2002 Ford Expedition Fuel system Problems
- Complaints
- 21about this part
- Share
- 6%of 340 total for the year
- Median mileage
- 62,000miles
- Trend
- FallingComplaints filed in the last 3 full calendar years are at least 25% lower than in the 3 years before.
NHTSA recorded 21 complaints about the fuel system of the 2002 Ford Expedition, 6% of the 340 complaints for this model year. Where a mileage was given, the median is 62,000 miles. 3 a fire, according to the filers.
Example complaints
Selected from NHTSA records; personal details are removed. They are consumer reports, not findings.
“Spark plug popped out my iginition coil and the threading section is stripped. When I started my car an exploration sound occurred. Also, my driver side head light won't stay lite even with replacement light unit. Also car stalls when car is facing down a hill, even with a full tank of gas.”
NHTSA complaint #10669326, filed 2014-12, 155,000 miles“On every fillup of gasoline I have gasoline vapors inside the car which necessitates my opening windows to rid the interior of the strong fumes. There is no spilled liquid and my shoes are clean and all windows are closed and the car is not running and the havoc is off. I am in fear of fire. The service department has not been able to find a problem. This has been present for more than 4 years and has been reported over 10 times to the service department.”
NHTSA complaint #10213502, filed 2008-01, 50,000 miles“Spark plug flew out of engine...was replaced before with a helicoil kit but same issue occurred today. I was driving to work and I heard it shoot from the engine.”
NHTSA complaint #10297710, filed 2009-12, 156,000 miles“My 2002 Expedition 4.6 has for the past year stalled out on an incline with 1/4 tank of gas. It will also revved up and lurch forward when restarted, even while standing on brakes. The dealership has replaced many things and has no reason why it does this. I have had enough. This is a 2002 automobile and the 21st century, this shoudl not be happening to a new car. A dealership should not be unable to correct this problem. Ford needs to find the problem and issue a recall, before a lawsuit ensues.”
NHTSA complaint #10098580, filed 2004-11, 48,000 miles“Ford triton engine spitting spark-plugs out of engine resulting in gasoline being sprayed all over engine. Costly repairs are minimum $400+. This has happened 4 times to me and I can anticipate it happening on the remaining 4 cylinders in my 2002 Ford Expedition. As a result of this problem Ford is aware of, gasoline is being sprayed on 1000's of engines when this happens. Bad design by Ford. Aluminum heads on iron engine. Duh. My investigation has determined that there are 1000's of Ford owner who have experienced this same problem yet Ford is unwilling to do anything about it. …”
NHTSA complaint #10288991, filed 2009-10, 41,000 milesFuel system: other model years
| Year | Complaints | Share of year |
|---|---|---|
| 2025 | 1 | 3% |
| 2024 | 2 | 3% |
| 2023 | 4 | 6% |
| 2022 | 14 | 12% |
| 2021 | 14 | 6% |
| 2020 | 5 | 1% |
| 2019 | 10 | 2% |
| 2018 | 9 | 2% |
| 2017 | 20 | 6% |
| 2016 | 17 | 8% |
| 2015 | 22 | 13% |
| 2013 | 2 | 2% |
| 2012 | 4 | 3% |
| 2011 | 4 | 6% |
| 2009 | 2 | 7% |
| 2008 | 9 | 6% |
| 2007 | 37 | 17% |
| 2006 | 24 | 8% |
| 2005 | 65 | 21% |
| 2004 | 23 | 8% |
| 2003 | 38 | 6% |
| 2002 | 21 | 6% |
| 2001 | 22 | 4% |
| 2000 | 19 | 2% |
| 1999 | 27 | 3% |
| 1998 | 28 | 3% |
| 1997 | 19 | 2% |
Other parts of the 2002 Ford Expedition
95 complaintsVehicle speed control
58 complaintsElectrical system
46 complaintsEngine
27 complaintsTires
26 complaintsBrakes
22 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 30, 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