2002 Ford Explorer Sport Trac Problems

What owners report

Owners of the 2002 Explorer Sport Trac most often describe transmission complaints — delayed or missed shifts, slipping, and occasional complete failure — which appear across a wide mileage range and are the single largest theme in the sample. A second recurring theme is the cruise-control recall: many owners describe switches that overheated or melted, and several report that their vehicle was excluded from the campaign. Brake wear and pulsation, intermittent stalling, and crumbling body-mount bushings also come up repeatedly, often at relatively low mileage.

1. 1
   Vehicle speed control

   Cruise-control switch overheating and recall parts

   • 17 complaints (12%)
   • median 99,761 mi at 6.2 yrs old (12 state mileage)
   • 4 mention a crash, fire or injury
   • filed 2004–2023

   Owners report the cruise-control deactivation switch on the steering column or master cylinder overheating, melting, smoking, or catching fire, sometimes while the vehicle was parked. Many describe being told their vehicle identification number was not covered by the campaign, or that recall parts were unavailable and the switch was simply disconnected as a temporary measure. A few complaints describe unexpected acceleration or a vehicle that did not respond normally to the brake pedal. Reported from low mileage up to roughly 150,000 miles, including vehicles sitting parked.

   Recall 07V336000

   What to check: Ask whether the speed-control recall work was completed on this specific vehicle and request documentation; visually inspect the cruise-control switch on the master cylinder area for melting, residue, or an added fused jumper harness.

   2 excerpts from owner complaints in NHTSA records

   “I currently own a 2002 Ford Explorer Sport Trac. During the thanksgiving holiday, while my vehicle was stationary, there was a spark, then a fire under my hood. The flame ignited and melted the speed control switch. After speaking to my regular mechanic he mentioned that there is a recall on this piece and we should have it looked at by Ford. Upon having it towed to a Ford dealership they told me my VIN was not included in the recall list and therefore would not be covered. …”

   NHTSA complaint #10294334, filed 2009-12, 106,000 miles

   “The Ford recall for cruise control switch is a joke. I just had the dealership perform the repair on my 2002 Ford Explorer Sport Trac and was surprised to find they only installed a fused jumper instead of replacing the failing switch. This is a safety issue not only because of the potential for fire but also the switch failure could cause a loss of brake fluid pressure. With the jumper installed a failure would blow the fuse and remove the switch from overheating but the switch could still leak brake fluid onto the hot exhaust manifold. …”

   NHTSA complaint #10228085, filed 2008-05, 103,000 miles
2. 2
   Transmission and drivetrain

   Transmission slipping or delayed/rough shifting

   • 35 complaints (24%)
   • median 65,000 mi at 6.2 yrs old (29 state mileage)
   • 2 mention a crash, fire or injury
   • filed 2001–2017

   Complaints describe the automatic transmission hesitating before engaging a gear, missing the 2-3 shift, slipping when pulling into traffic, and in some cases staying in gear or refusing to move. Several owners say the dealer could not identify the cause, performed a fluid flush, or recommended removing and rebuilding or replacing the transmission. Some report the overdrive light flashing after service and repeated 4x4 control module replacement. Reported from roughly 30,000 to 120,000 miles, with many complaints between 37,000 and 90,000 miles.

   3 related service bulletins

   What to check: Test drive from a cold start and check every upshift and downshift, including a firm pull into traffic; ask whether the transmission fluid and filter have been serviced and whether any leak from the front axle vent tube was addressed.

   2 excerpts from owner complaints in NHTSA records

   “I am having problems with my 2002 Ford Explorer Sport Trac transmission and am being told that it needs to be replace at a cost of 3200.00 of which I can not afford right now as I live on a fixed income, there is a known problem with this transmission that Ford motor company will not address.... Please make Ford fix this problem I need my car to get to work.”

   NHTSA complaint #10252884, filed 2008-12, 69,000 miles

   “I own a 2002 sport trac, at about 46000 miles mi transmission started to miss shifts from 2nd to 3rd gear, it took about 3 to 4 seconds for the transmission to get into the next gear, so I took it to the dealer where I usually have the truck serviced thinking that it just needed a fluid check due to the fact they performed a transmission fluid change at about 30000. …”

   NHTSA complaint #10018893, filed 2003-05, 18 miles
3. 3
   Brakes

   Brake pulsation, grinding, and premature pad/rotor wear

   • 18 complaints (13%)
   • median 38,000 mi at 4.0 yrs old (15 state mileage)
   • 2 mention a crash, fire or injury
   • filed 2003–2019

   Complaints describe pulsating pedals, grinding or thumping noises, and front pads wearing to the rotor well before expected intervals. Some owners say rotors required turning or replacement more than once and that a spongy pedal remained after repairs. Others report the anti-lock system activating at very low speeds, and in some cases the dealer replaced a sensor without resolving the symptom. Mostly reported between about 10,000 and 75,000 miles, with several cases under 40,000 miles.

   What to check: Have the front and rear brakes measured and the rotors checked for thickness and runout; a pulse through the pedal or a grinding noise on a test drive should be investigated before purchase.

   2 excerpts from owner complaints in NHTSA records

   “While applying the brakes at approximate speed of 3 to 5 MPH, anti lock brakes activate. Ford dealership had the vehicle for 7 days, replaced the anti lock brake sensor and advised me that the vehicle was fixed. As soon as I left the dealership, I noticed the same problem. To date, Ford has not fixed the problem, or refunded my money for the repair that was not necessary (anti lock brake sensor.)”

   NHTSA complaint #10440220, filed 2011-12, 70,400 miles

   “I purchased a Ford Explorer Sport Trac in dec. 2002. I have been in and out of the service department a number of times. The following is a list of items that I've had repaired under warranty: 1.) front brakes: a loud rubbing/griding sound became increasingly louder. The first time the service dept. Folks said that it was normal. The next time I brought the car in, they could deny the noise and they subsequently replace one rotor and resurfaced the other. …”

   NHTSA complaint #10086489, filed 2004-08, 500 miles
4. 4
   Engine cooling

   Engine stalling or loss of power while driving

   • 21 complaints (15%)
   • median 10,812 mi at 2.0 yrs old (17 state mileage)
   • filed 2001–2013

   Owners describe the engine cutting out or stumbling at speed, sometimes restarting after a brief wait and sometimes leaving the vehicle without power in traffic. Complaints mention that no warning light or stored code was present, which made diagnosis difficult. Repairs reported in the complaints include reflashing the powertrain control module and replacing the fuel pump, fuel tank, and air flow sensor. Reported from a few hundred miles to about 120,000 miles, with several cases under 35,000 miles.

   2 related service bulletins

   What to check: Ask for service records showing whether the powertrain control module was reprogrammed or the fuel pump and tank were replaced; note whether the engine idles steadily and whether any warning light appears on a longer test drive.

   2 excerpts from owner complaints in NHTSA records

   “My 2002 Ford Explorer Sport Trac stalls when going down the road. It's like you're taking your foot off the gas and back on it again except that isn't what I'm doing. Today it did that and then went dead while driving down the road. I took it to the Ford place but they said with no lights on it wouldn't do any good to hook it up to a machine. They said it could be anything from electronics, fuel pump, etc. My warranty runs out in about 4,500 miles. …”

   NHTSA complaint #10079149, filed 2004-07, 32,000 miles

   “While driving my 2002 Ford sport trac at about 40 MPH,engine shut off without any warning,just a shaking feeling,then completely shut off,while in motion. Very dangerous situation! No check engine light came on and no codes were present. I was able to get out of traffic and avoid being hit. Had to crank for about half a minute and it restarted. Have driven on a daily basis about 200 miles since and problem has not recurred as of yet.vehicle is well maintained and up to date on filters,etc...”

   NHTSA complaint #10525025, filed 2013-07, 120,000 miles
5. 5
   Body and structure

   Deteriorated body mount bushings

   • 10 complaints (7%)
   • median 78,653 mi at 9.4 yrs old (9 state mileage, few)
   • filed 2010–2014

   Complaints describe the rubber insulators between the cab and frame crumbling, cracking, or falling apart, leaving the body loosely supported. Owners report the repair quoted at several thousand dollars and say the dealer or manufacturer declined assistance. One complaint notes the body could separate from the chassis as the mounts deteriorate. Reported from about 23,000 to 120,000 miles, often noticed during inspection or routine service.

   What to check: Inspect the rubber body mounts between the cab and frame for cracking, crumbling, or missing material, and listen for clunks or body movement over bumps during a test drive.

   2 excerpts from owner complaints in NHTSA records

   “There is extreme deterioration of the rubber body mount bushings...these are what holds the cab to the frame. The ones on my 2002 Ford Explorer Sport Trac are so badly deteriorated that what rubber is left will crumble in my fingers.”

   NHTSA complaint #10303600, filed 2010-02, 42,302 miles

   “Ford explorer sport-trac 2001-2005 the body mounts are crumbling, known defect on all these vehicles, inferior rubber - causing exposure of body to frame. Potential safety issue - could very likely can cause roll-overs as the rubber disintegrates there is no support between the body and the frame. Ford is aware of this defect but has not done anything to rectify the problem.”

   NHTSA complaint #10382471, filed 2011-02, 96,793 miles

Buying note. Given the volume of transmission, brake, and stalling complaints in this sample, a pre-purchase inspection that covers the transmission behavior, brake condition, and stored engine codes is worthwhile. Ask for recall documentation on the speed-control campaign for this specific vehicle, since several owners report their vehicle was outside the covered population.

Summary written with AI from a sample of 60 NHTSA complaints for this model year (picked at random, with complaints that state a mileage and recent ones taken first), then checked automatically against the source records. Where a problem shows a complaint count, every complaint for this model year was matched with fixed keyword rules (written with AI and tested against the sample), and the mileage, age and repair figures are calculated from those complaints; owners' figures are as stated, not verified. Other counts refer to the sample. The excerpts come from NHTSA's public complaint records and are unverified; capitalisation is normalised, NHTSA staff notes are removed, and shortened text ends with “…”. Something wrong? Request a correction.