15, 2005
BOTH REAR COIL SPRINGS BROKE ON BOTH SIDES OF FORD EXPLORER. *TS *JB
Suspension, Power train, Nov 15, 2005
WE NOTICED A HUMMING NOISE AND A SMALL OIL LEAK COMING FROM THE REAR AXLE. WE TOOK THE VEHICLE TO THE FORD DEALER AND WERE INFORMED THAT THE REAR DIFFERENTIAL WAS IN NEED OF REPAIR AND THAT THIS WAS A KNOWN PROBLEM WITH EXPLORERS. WE WERE GIVEN A DISCOUNTED RATE FOR THE REPAIR. TWO WEEKS LATER THE LEFT REAR WHEEL BEARING WENT OUT (WITH ONLY 59,000 MILES) AND WERE TOLD THAT THIS HAD NOTHING TO DO WITH THE REAR DIFFERENTIAL REPAIR AND WOULD COST A TOTAL OF $700 FOR BOTH REAR WHEEL BEARINGS. *NM
Suspension, Oct 6, 2005
WE NOTICED A SLIGHT RUBBING WHEN VEHICLE WAS TURNING TO RIGHT WHILE ON VACATION. WITHIN 2 DAYS IT BECAME WORSE, THE THUMPING AND RUBBING SOUND WERE VERY LOUD AND FELT IN THE CAR. WE OPTED TO LEAVE THE CAR. LUCKILY WE DID, AS THE REPAIR SHOP INFORMED US THAT THE WHEEL BEARING WAS COMPLETELY CRACKED, AND NOTED THIS IS NOT COMMON. WE WERE TOLD THAT HAD WE ATTEMPTED TO DRIVE HOME, THE WHEEL WOULD HAVE FALLEN OFF ON THE HIGHWAY, AS IT WAS EXTREMELY LOOSE. THIS IN TURN DAMAGED OUR BACK BRAKES, RESULTING IN NEW ROTORS AND PADS, AND THE SHOP WAS UNABLE TO GET THE EMERGENCY BRAKES BACK ON AS THEY WERE RUSTED ON THE CAR. *NM
Suspension, Oct 5, 2005
ON ROUTINE INSPECTION, IT WAS DISCOVERED THAT THE LEFT REAR SPRING ON MY 2002 FORD EXPLORER WAS BROKEN. THIS VEHICLE HAS 55,000 MILES ON THE ODOMETER. FORTUNATELY, IT WAS PROBABLY NOT BROKEN LONG SINCE I INSPECT MY VEHICLES REGULARLY. WHEN I WENT TO THE LOCAL FORD DEALER, THEY INITIALLY WANTED ME TO PAY THE FULL REPAIR BILL FOR REPLACEMENT OF THE SPRING; HOWEVER, AFTER NEGOTIATION, THEY OFFERED REPLACEMENT IF I PAID HALF OF THE BILL, OR $78.00. I AGREED TO THIS OFFER, AND HAD THE SPRING REPLACED. I FEEL, AND EXPRESSED THIS OPINION TO THE FORD AGENCY, THAT THIS SPRING SHOULD NOT BREAK AFTER ONLY 55,000 MILES. IN ADDITION, I AM NOW CONCERNED ABOUT THE OTHER REAR SPRING, AND WHAT WOULD HAPPEN IF I WAS TRAVELING AT HIGHWAY SPEEDS AND IT BROKE. *JB
Suspension, Sep 15, 2005
WE RECENTLY LEARNED FROM HTTP://WWW.NHTSA.GOV/ THAT FORD COIL SPRING PROBLEMS MAY NOT BE LIMITED TO WINDSTAR MINIVANS. " FORD COIL SPRING PROBLEMS MAY NOT BE LIMITED TO WINDSTARS WASHINGTON, JAN. 31, 2001 -- THE NATIONAL HIGHWAY TRANSPORTATION SAFETY ADMINISTRATION (NHTSA) HAS UPGRADED ITS INVESTIGATION OF 926,000 FORD WINDSTAR MINIVANS AFTER REPORTS THAT A SPRING IN THE SUSPENSION SYSTEM CAN BREAK AND PUNCTURE A TIRE. " WE OWN A 2002 FORD EXPLORER, [XXX], WHICH HAS TWO (2) BROKEN REAR COIL SPRINGS, BOTH OCCURRING AT THE SAME TIME. THE SPRINGS BROKE FOR NO APPARENT REASON AND THE TRUCK IS SELDOM USED FOR HAULING; HAS NEVER BEEN OVERLOADED. THE SERVICE MANAGER AT THE LOCAL FORD DEALERSHIP ADMITTED HE HAS SEEN THIS BEFORE ON WINDSTAR AND OTHER FORD VEHICLES, BUT WOULD NOT DO ANYTHING ABOUT IT, OTHER THAN REPAIR IT AT MY COST. THE COST FOR THE REPAIRS & REPLACEMENT COIL SPRING(S) WAS $ 535.00. THE TRUCK WAS OUT OF COMMISSION FOR THREE DAYS. THE FORD DEALERSHIP IS: IRWIN MOTORS UNION & BISSON AVENUE LACONIA, NH 03246 THANK YOU FOR ACCEPTING THIS INFORMATION AND FOR ANY ASSISTANCE YOU MAY PROVIDE IN FORCING THE MANUFACTURER TO STAND UP TO THIS ISSUE, AN ISSUE WORTHY OF A RECALL DUE TO THE SAFETY HAZARD - THE BROKEN COILS CAN CUT THE TIRES DURING TRAVEL. [XXX] [XXX] [XXX] . *NM UPDATED 07/18/2012 *JS INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)
Suspension, Wheels, Sep 7, 2005
1. I NOTICED A HUMMING TYPE SOUND THAT WOULD INCREASE AS I SPED UP. I THOUGHT I HAD A WHEEL OUT OF ALIGNMENT, OR TIRE OFF BALANCE. I WAS DUE FOR MY 36,000 MILE MAINTENANCE CHECK, SO I TOOK IT TO THE DEALERSHIP TO HAVE EVERYTHING CHECKED OUT. THEY PERFORMED A $400.00 MAINTENANCE PACKAGE TO MY VEHICLE ON MAY 4, 2004, OF WHICH I THOUGHT INCLUDED INSPECTING TIRES, WHEELS, ETC. THEY RETURNED MY VEHICLE TO ME AND AS I DROVE HOME, NOTICED THE HUMMING SOUND WAS STILL OCCURRING, BUT I JUST HAD EVERYTHING CHECKED, AND THOUGHT IT WAS JUST A NOISE THAT WAS NORMAL. 2. THE NOISE CONTINUED ON, GETTING WORSE (LOUDER) AND WAS BOTHERSOME, SO I TOOK IT TO A LOCAL MECHANIC FOR A SECOND OPINION. UPON REVIEW OF MY VEHICLE, HE SUGGESTED REPLACING THE RIGHT REAR WHEEL HUB ASSEMBLY AND BEARINGS. 3. ON JULY 3, 2004 THE RR HUB ASSEMBLY AND BEARINGS WERE REPLACED AT A COST OF $360.52. THE PROBLEM WAS SOLVED. I DON'T BELIEVE THE OLD PART IS STILL AVAILABLE. BUT, AFTER SPEAKING WITH OTHER MECHANICS, I HAVE HEARD THIS HAS BEEN A PROBLEM WITH SEVERAL VEHICLES OF THIS TYPE AND WANTED TO LET SOMEONE KNOW I HAD A PROBLEM WITH THIS TOO.
Steering, Suspension, Sep 7, 2005
DT: THE CONTACT OWNS A 2002 FORD EXPLORER. THE CONTACT STATED THAT THE REAR BEARING WENT OUT ON 9-6-05. THE CONSUMER IS UNSURE IF IT WAS ON THE RIGHT OR THE LEFT. SHE DID NOT HEAR A NOISE PRIOR TO THIS BUT REPORTED THAT THE VEHICLE FELT SLUGGISH. THE CONTACT SAID THAT THE VEHICLE WAS NOT STEERING PROPERLY AND IT WAS PULLING ALL OVER THE ROAD. SHE REPORTED THAT STEERING WAS VERY SLOPPY AND SHE COULD NOT CONTROL THE VEHICLE. SHE CALLED FORD MOTOR COMPANY AND THEY TOOK A COMPLAINT FROM HER AND SAID THEY WOULD EVALUATE IT WITHIN 3-5 DAYS.*AK *MR
Suspension, Aug 28, 2005
BOTH REAR COIL SPRINGS ARE BROKEN - MILEAGE 50,000. JUST NOTED WHILE DOING UNDERCARRIAGE INSPECTION. *JB
Suspension, Aug 19, 2005
BROKEN REAR SPRINGS
Suspension, Power train, Structure, Aug 18, 2005
DT: THE CONTACT OWNS A 2002 FORD EXPLORER XLT. THE CONTACT HAS BEEN HAVING A PROBLEM WITH THE REAR END. THE REAR END MADE AN EXTREMELY LOUD ROARING SOUND. TOOK THE VEHICLE THE VEHICLE TO THREE DIFFERENT REPAIR SHOPS. ONE SAID IT WAS THE TIRES, AND THE OTHER TWO MAINTAINED THAT IT WAS AN EXPENSIVE REAR END PROBLEM. SHE TALKED TO OTHER PEOPLE WITH THIS SAME TYPE OF VEHICLE AND THEY ALL HAD THIS PROBLEM. ALSO, HAD A RING AND PINION REPLACED IN THE REAR END NOT LONG AFTER SHE PURCHASED THE VEHICLE. CURRENTLY, THEY TOLD HER THAT THIS WHAT WAS NEEDED TO BE REPLACED AGAIN ALONG WITH OTHER PARTS , INCLUDING THE REAR AXLE. THIS NOISE ORIGINALLY STARTED AT 55-65 MPH, AND NOW IT WAS MAKING NOISE AT 40-70 MPH. AFTER GOING OVER 70 MPH COULD NOT HEAR IT AS BADLY. ALSO, THE VEHICLE WAS LEAKING FLUID FROM THE RING AND PINION. A STRANGE SOUND THAT WAS COMING FROM UNDER THE HOOD, LIKE A BUZZING SOUND THAT SOUNDS LIKE TRANSMISSION. IN ADDITION, THE HATCHBACK GLASS FELL ON THE CONTACT'S HEAD. IT JUST POPPED OUT. THIS HAPPENED TWICE. THEY DO NOT EVEN ATTEMPT TO OPEN THE GLASS IN THE HATCH. THE DEALERSHIP WHERE SHE PURCAHSED HER VEHICLE STILL HAS RECORDS OF WHAT WAS REPLACED ON VEHICLE.*AK
Steering, Suspension, Engine and engine cooling, Power train, Aug 17, 2005
ABS LIGHT CAME ON AT 19,518 MILES, 22,071 MILES, AND 27,078 MILES. MORE IMPORTANTLY, HOWEVER, ARE MY ISSUES WITH THE 2002 EXPLORER REAR END. 10/1/03: 27,078 MILES ABS LIGHT CAME ON, THE DEALER REPLACED THE ASSEMBLY. REAR DIFFERENTIAL WAS LEAKING, DEALER REPLACED THE SEALS. 7/28/04: 40,541 MILES REAR END LEAKING AGAIN. HALF SHAFTS WERE WORN. REAR LOCKING DIFF WAS SLIPPING. THE DEALER HAD TO REPLACE BOTH HALFSHAFTS, SEALS, AND CLUTCH PACKS. 9/22/04: 43,203 MILES REAR AXLE CHATTERING. REPLACED WHOLE REAR AXLE ASSEMBLY. 2/25/05: 54,960 MILES REAR DIFF MAKING MORE NOISE. LEFT REAR AXLE BEARING WAS NOISY. REPLACED LEFT REAR AXLE HUB AND ASSEMBLY. ON TEST DRIVE, THE DEALER FOUND THAT THE BEARING THEY JUST INSTALLED WAS BAD, SO THEY HAD TO REPLACE IT AGAIN. 8/11/05: 68,000 MILES LEAKING FLUID FROM REAR END. THE DEALER PERFORMED THE FOLLOWING MAINTENANCE: REPLACED DIFF SEALS, REPLACED TIMING CHAIN, REPLACED RIGHT FRONT HUB ASSEMBLY, REPLACED RING AND PINION, REPLACED FRONT END TIE RODS, REPLACED BOTH LOWER BALL JOINTS, PERFORMED FRONT END ALIGNMENT. ALL TOLD, I HAVE HAD MY EXPLORER IN THE SHOP AT LEAST 10 TIMES. MY WARRANTY IS ABOUT TO EXPIRE (7,000 MORE MILES) AND I'M GOING TO TRY TO GET FORD TO BUY THE VEHICLE BACK. FROM WHAT I'VE HEARD, THIS IS NOT AN EASY PROCESS AND APPARENTLY DOESN'T HAPPEN OFTEN WITH SUCH 'HIGH MILEAGE' VEHICLES. IF THEY DON'T BUY IT BACK I WILL BE FORCED TO TAKE A HUGE LOSS ON THE VEHICLE. I WILL THEN PURCHASE ANYTHING BUT A FORD. *JB