NHTSA lists 3,428 complaints for the 2002 Ford Explorer, 154 of them mention a crash and 64 mention a fire. 162 complaints mention an injury, with 201 injuries and 6 deaths reported.
Data build 2026-10-07.
NHTSA lists this vehicle as FORD EXPLORER.
Model-generated complaint tags: This model year has not been tagged.
Recalls
7 recalls.
Date: 2009-10-13. Systems: VEHICLE SPEED CONTROL.
Defect: 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 OVERHEA (excerpt)
Consequence: A VEHICLE FIRE COULD OCCUR WITH OR WITHOUT THE ENGINE RUNNING. (excerpt)
Remedy: 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. (excerpt)
Do not drive: No. Park outside: No.
Date: 2007-08-03. Systems: VEHICLE SPEED CONTROL.
Defect: ON CERTAIN PICKUP TRUCKS, PASSENGER VEHICLES, SPORT UTILITY VEHICLES, AND MOTOR HOMES CHASSIS, THE SPEED CONTROL DEACTIVATION SWITCH MAY, UNDER CERTAIN CONDITIONS, LEAK INTERNALLY AND THEN OVERHEAT, SMOKE, OR BURN. (excerpt)
Consequence: THIS COULD RESULT IN AN UNDERHOOD FIRE. (excerpt)
Remedy: DEALERS WILL INSTALL A FUSED WIRING HARNESS. OWNERS OF THE PASSENGER CARS INCLUDED IN THIS CAMPAIGN WILL BE INSTRUCTED TO RETURN THEIR VEHICLES TO THEIR DEALERS TO HAVE THE SPEED CONTROL DEACTIVATION SWITCH DISCONNECTED AS AN INTERIM REPAIR. AS SOON AS REPAIR PARTS ARE AVAILABLE (EXPECTED OCTOBER 2007), OWNERS WILL BE INSTRUCTED TO RETURN TO THE DEALERS FOR INSTALLATION OF A FUSED WIRING HARNESS (excerpt)
Do not drive: No. Park outside: No.
Date: 2006-04-10. Systems: SEATS.
Defect: ON CERTAIN SPORT UTILITY VEHICLES EQUIPPED WITH HIGH BACK SEATS, THE UPPER BOLT ON THE DRIVER'S SIDE HIGH BACK SEAT THAT ATTACHES THE SEAT RECLINER MECHANISM TO THE SEAT BACK FRAME, COULD FRACTURE. IF THE BOLT FRACTURES, THE SEAT BACK MAY RECLINE UNTIL IT MAKES CONTACT WITH AN OBJECT BEHIND THE SEAT, SUCH AS THE SECOND ROW SEAT CUSHION.
Consequence: THE DRIVER COULD POTENTIALLY LOSE CONTACT WITH THE STEERING WHEEL OR FOOT PEDALS DURING SUCH AN EVENT, INCREASING THE RISK OF A CRASH.
Remedy: DEALERS WILL REPLACE THE DRIVER SEAT UPPER BOLT WITH A METAL SPACER AND BOLT. IN ADDITION, SEATS WITH TUBULAR BACK FRAMES WILL HAVE THE FULLY THREADED LOWER RECLINER BOLT REPLACED WITH A PARTIALLY THREADED BOLT. THE RECALL BEGAN ON APRIL 10, 2006. OWNERS MAY CONTACT FORD AT 1-800-392-3673. THIS IS A SUPPLEMENT TO A PREVIOUS RECALL CAMPAIGN (03V281).
Do not drive: No. Park outside: No.
Date: 2004-09-13. Systems: STRUCTURE.
Defect: 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. (excerpt)
Consequence: IF THE HINGE SHOULD FRACTURE, THERE IS A POTENTIAL FOR THE GLASS TO FALL AND ULTIMATELY BREAK AND PERSONAL INJURIES COULD OCCUR. (excerpt)
Remedy: 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, (excerpt)
Do not drive: No. Park outside: No.
Date: 2003-08-05. Systems: SEATS.
Defect: ON CERTAIN SPORT UTILITY VEHICLES EQUIPPED WITH HIGH BACK SEATS, THE UPPER BOLT ON THE DRIVER'S SIDE HIGH BACK SEAT, THAT ATTACHES THE SEAT RECLINER MECHANISM TO THE SEAT BACK FRAME, COULD FRACTURE. IF THE BOLT FRACTURES AND DOES NOT JAM IN THE SEAT BACK FRAME, THE SEAT BACK MAY RECLINE UNTIL IT MAKES CONTACT WITH AN OBJECT BEHIND THE SEAT, SUCH AS THE SECOND ROW SEAT CUSHION.
Consequence: THE DRIVER COULD POTENTIALLY LOSE CONTACT WITH THE STEERING WHEEL OR FOOT PEDALS DURING SUCH AN EVENT, INCREASING THE RISK OF A CRASH.
Remedy: DEALERS WILL REPLACE THE DRIVER SEAT UPPER BOLT WITH A METAL SPACER AND BOLT. IN ADDITION, SEATS WITH TUBULAR BACK FRAMES WILL HAVE THE FULLY THREADED LOWER RECLINER BOLT REPLACED WITH A PARTIALLY THREADED BOLT. OWNER NOTIFICATION BEGAN ON AUGUST 29, 2003. OWNERS SHOULD CONTACT FORD AT 1-800-392-3673.
Do not drive: No. Park outside: No.
Date: 2003-03-07. Systems: STRUCTURE.
Defect: 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.
Consequence: THIS OVERHEATING CONDITION CAN CAUSE THE RUNNING BOARD TO MELT OR CAUSE A FIRE.
Remedy: 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.
Do not drive: No. Park outside: No.
Date: 2001-05-24. Systems: TIRES.
Defect: 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.
Consequence: OVER TIME, THE TIRE COULD FAIL, INCREASING THE RISK OF A CRASH.
Remedy: 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.
Do not drive: No. Park outside: No.
Investigations
8 investigations; 0 open.
EA09013
Opened: 2009-08-18. Closed: 2013-02-12.
Vehicle Rollaway Allegations
This investigation is being closed based on several considerations.By the most inclusive counting of all alleged rollaway incidents (i.e., counting all alleged rollaway incidents and assuming a singular failure mechanism), the incident rate is low, however during EA09-013, ODI identified a number of different failure mechanisms in 180 incidents related to the alleged defect.The highest rate for an
Systems: POWER TRAIN, STEERING.
Linked campaign numbers: None listed.
PE09020
Opened: 2009-04-21. Closed: 2009-08-19.
VEHICLE ROLLAWAY ALLEGATIONS
IN RESPONSE TO AN INFORMATION REQUEST (IR) LETTER SENT BY THE OFFICE OF DEFECTS INVESTIGATION (ODI), FORD STATED CONSUMER REPORTS OF HIGHER THAN EXPECTED EFFORTS WHEN SHIFTING INTO AND OUT OF PARK COULD BE A RESULT OF A GROOVE BEING WORN INTO THE SWING ARM RAMP OF THE STEERING COLUMN. THE SWING ARM IS A COMPONENT BOLTED TO THE STEERING COLUMN THAT ASSISTS IN SHIFTING THROUGH THE TRANSMISSION GEARS
Systems: STEERING.
Linked campaign numbers: None listed.
DP05005
Opened: 2005-09-22. Closed: 2006-01-04.
SPARK PLUG EJECTION FROM CYLINDER HEAD
ON SEPTEMBER 6, 2005, ODI RECEIVED A PETITION REQUESTING THAT THE AGENCY INVESTIGATE ALLEGATIONS OF ENGINE SPARK PLUG EJECTION IN CERTAIN MODEL YEAR 1997 THROUGH 2004 FORD VEHICLES WITH TRITON V-8 AND V-10 ENGINES.ODI RECEIVED A TOTAL OF 474 NON-DUPLICATIVE COMPLAINTS ON THE SUBJECT VEHICLES WHERE THE COMPLAINANT, OR THE DEALER REPAIRING THE VEHICLE, REPORTED THAT A SPARK PLUG DETACHED FROM THE CY
Systems: ENGINE AND ENGINE COOLING.
Linked campaign numbers: None listed.
PE05037
Opened: 2005-07-07. Closed: 2005-11-02.
STUCK ENGINE THROTTLE
ON JULY 7, 2005, THE OFFICE OF DEFECTS INVESTIGATION (ODI) OPENED A PRELIMINARY EVALUATION TO INVESTIGATE ALLEGED STUCK THROTTLE COMPLAINTS IN CERTAIN MODEL YEAR (MY) 2002 FORD EXPLORER AND MERCURY MOUNTAINEER VEHICLES EQUIPPED WITH THE STANDARD AVAILABLE 4.0L SOHC V6 ENGINE.AT THAT TIME, ODI WAS AWARE OF 15 COMPLAINTS THAT ALLEGED STUCK ENGINE THROTTLE CAUSING UNWANTED VEHICLE ACCELERATION AND 1
Systems: VEHICLE SPEED CONTROL.
Linked campaign numbers: None listed.
PE04045
Opened: 2004-06-02. Closed: 2004-09-28.
REAR LIFTGATE GLASS ASSEMBLY
COMPLAINTS REPORT FAILURE OF THE REAR LIFTGATE GLASS SUPPORT WHILE THE OPERATOR IS OPENING OR CLOSING THE GLASS.THE FALLING GLASS CAN STRIKE THE OPERATOR OR BYSTANDER.THE INJURIES REPORTED ARE BRUISES TO THE HEAD, NECK OR BACK, CUTS TO THE FACE, ARM OR HAND.ON SEPTEMBER 9, 2004, FORD NOTIFIED THE AGENCY THAT IT WILL RECALL APPROXIMATELY 955,732 MY 2002 AND 2003 FORD EXPLORER AND MERCURY MOUNTAINEE
Systems: STRUCTURE.
Linked campaign numbers: 04V442000.
PE03020
Opened: 2003-05-21. Closed: 2003-09-05.
FRONT SEAT BACK RECLINER ATTACHMENT
BY LETTER DATED AUGUST 4, 2003, FORD NOTIFIED THE AGENCY THAT IT IS CONDUCTING A VOLUNTARY SAFETY RECALL (NHTSA RECALL NO. 03V281) INVOLVING CERTAIN MODEL YEAR (MY) 1998-2001 FORD EXPLORER / MERCURY MOUNTAINEER 4-DOOR, MY 1998-2000 FORD EXPLORER 2-DOOR AND MY 2001-2002 FORD EXPLORER SPORT AND SPORT TRAC VEHICLES EQUIPPED WITH HIGH BACK SEATS.COMPLAINTS ALLEGE THAT THE DRIVER'S SEAT BACK RECLINED W
Systems: SEATS.
Linked campaign numbers: 03V281000.
EA02010
Opened: 2002-07-02. Closed: 2003-02-25.
MIS-ASSEMBLED AIRBAG CLOCKSPRING
IN JULY 2001, FORD ISSUED A SPECIAL SERVICE MESSAGE ANNOUNCING THAT SOME AIR BAGCLOCKSPRING DEVICES MAY PRODUCE NOISE WHEN THE STEERING WHEEL IS TURNED FULL LEFT OR RIGHT.FORD WAS AWARE THAT SOME CLOCKSPRINGS MAY HAVE BEEN IMPROPERLY INSTALLED.THE IMPROPER INSTALLATION MAY ALSO CAUSE AN OPEN CIRCUIT AND THE AIR BAG WARNING LIGHT TO ILLUMINATE.STARTING WITH VEHICLES PRODUCED IN SEPTEMBER 2001, FORD
Systems: AIR BAGS.
Linked campaign numbers: None listed.
SQ01015
Opened: 2001-12-12. Closed: 2002-07-02.
INOPERATIVE AIR BAG SYSTEM
Summary unavailable
Systems: AIR BAGS.
Linked campaign numbers: None listed.
Manufacturer communications
323 manufacturer communications.
Communications by system| System | Count |
|---|
| POWER TRAIN | 78 |
|---|
| ENGINE AND ENGINE COOLING | 67 |
|---|
| ELECTRICAL SYSTEM | 32 |
|---|
| STRUCTURE | 23 |
|---|
| UNKNOWN OR OTHER | 18 |
|---|
| SERVICE BRAKES, HYDRAULIC | 15 |
|---|
| STEERING | 15 |
|---|
| EQUIPMENT | 14 |
|---|
10155551
Date: 2019-02-07. Type: Service Bulletin/Repair Instructions. Systems: STRUCTURE.
Some 2000 and newer Ford, Lincoln and Mercury vehicles equipped with aluminum body panels may exhibit corrosion concerns appearing as bubbled and/or peeling paint with or without accompanying white dust. Panel replacement is recommended. Follow the Service Procedure steps to correct the condition
10156863
Date: 2019-02-07. Type: Service Bulletin/Repair Instructions. Systems: EQUIPMENT, STRUCTURE.
Some 2000 and newer Ford, Lincoln and Mercury vehicles equipped with aluminum body panels may exhibit corrosion concerns appearing as bubbled and/or peeling paint with or without accompanying white dust. Panel replacement is recommended. Follow the Service Procedure steps to correct the condition
10028736
Date: 2009-05-01. Type: Service Bulletin/Repair Instructions. Systems: POWER TRAIN.
FORD: SOME VEHICLES MAY EXHIBIT OIL SEPARATION FROM THE INTERNAL LUBE FOUND IN THE UNITIZED CARTRIDGE SEAL. OIL SEPARATION APPEARS TO BE AND IS OFTEN MISDIAGNOSED, AS AN AXLE LUBE LEAK. *PE
10023943
Date: 2007-10-01. Type: Service Bulletin/Repair Instructions. Systems: ENGINE AND ENGINE COOLING.
SOME 1997-2008 VEHICLES EQUIPPED WITH A 4.6L 2V, 5.4L 2V, OR 6.8L 2V ENGINE--SPARK PLUG THREAD REPAIR PROCEDURE--NOT COVERED UNDER NEW VEHICLE LIMITED WARRANTY. *NJ THIS INCLUDES F-53 MOTORHOME CHASSIS. UPDATED 2/23/10. *PE
10014100
Date: 2006-01-01. Type: Service Bulletin/Repair Instructions. Systems: POWER TRAIN.
LIMITED SLIP AXLE CHATTER, SHUDDER, BINDING SENSATION, OR VIBRATION DURING LOW SPEED TURNING MANEUVERS. *TT
10019379
Date: 2006-01-01. Type: Service Bulletin/Repair Instructions. Systems: FUEL SYSTEM, OTHER.
MALFUNCTION INDICATOR LAMP ON WITH PCM DIAGNOSTIC TROUBLE CODE P0463 AND/OR IC DIAGNOSTIC TROUBLE CODE B1201 - FUEL GAUGE DROPS TO EMPTY OR SLOW TO UPDATE AFTER REFUELING. *TT
10018959
Date: 2005-12-14. Type: Service Bulletin/Repair Instructions. Systems: ENGINE AND ENGINE COOLING.
EXTENDED COVERAGE PROGRAM 05N04 - EXTENDED COVERAGE FOR COMPOSITE INTAKE MANIFOLD. THIS PROGRAM IS BEING PROVIDED AS A SETTLEMENT TO A CLASS ACTION LAWSUIT. THE TERMS OF THE SETTLEMENT EXTEND THE COVERAGE OF THE ALL-COMPOSITE INTAKE MANIFOLD TO 7 YEARS FROM THE ORIGINAL WARRANTY START DATE OF THE
10018745
Date: 2005-11-14. Type: Service Bulletin/Repair Instructions. Systems: ENGINE AND ENGINE COOLING.
WDS COP KIT DIAGNOSTIC TIP - COIL ON PLUG (COP) IGNITION SYSTEMS - ENGINE MISFIRE OR ROUGH RUNNING. *TT
10013388
Date: 2005-10-31. Type: Service Bulletin/Repair Instructions. Systems: FUEL SYSTEM, DIESEL.
FUEL GAUGE SLOW TO UPDATE AFTER REFUELING. *EH
10018064
Date: 2005-10-07. Type: Service Bulletin/Repair Instructions. Systems: SUSPENSION.
NOISE FROM REAR WHEEL HUB BEARINGS. *TT