2002 Ford Expedition Engine cooling Problems
- Complaints
- 95about this part
- Share
- 28%of 340 total for the year
- Median mileage
- 95,800miles
- Trend
- StableComplaints filed in the last 3 full calendar years are within 25% of the 3 years before.
NHTSA recorded 95 complaints about the engine cooling of the 2002 Ford Expedition, 28% of the 340 complaints for this model year. Where a mileage was given, the median is 95,800 miles. 11 a fire, according to the filers.
Example complaints
Selected from NHTSA records; personal details are removed. They are consumer reports, not findings.
“I have a 2002 Ford Expedition and have now twice in the last 6 months have had to have it repaired for the spark plug ejection fro, the motor. The vehicle gave way with its power right in the middle of the intersection. I feel this is a defect and that Ford should take some ownership, it only has 75 thousand miles on it.”
NHTSA complaint #10277512, filed 2009-07, 75,000 miles“While driving my youngest daughter to school there was a loud bang from under the hood and a noticeable loss of power. It sounded like the car had a severe exhaust leak. When taken to my local dealer I was informed that a spark plug had blown out of the engine and that this was a very common occurrence with the 2002 5.4 liter engine. I was told that repairs would run anywhere from $700 to $3500.”
NHTSA complaint #10336099, filed 2010-06, 120,000 miles“I have had two spark plugs blow out of my 2002 Ford Expedition 5.4l v8. The first blew out after pulling out of an intersection from a dead stop. The second was the #2 plug. I was pulling a travel trailer through mountains on a highway. First noticed was a reduction in power for about 60 miles. Then after rounding the top of the mountain, letting off the gas to go down the hill, the plug blew out.”
NHTSA complaint #10328326, filed 2010-05, 109,500 miles“While driving my 2002 Ford Expedition (5.4l) on the interstate, I heard a loud pop and the vehicle immediately lost power and decelerated in heavy traffic. The nearby Ford dealer determined that the no.7 spark plug had blown out . The dealer indicated that they see this all the time with this engine. The vehicle was at the same dealer a few weeks prior, and had the no.8 spark plug replaced (while addressing an ignition coil problem).”
NHTSA complaint #10398962, filed 2011-04, 162,000 miles“# 3 spark plug blew out of head. I was told my Ford dealer its common and Ford will not issue a recall. Triton engines are faulty and Ford knew they sold a bad engine for years, the government must step in. I need a refund.”
NHTSA complaint #10443768, filed 2012-01, 79,000 milesRelated service bulletins
- 10023943Oct 1, 2007Some 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…
- 10018745Nov 14, 2005Wds cop kit diagnostic tip - coil on plug (cop) ignition systems - engine misfire or rough running.
- 10014685Mar 21, 2005Use of stainless steel exhaust studs in service for 5.4l 2v engine.
- 10014666Mar 7, 2005Intermittent rough idle - non-commanded egr (exhaust gas recirculation valve) flow.
- 10011162Aug 23, 2004Engine misfire or running - coil on plug (cop) ignition systems - wds cop kit diagnostic tips. To include various 2005 models. * ar this article 04161 supersedes tsb 03-14-04.
Engine cooling: other model years
| Year | Complaints | Share of year |
|---|---|---|
| 2023 | 1 | 2% |
| 2021 | 3 | 1% |
| 2020 | 4 | 1% |
| 2019 | 31 | 6% |
| 2018 | 25 | 7% |
| 2017 | 5 | 1% |
| 2016 | 3 | 1% |
| 2015 | 1 | 1% |
| 2013 | 1 | 1% |
| 2011 | 2 | 3% |
| 2010 | 3 | 5% |
| 2008 | 3 | 2% |
| 2007 | 9 | 4% |
| 2006 | 75 | 25% |
| 2005 | 47 | 15% |
| 2004 | 26 | 9% |
| 2003 | 127 | 21% |
| 2002 | 95 | 28% |
| 2001 | 122 | 21% |
| 2000 | 116 | 13% |
| 1999 | 248 | 26% |
| 1998 | 127 | 15% |
| 1997 | 89 | 10% |
Other parts of the 2002 Ford Expedition
58 complaintsElectrical system
46 complaintsEngine
27 complaintsTires
26 complaintsBrakes
22 complaintsFuel system
21 complaintsSeat belts
20 complaintsTransmission and drivetrain
18 complaintsAir bags
16 complaintsBody and structure
14 complaintsSuspension
14 complaintsExterior lighting
7 complaints
← All problems reported for the 2002 Ford Expedition
About this data. Data from NHTSA (ODI) complaints, recalls, TSBs and investigations, updated Oct 27, 2026. Complaints are unverified consumer reports and may be duplicated or inaccurate.
To check a specific vehicle for open recalls, use its VIN at nhtsa.gov/recalls. Methodology