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
3,613 reports, newest first.
Service brakes, Hydraulic, Aug 20, 2002
VEHICLE WOULD INTERMITTENTLY HAVE EXTENDED STOPPING DISTANCE. BRAKE WOULD SQUEAL ,AND PEDAL WOULD BE SOFT WHEN APPLIED. DEALER CONTACTED. FEEL FREE TO PROVIDE ANY FURTHER INFORMATION.*AK
Engine and engine cooling, Aug 20, 2002
VEHICLE WOULD INTERMITTENTLY STALL WHILE DRIVING AT MULTIPLE SPEED. DEALER WAS NOTIFIED, AND UNABLE TO LOCATE CAUSE OF PROBLEM. FEEL FREE TO PROVIDE ANY FURTHER INFORMATION.*AK
Structure, Aug 15, 2002
WHILE PARKED WITH REAR WINDOW OF LIFTGATE RAISED FOR ABOUT 30 MINUTES, IT WAS SHATTERED. OCCUPANT DID GET CUT BY PIECES FLYING OF GLASS. TEMPERATURE THAT DAY WAS ABOUT 70 DEGREES. A WITNESS SAW THE INCIDENT, AND TOLD THE OTHER PARTY THAT THE YOUNG LADY DIDN'T DO ANYTHING TO CAUSE THIS. GLASS/ASSEMBLY IS BEING ORDERED AND GLASS HAS BEEN MODIFIED. A FORD DEALERSHIP TOLD HER THAT THEY HAVE NEVER HEARD OF AN INCIDENT LIKE THIS. PLEASE DESCRIBE DETAILS. *AK PE04045.PCO
Vehicle speed control, Aug 14, 2002
WHILE GIVING ACCELERATION AT ANY SPEED AND NO WARNING ACCELERATOR PEDAL WILL GET STUCK, AND IT WILL BE HARD TO STOP VEHICLE. DEALER NOTIFIED. *AK
Service brakes, Hydraulic, Aug 13, 2002, crash
WHILE APPROACHING AN INTERSECTION APPLIED BRAKES AND PEDAL WENT ALL THE WAY TO THE FLOOR. VEHICLE RAN ON A CURB AND HIT A FIRE HYDRANT. DEALERSHIP WAS AWARE OF PROBLEM.*AK
Service brakes, Hydraulic, Aug 13, 2002
WHILE DRIVING CALIPERS ARE NOT CATCHING ONTO BRAKES, MAKING IT HARD FOR CONSUMER TO STOP. DEALER NOTIFIED.*AK
Power train, Aug 13, 2002
WHEN COMING TO A STOP ON AN INCLINE TRANSMISSION SHIFTS TO NEUTRAL, CAUSING VEHICLE TO ROLL BACKWARDS. DEALER STATED THERE IS A TSB ON THIS ISSUE, TO REFILL TRANSMISSION FLUID. FORD HAS NO REMEDY FOR IT AT THIS TIME. TRANSMISSION FLUID LEAKS FROM CONVERTER HOUSING INTO TRANSFER CASE.*AK
Vehicle speed control, Aug 12, 2002
MY FAMILY AND I WERE TRAVELING ON VACATION ON JULY 20,2002. WE WERE DRIVING OUR NEW FORD EXPLORER XLT. I STOPPED FOR FUEL AND WAS RE-ENTERING THE INTERSTATE. TRAFFIC WAS HEAVY SO I HAD TO ACCELERATE TO ABOUT 60MPH TO ENTER THE TRAFFIC. AS I MADE MY ENTRANCE, I LET OFF THE ACCELERATOR AS I WAS BETWEEN TWO 18 WHEELERS. I REMOVED MY FOOT FROM THE ACCELERATOR AND THE VEHICLE CONTINUED AT FULL SPEED ALMOST REAR ENDING THE SEMI. I WAS APPLYING MY BRAKE WITH ALL MY STRENGTH TO NO AVAIL. THE VEHICLE CHARGED AHEAD. I STEERED TO THE SHOULDER AVOIDING THE SEMI AND BEGAN STOMPING THE ACCELERATOR AT WHICH TIME IT FINALLY RELEASED. MY FAMILY AND I WERE TERRIFIED. I GOT THE VEHICLE BACK TO MY DEALER IN LEXINGTON WHERE IT WAS EXAMINED AND THE POSITION TAKEN THAT THERE IS NOTHING WRONG WITH THE VEHICLE. "THE PROBLEM COULDN'T BE VERIFIED". I WAS TOLD TO COME AND GET MY VEHICLE THAT NOTHING IS WRONG WITH IT. MY WIFE AND DAUGHTER ARE TERRIFIED OF THE VEHICLE AND WE CAN GET NO RELIEF FROM FORD. I DID CONTACT FORD IN DETROIT AND GOT THE SAME ANSWER-NOTHING WRONG WITH THE VEHICLE.*AK
Suspension, Aug 9, 2002
THE TRUCK SEEMS TO HAVE A TIRE OR SUSPENSION HOP/CHATTER AFTER GOING OVER ALL TYPES OF BUMPS SMALL/LARGE, DOES NOT SEEM AFFECT THE DRIVING ABILITY BUT IT IS ANNOYING. ANY OTHER COMPLAINTS ON THIS? ALSO COULD NOT LOCATE DOT # ON TIRES, MADE IN CANADA.*AK
Seat belts, Aug 8, 2002
THE FRONT PASSENGER-SIDE SEAT BELT UNIT LOCKS UP IN FULLY RETRACTED POSITION, RENDERING IT TOTALLY UNUSABLE.*AK
Tires, Aug 6, 2002
I HAVE THE WARRANTY AND THEY WILL NOT COVER. I AM DRIVING WITHOUT A SPARE TIRE.*AK
Steering, Aug 6, 2002
DRIVING ON HIGHWAY 70 MPH SWERVED TO AVOID A TIRE IN ROAD CAR OVER STEERS, YOU MUST TURN BACK THE OPPOSITE WAY THEN YOU ARE OUT OF CONTROL IN THAT DIRECTION. ANY SUDDEN MANUVER YOU ARE OUT OF CONTROL. I TOOK THE TRUCK TO FORD SERVICE THEY SAID "YOU HAVE A SHORT WHEEL BASE, THAT WILL GET YOUR ATTENTION"*AK
Power train, Jul 31, 2002
BECAUSE IT PERFORMED AS IF IT WERE IN NEUTRAL WHILE IN DRIVE COMING FROM A STOP, I NEARLY ROLLED INTO VEHICLES BEHIND ME THEN WHEN IT SPED OUT OF CONTROL WHEN IT GRABBED DRIVE, I NEARLY COLLIDED INTO VEHICLES IN FRONT OF ME EVEN WHILE BRAKING.*AK
Fuel system, Gasoline, Visibility, Seat belts, Jul 31, 2002
DRIVERS SIDE SAFTEY BELT HAS BROKEN TOO, AIR VENT HAS BROKEN TOO, SUNROOF DESIGN PROBLEM TOO, FUEL PUMP FAILED AT 14000 MI TOO
Steering, Engine and engine cooling, Jul 25, 2002
CONSUMER STATES WHILE DRIVING THE STEERING WHEEL LOCKED AND VEHICLE STALLED. CONSUMER IS NOT ABLE TO UNLOCK STEERING WHEEL AND VEHICLE WILL NOT START.*JB
Power train, Jul 24, 2002
WHEN AT STOP SIGN OR SWITCHING FROM BRAKE TO GAS PEDAL TRUCK WOULD ROLL EITHER FORWARD OR BACKWARDS BECAUSE OF TRANSMISSION HESITATION. TRANSMISSION HAS BEEN REPLACED BEFORE THREE OTHER TIMES. PLEASE DESCRIBE DETAILS. *AK
Power train, Electrical system, Visibility, Structure, Jul 24, 2002
MAIN COMPUTER MODULE MALFUNCTIONS, CAUSING OTHER MAJOR COMPONENTS, SUCH AS TRANSMISSION/ POWER WINDOW, AND DOORS NOT TO WORK. *AK
Suspension, Jul 24, 2002
WHEN DRIVING AT 50MPH AND HIGHER VEHICLE VIBRATES UNCONTROLLABLY. DEALER HAS INSPECTED VEHICLE SEVERAL TIMES, AND PROBLEM STILL EXISTS. *AK CONSUMER STATES THAT FORD BOUGHT BACK VEHICLE AND REFUNDED HIS MONEY. *SLC
Engine and engine cooling, Jul 23, 2002
FREQUENCY AND INTENSITY OF STALLING INCREASING.*AK
Engine and engine cooling, Jul 22, 2002
WHILE DRIVING CONSUMER LOST ALL STEERING POWER AT 70 MPH AND THE DASH LIGHTS BEGAN BLINKING. DEALER CAN NOT DUPLICATE PROBLEM. *TT
Service brakes, Hydraulic, Engine and engine cooling, Fuel system, Gasoline, Power train, Vehicle speed control, Jul 19, 2002
VEHICLE EXPERIENCES PERIODS OF STALLING AT LOW SPEEDS. APPLYING BRAKES THERE IS A LOSS OF BRAKES AND STEERING. NO PRIOR WARNING BEFORE STALLING. EXISTING PROBLEM 5 TIMES, TAKEN INTO THE DELAER. *AK DEALER REPLACED FUEL PUMP, MAIN CONTROL VALVE BODY, TRANSMISSION OIL PAN, IDLE AIR CONTROL VALVE AND PROGRAMMED PCM. VIBRATION LIKE ANTI-LOCK BRAKE SYSTEM IS KICKING IN. DEALER COULD NOT DUPLICATE. OVERDRIVE COMES IN AND OUT AT ODD SPEEDS. NO PROBLEM FOUND.
Power train, Jul 19, 2002
OVERDRIVE LIGHT WAS FLASHING, THEN STAYED ON. DEALER DETERMINED TRANSMISSION HAD TO BE REPLACED.*AK
Exterior lighting, Jul 18, 2002
WHILE DRIVING AT HIGHWAY SPEEDS HEADLIGHTS WENT OUT. DEALER HAS REPLACED HEAD LAMP CONTROL AND HEAD LAMP RELAY. PLEASE PROVIDE FURTHER INFORMATION.*AK
Power train, Jul 17, 2002
VEHICLE WAS PURCHASED IN APRIL 2002. VEHICLE BROKE DOWN IN JULY WHILE CONSUMER WAS DRIVING, ALMOST CAUSING AN ACCIDENT. DEALER ADVISED CONSUMER THAT TRANSMISSION NEEDED TO BE REPLACED.*AK
Electrical system, Structure, Jul 17, 2002
MOUNTING BRACKET ON GLASS LIFTGATE BECAME DETACHED FROM STRUT-LIFT MECHANISM JOINT UPON REACHING MAXIMUM EXTENSION CAUSING GLASS TO FALL ONTO MY HEAD. REPORTED TO DEALER BUT NOT REPAIRED/REPLACED DUE TO PARTS N/A. OFTEN HAVE DIFFICULTY TURNING IGNITION SWITCH AFTER INSERTING EITHER OF THE FACTORY KEYS. IT REQUIRES A "JIGGLING" MOTION TO ENGAGE AND TURN IGNITION. PE04045.PCO