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Vehicle safety record

2002 Ford Expedition Problems, complaints & recalls

Owners have filed 383 complaints about the 2002 Ford Expedition with NHTSA, most often about the engine & cooling (123) and the acceleration & cruise control (61). Those complaints describe 21 crashes, 73 fires, 30 injuries and 2 deaths. It is covered by 4 recalls, the latest in August 2006 for the headlights. For comparison, the 2001 has 609 and the 2003 has 655.

NHTSA data checked

FFar more problems than a typical Expedition year, for its age

#34 most complained-about 2002 vehicle

Complaints
383
Recalls
4
Crashes
21
Fires
73
Injuries
30
Deaths
2

Most common 2002 Ford Expedition problems

Share of all 383 complaints. One complaint can name more than one area. Tap an area for its complaints and recalls.

2002 Ford Expedition recalls 4

Recall repairs are free. Your dealer fixes them whether or not you bought the car there - check your VIN at nhtsa.gov/recalls to see if yours is done. What to do

Exterior lighting: headlights

06E06700019,413 vehicles affected

The problem
Certain maxzone headlight assemblies, depo brand, p/nos. 331-1129L-asn and 331-1129r-asn, sold for use as aftermarket equipment for the above listed passenger vehicles. These headlamps fail to conform to the photometric requirements of federal motor vehicle safety standard no. 108, Lamps, reflective devices, and associated equipment.
The risk
Decreased lighting visibility may result in a vehicle crash.
The fix
Maxzone will notify owners and offer reimbursement for any noncompliant headlights. The recall began on july 28, 2006. Owners may contact maxzone at 909-822-3288.

Fuel system

06E05600058,640 vehicles affected

The problem
Certain aftermarket fuel filters sold under the purolator brand name, p/n f65277, shipped from january 16 through june 2, 2006, for use on the above listed passenger vehicles. Due to incorrect design, the quick connectors may not fully seat with the tube interface, even though the person making the connection may believe that the quick connector is fully attached.
The risk
Failure of this connection could lead to fuel spillage and, in the presence of an ignition source, a fire could occur.
The fix
Ufi will notify owners and replace the filters free of charge. The recall began on august 4, 2006. Owners may contact ufi filters usa at 800-230-5876.

Vehicle speed control

05V3880004,500,000 vehicles affected

The problem
On certain pickup trucks and sport utility vehicles equipped with speed control, the speed control deactivation switch may overheat, smoke, or burn.
The risk
A FIRE AT THE SWITCH COULD OCCUR.
The fix
By letter dated september 12, 2005, owners were instructed to return their vehicles to their dealers to have the speed control deactivation switch disconnected. Owners who have had their speed control deactivated are being notified that parts will be available and advised to make an appointment to reconnect the speed control beginning in february 2006. Owners who did not have their speed control deactivated are being notified to have their system remedied beginning in february 2006. Owners are urged to avail themselves of the free disconnect service as soon as possible because of the significant risk of fire. Owners may contact ford at 1-800-392-3673. (Note: also see recalls 05v017 and 06v286)

Structure

03V0940003,674 vehicles affected

The problem
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.
The risk
This overheating condition can cause the running board to melt or cause a fire.
The fix
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.

What owners say

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383 complaints about the 2002 Ford Expedition

Newest first, as filed with NHTSA by owners. Page 1 of 16.

Acceleration & cruise controlFire

Cruise control deactivation switch. I was getting in my truck on my way to work in the early morning. as I walked by the hood I could smell what seemed like burning wire, so I opened the hood & right as I got it all the way up flames started shooting up. I put the fire out and had to wait to call my mechanic he came and told me it was definitely the deactivation switch that had caught fire.

Filed Incident Vehicle speed controlNHTSA 11603537
BrakesAcceleration & cruise control

The contact's fiancée owns a 2002 Ford Expedition. The contact stated that there was smoke coming from the driver's side front end of the vehicle. The contact stated that while his fiancée was attempting to drive the vehicle the following day, the brake pedal was depressed but was firm, requiring the contact's fiancée to step on the brake pedal to drive. The brake pedal remained on the floorboard and was inoperable, causing the contact's fiancée to shift to park(P) to stop the vehicle. The vehicle was towed to the...

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dealer, where it was diagnosed that the speed control deactivation switch (SCDS) connectors had burned, and the brake fluid had leaked from the brake fluid reservoir. The dealer replaced the SCDS sensor and harness under NHTSA Campaign Number: 05V388000 (Vehicle Speed Control). The dealer declined to perform repairs for collateral damages. The contact stated that he was an auto-electrician mechanic who owned an auto shop. The vehicle was then towed to the contact's auto repair shop, where mechanics replaced the brake master cylinder and cleaned brake fluid off the engine bay. The vehicle was repaired. The manufacturer was notified of the failure and referred the contact to the NHTSA Hotline for assistance. The failure mileage was approximately 163,745.

Filed Incident Service brakes, hydraulic · Vehicle speed controlNHTSA 11592816
Acceleration & cruise controlBrakesFuel system

My spark plugs are going bad, I bought three tires. But now I'm having to take it to the shop because it's weird noises coming from the tire it may be the wheel baring or sway bar link and bushing the mechanic say.

Filed Incident Vehicle speed control · Service brakes · Fuel / propulsion systemNHTSA 11470581
Brakes

re: IR 11467550. See attached photo.

Filed Incident Service brakesNHTSA 11467956
Brakes

2002 expedition mfg date 12/2001 right front brake separated at swagged fitting to short tubing to caliper. had just parked, stopped fine. next day all fluid had drained through separated hose.

Filed Incident Service brakesNHTSA 11467550
Acceleration & cruise controlFire

The contact owns a 2002 Ford Expedition. The contact stated that while the vehicle was parked, it caught fire. The fire started from under the hood of the vehicle. The contact was able to extinguish the fire with water. An independent mechanic came to the contact's residence and diagnosed that the failure was related to NHTSA Campaign Number: 05V017000 (Vehicle Speed Control) however, the contact did not receive notification of the recall. The mechanic informed the contact that the speed control deactivation switch...

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caused the fire that damaged the hydraulic control unit and the pigtail. The vehicle was towed to the dealer. The dealer confirmed that the failure was related to the recall. However, the dealer denied the recall repair since the recall was open for many years but was left unrepaired. The contact stated that she had owned the vehicle for a couple of months and was not aware there was a recall. The vehicle was not repaired and remained at the dealer. The manufacturer was not made aware of the failure. The failure mileage was approximately 146,457.

Filed Incident Vehicle speed control · FirerelatedNHTSA 11446373
Engine & cooling

I have replace the drive belt 2 times this month. The belt keep messing up now I have get another belt because it is twisted around the tensioner. I don't know hiw it happen I drive all that day.

Filed Incident EngineNHTSA 11388908
Seats & seat belts

The driver's seat belt disconnects at random times.

Filed Incident Seat beltsNHTSA 11282042
SuspensionSeats & seat beltsFuel system

Two weeks before this problem happen ,the truck starts making tomuch noise and air supention didn't go up no more . And stop making noise .

Filed Incident Suspension · Seat belts · Fuel / propulsion systemNHTSA 11253901
Electrical systemAcceleration & cruise control

CRUSE CONTROL NOT WORKING AND NO HORN

Filed Incident Electrical system · Vehicle speed controlNHTSA 11052067
BrakesAcceleration & cruise controlFire

Tl* the contact owned a 2002 ford expedition. While the vehicle was parked, the contact smelled a burning odor. The contact found that the master cylinder caught fire. The fire department was not contacted. A fire report was not filed. There were no injuries. The vehicle was towed to crowley ford lincoln (225 new britain ave, plainville, ct 06062) where it was deemed destroyed. The dealer did not give a diagnosis, but contacted the manufacturer multiple times to determine what ford should cover. The manufacturer...

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was made aware of the failure and stated that the vin was included in nhtsa campaign number: 05v017000 (vehicle speed control). The manufacturer provided case number: cas12637815 and advised the contact to call his insurance company. The manufacturer stated that they would send an inspector. The approximate failure mileage was 183,000. Updated 09/07/17*lj *cn

Filed Incident Service brakes, hydraulic · Vehicle speed controlNHTSA 11004132
Engine & cooling

Two spark plugs blew out of the head. Pain in the butt to fix. Ford needs to stand behind its name and fix the known problem.

Filed Incident EngineNHTSA 10983475
Engine & cooling

I went to get an oil change I was told by worker at shop that everything under hood was rusty and chances are that this truck was in the new orleans flood (katrina) it was down hill from then. Everything started to malfunction.

Filed Incident EngineNHTSA 10983319
Suspension

Takata recall during an inspection of my suspension for worn bushings, I noted severe corrosion on my rear trailing arms for the rear axle. The lower arm on the passenger side actually had a quarter size hole in the inboard side of the web. This obviously greatly reduces the strength of the arms and could cause axle separation from the vehicle and an obvious control hazard.

Filed Incident SuspensionNHTSA 10981416
Seats & seat belts

The seat belts front, passenger side unlock by themselves while in motion. It can happen during city or highway driving. This has not been repaired by anyone and is factory original. Seems like a danger to passengers.

Filed Incident Seat beltsNHTSA 10958288
Engine & cooling

This is about a blown out spark plug. The blown out spark plug (#4 on passenger side)) happened when my family & I were traveling in highway near stockton ca at around 5 pm. There was no shop open and I had to call aaa to tow the 2002 ford expedition to our friend's house about 30 miles away. It was also a very cold night and we waited for about 1 hr for the tow truck to arrive. It was incredibly inconvenient for this incident to happen on the freeway/highway. I heard that this is a common problem for the older...

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expedition with triton engine. I love ford trucks/suvs and I hope they can fix this problem with the engine before somebody gets in serious trouble. I would rather want to see a recall than a class action suit in the future.

Filed Incident EngineNHTSA 10938939
Engine & cooling

Just want to add my car to the list of ford expedition 5.6L engines that have experienced the spark plug ejection issue. Thankfully, this occured when starting the vehicle, so it did not cause any accident or injury. This is our son's car and we intended it to be the vehicle our 15 year old used as well. However, now that we know about the spark plug problem, we no longer feel it's safe and hope to trade it in. It's extremely disappointing and disheartening to know that ford has not taken responsibility for this issue. Our vehicle had all original factory-installed spark plugs.

Filed Incident EngineNHTSA 10918916
Engine & coolingFire

Tl* the contact owns a 2002 ford expedition. While the vehicle was parked in a residential driveway, the engine compartment erupted into flames without warning and a loud explosion sound emitted from the vehicle. The contact mentioned that the vehicle was completely burned and part of the garage was damaged. The police and fire departments filed reports. There were no injuries. The vehicle was not taken to the dealer. The manufacturer was not made aware of the failure. The vehicle was not repaired. The vin was not available. The failure mileage was 180,000.

Filed Incident EngineNHTSA 10874409
Engine & cooling

Idling at a metered ramp I experienced unintended acceleration while in line waiting for my turn at the metered light.The car in front of me rolled forward and I following suit. I did not touch the accelerator but merely released my foot from the brake pedal. The truck surged forward unexpectedly. I was able to apply the brakes before impacting the car in front of me. As I sternly applied the brakes the engine settled down and all systems worked as expected for the remainder of my commute. 5/23/2016 Approx. 7:25 Am...

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cdt. Sunny and clear weather approx 63 degrees f. "Normal" humidity. My daughter is the primary driver of this vehicle and when asked if this has happened to her the answer to my surprise was yes.

Filed Incident EngineNHTSA 10870278
Body, doors & structureWheels & tiresEngine & coolingFire

The vehicle was driven earlier that day for about 2 to 3 miles and then it was parked inside a private mobile home park. After 30 to 45 minutes had passed, an explosion was heard outside the mobile home park; the vehicle exploded and was on fire. The explosion occurred in the hood and now it is a total loss. This occurred on april 18th, 2016. We contacted the national highway traffic safety administration and they informed us that a recall back in 2005 was issued. The ford motor company has not helped us out in this accident.

Filed Incident Structure · Wheels · EngineNHTSA 10865679
Electrical systemEngine & cooling

Tl* the contact owns a 2002 ford expedition. While starting the vehicle, an abnormal noise was heard from the engine. In addition, the vehicle stuttered without warning. The vehicle was taken to a dealer where it was diagnosed that the plug and ignition coil were replaced. The vehicle was repaired; however, the failure persisted eight months later. The vehicle was taken back to the dealer where it was diagnosed with the same failure. The vehicle was repaired, but the failure persisted. The manufacturer was notified of the failure. The approximate failure mileage was 89,000.

Filed Incident Electrical system · EngineNHTSA 10865245
Engine & cooling

I was driving my truck, when it started to make a crazy noise coming from the engine. I had to pull over and pop the hood and I noticed that my plug on right side head, had blew out. I was on the side of the road and ended up having it towed because I didn't want to drive it in the condition that it was in. I understand most will say this is not a safety issue, however, when this happens in the middle of traffic or going down the interstate, it could very well be a big safety issue. This is a very common issue that I feel ford should be held responsible for.

Filed Incident EngineNHTSA 10852364
Lights

The passenger side turn signal will not work. I have changed fuses, bulb( even though both were good), and have checked wiring and can not get it to work. This is very much a safety issue and I can't imagine that I am the only one this has happen to.

Filed Incident Exterior lightingNHTSA 10852363
Engine & cooling

Spark plug shot from engine. Has 112500 miles on suv. Was ice and snow on back road 30 miles from home at 14 degrees. Sounded like engine blowing up. Then load ping sound in motor and lack of power. Engine shut off on idle. Was stuck. Have not serviced yet. Ford needs to fix this issue immediately. This 5.4 L triton should run for longer than 110,000 miles. My old dodge would not and did not have any issue and it had 130,000 miles when it was wrecked.

Filed Incident EngineNHTSA 10819870
Seats & seat belts

Tl* the contact owns a 2002 ford expedition. The contact stated that the vehicle's driver side seat belts would unlatch independently. The failure occurred without warning. The vehicle was not taken to an independent mechanic or dealer to be diagnosed or repaired. The manufacturer was not made aware of the failure. The failure mileage was approximately 123,000.

Filed Incident Seat beltsNHTSA 10811530

Ford Expedition: every year compared

YearComplaintsRecallsCrashesFiresTop problemGrade
20060600-A
20050500-A
200429744915Engine & coolingF
200365565838Engine & coolingF
200238342173Engine & coolingF
2001609103997Engine & coolingF
200001100-A
19990900-A
19980700-A
All Expedition years

2002 Ford Expedition vs rivals

More sales usually means more complaints, so compare similar vehicles of the same year. The grade compares each vehicle with its own model's other years.

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Questions about the 2002 Ford Expedition

Does the 2002 Ford Expedition have any recalls?

Yes - NHTSA lists 4 recalls for the 2002 Ford Expedition: headlights (August 2006); fuel system, gasoline (June 2006); vehicle speed control (September 2005); structure (March 2003). Recall repairs are free at any authorized dealer. Enter your VIN at nhtsa.gov/recalls to see whether yours has been fixed.

What are the most common problems with the 2002 Ford Expedition?

By the complaints owners filed with NHTSA, the most common problem areas are the engine & cooling (123), acceleration & cruise control (61), electrical system (47).

How many complaints has the 2002 Ford Expedition had?

383 complaints have been filed with NHTSA, the first on July 10, 2001 and the latest on July 20, 2024. Of these, 21 describe a crash and 73 a fire, and together they report 30 injuries and 2 deaths.

Is the 2002 Ford Expedition a reliable vehicle?

Its Safety Index is 15 out of 100 (grade F: far more problems than a typical Ford Expedition year, for its age). The index weighs complaints, crashes, fires, injuries, deaths and recalls against how long the vehicle has been on the road, compared with the same model's other years. It is not a measure of every repair - read the complaints and owner experiences, and have any used vehicle inspected before you buy.

Which Ford Expedition years have the most complaints?
What should I do if my 2002 Ford Expedition has a problem?

If it is a safety problem, stop driving it if it is unsafe and contact your dealer. Report it to NHTSA at nhtsa.gov/report-a-safety-problem - enough reports start investigations and recalls - and share your experience here so other owners know what to look for.

Source: U.S. National Highway Traffic Safety Administration (NHTSA) complaints and recalls, checked . Complaints are owners' own reports and are not verified. How we use the data

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