2002 Ford Explorer Sport Problems

What owners report

Owners of this model year most often describe rear liftgate glass hinge problems and transmission trouble, and both appear across a wide mileage range in the sampled complaints. Many hinge complaints involve glass that detaches or shatters while the vehicle is parked or being loaded, while transmission complaints tend to involve slipping gears and a flashing overdrive light that owners say develops over time.

1. 1
   Body and structure

   Rear liftgate glass hinge failure

   • 21 complaints (16%)
   • median 79,834 mi at 8.8 yrs old (20 state mileage)
   • 3 mention a crash, fire or injury
   • filed 2004–2016

   Owners describe the hinges that hold the rear liftgate glass breaking or pulling loose, leaving the window hanging by one corner or dropping away from the vehicle. Several say the glass came off while opening or closing the hatch, or that the hinge bolts were stripped and the dealer recommended a replacement hinge kit. Many owners report being told their vehicle was not included in a related hinge recall, and some paid for repairs themselves. Reported from roughly 40,000 miles up to the 100,000s, often when opening or closing the rear glass.

   What to check: Open and close the rear glass and check both hinges for looseness, cracked mounts, or missing bolts. Ask whether the hinges have ever been replaced and keep the gas struts in mind, since owners describe the glass dropping quickly when a hinge lets go.

   2 excerpts from owner complaints in NHTSA records

   “I noticed the rear window lift gate was slightly ajar, so I closed it, and suddenly the hinge bracket on the right side, connecting the window at the roof, popped loose, extending the window lift support, making it now impossible to close the back lift gate glass. I checked into the issue, and found a recall, campaign # 04v442000. This hinge has never been replaced. I want to have this fixed under recall.”

   NHTSA complaint #10927073, filed 2016-11, 77,816 miles

   “When I open the back glass window, one hinge broke off. I try to set the window, the other hinge broke. I have to tie a rope to keep the glass from falling off. I find on line there is a recall for 2002 - 2003 Ford explorer liftgate glass hinge and strut brackets, NHTSA campaign id number: 04v442000. When I contacted Ford dealer and Ford company, they say my vehicle VIN is not covered by the recall. If other Ford expolorers are covered, why my VIN is not covered? …”

   NHTSA complaint #10551072, filed 2013-11, 89,100 miles
2. 2
   Transmission and drivetrain

   Transmission slipping and flashing overdrive light

   • 24 complaints (18%)
   • median 93,159 mi at 8.1 yrs old (22 state mileage)
   • owner-quoted repair $2,000 (median of 5 quotes)
   • filed 2003–2015

   Owners describe the overdrive off light blinking, delayed or harsh shifts, and the transmission slipping between gears so the engine races while the vehicle barely moves. Some report the vehicle stalling or losing power when slowing for a light, and a few had the transmission stop working entirely. Complaints mention dealers replacing or rebuilding transmissions, and several owners say the problem returned after a repair. Mostly reported between about 33,000 and 105,000 miles, with problems often building gradually before the light starts flashing.

   2 related service bulletins

   What to check: Test drive at low and highway speeds and watch for delayed or harsh shifts and a blinking overdrive light. Ask for transmission service records and whether the power train control module has been reprogrammed.

   2 excerpts from owner complaints in NHTSA records

   “My 2002 Ford Explorer Sport is having transmission problems. It slips all of the time, makes grinding noises and at times does not let me drive (goes no where while stepping on the gas pedal. Similar to what is happening to a lot of people out there with this same make and model of car. It happens on and off, it started a couple of months back.”

   NHTSA complaint #10294138, filed 2009-12, 92,318 miles

   “My 2002 Ford explorers transmission just completely stopped working at 94,000 miles. Reading forums online LED me to this site, after reading many, many others' exact same experiences with this car. Ford will do nothing about it and my family does not have the money to replace a transmission! Ford needs a recall on transmissions for this make and model!”

   NHTSA complaint #10243229, filed 2008-09, 94,000 miles
3. 3
   Visibility (wipers, defrost, mirrors)

   Rear glass shattering

   • 9 complaints (7%)
   • median 110,000 mi at 9.1 yrs old (9 state mileage, few)
   • 2 mention a crash, fire or injury
   • filed 2005–2017

   Owners report the rear liftgate glass shattering with a loud bang while the vehicle is parked, stopped at a light, or just after the hatch was closed. Several say there was no impact or object involved, and in some cases the glass broke into many pieces that scattered into the cargo area or toward the person closing the hatch. Owners describe replacing the glass, sometimes more than once. Reported mostly between about 67,000 and 120,000 miles, in some cases in cool weather or shortly after the glass was replaced.

   What to check: Inspect the rear glass and its hinges for cracks, chips, or gaps at the seals, and ask whether the glass has ever been replaced. Close the hatch gently during a test drive and listen for creaks or movement.

   2 excerpts from owner complaints in NHTSA records

   “This is the second time this has happened. My rear tailgate window exploded. The car had been on for about ten minutes, warming up. I loaded my items into the car through the tailgate window. When I was done, I closed the window. Before it was even closed, the window exploded into thousands of pieces. There was glass all over. The window was recently replaced at the Ford dealership.”

   NHTSA complaint #10680401, filed 2015-02, 116,677 miles

   “I was stopped at a red light in my 2002 Ford Explorer Sport in 43 degree weather with no temperature controls being used when my rear windshield shattered into the vehicle. I then pulled over to a safe location and inspected the broken glass. There were no foreign objects in the back of my vehicle indicating malice. After doing some research it seems this is not the first time that a 2000-2004 Ford vehicle has had this kind of an issue. …”

   NHTSA complaint #10310433, filed 2010-02, 110,000 miles
4. 4
   Suspension

   Worn body mounts and rear suspension

   • 6 complaints (5%)
   • median 60,000 mi at 8.9 yrs old (5 state mileage, few)
   • filed 2003–2017

   Owners describe body mount bushings that corrode or come apart, leaving the body loose on the frame, and worn rear sway bar links, springs, or shocks that make the vehicle hard to control at highway speed. Some report the vehicle pushing or swerving and feeling unstable in corners. Complaints mention independent mechanics and dealers identifying the worn parts, with repairs paid by the owner. Reported from about 16,000 miles up to roughly 90,000 miles, often noticed as vague steering or body movement at speed.

   What to check: Look under the vehicle at the body mount bushings for corrosion or missing rubber, and check the rear sway bar links and shocks for wear. Drive at highway speed and note any wander, body roll, or vibration.

   2 excerpts from owner complaints in NHTSA records

   “I just purchased a used 2002 Ford Explorer Sport on 08/06/2011 so that I had a vehicle that I could take the kids on camping trips. On 09/04/2011 on our way to daytona beach I noticed the car was pushing and swerving in both directions, I had just put brand new tires on it and replaced both the upper control arms and all 4 ball joints and had an alignment done, I thought that it's a bigger vehicle than what I'm used to and had been a slightly windy. …”

   NHTSA complaint #10424133, filed 2011-09, 90,500 miles

   “The vehicle was hard to steer and control when it was driven at speeds at ar over 70 MPH. The technician noticed that the rear sway bar links were worn. The technician replaced the rear sway bars, rear springs and rear shocks.”

   NHTSA complaint #10032151, filed 2003-09, 16,625 miles

Buying note. Check the rear liftgate glass and hinges closely and drive the vehicle at highway speed to judge transmission shifting and suspension stability, since these are the areas owners describe most. Ask for service records on the transmission and any hinge or glass repairs before deciding.

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.