2002 Ford Explorer Problems
- Complaints
- 3,295filed with NHTSA
- Median mileage
- 79,000miles, 2,521 complaints with mileage
- Recalls
- 4campaigns on record
- Trend
- FallingComplaints filed in the last 3 full calendar years are at least 25% lower than in the 3 years before.
- NHTSA crash rating
- —overall rating starts with 2011 models
- EPA fuel economy
- 16 mpgcombined, 4.0L 6-cyl RWD · 14 city / 19 hwy
Sources: NHTSA records for the 2002 Ford Explorer (complaints, recalls, investigations), NHTSA crash tests, EPA fuel economy. Report an error
What owners report
Owners of the 2002 Explorer most often report transmission trouble — slipping, hard or delayed shifts, a flashing overdrive light, and in some cases a unit that stops driving altogether — typically between 50,000 and 150,000 miles. A second recurring theme is rear-end and body hardware: wheel bearing noise and failure, broken rear coil springs, cracks and shattering in the liftgate area, and gear shift levers snapping off the steering column. Complaints are spread across the whole life of the vehicle, and several describe repairs costing over $2,000.
- Transmission and drivetrain
Transmission slipping, harsh shifts and flashing overdrive
- 897 complaints (27%)
- median 85,000 mi at 6.7 yrs old (789 state mileage)
- 25 mention a crash, fire or injury
- owner-quoted repair $2,620 (median of 218 quotes)
- filed 2001–2021
Owners describe the transmission slipping or hesitating between second and third gear, hard or banging engagements, engine revving without a shift, and the overdrive-off light blinking. Some report the vehicle dropping out of gear or losing drive entirely while moving. Dealers and independent shops frequently rebuilt or replaced the transmission, with owners citing quotes in the $2,200 to $3,000 range, and a few report the symptoms returning after repair. Reported from under 20,000 miles to beyond 180,000 miles, with most complaints between roughly 50,000 and 150,000 miles.
What to check: Ask for transmission service records and whether the unit has been rebuilt or replaced, and test drive long enough to feel the 2-3 upshift. Watch the overdrive-off light during the drive — a flashing light points to stored transmission codes worth scanning.
2 excerpts from owner complaints in NHTSA records
“My wife was in the left lane of a busy hwy and the transmission went out. There was no shoulder to safely pull off on. I own a 2002 Ford Explorer, there are numerous complaints for the exact same failure. How can Ford not recall this problem? My wife was lucky that she was not seriously hurt. It could have been alot worse.”
NHTSA complaint #10242968, filed 2008-09, 67,000 miles“I have had to replace my transmission twice in the past 18 months and now it's slipping again. It just happens all he sudden and my car ramps up and then takes off jerking us as we are driving. It's ridiculous that this hasn't been recalled already. The o/d light comes on and it ramps up to 4000 rpms before I have to take my foot off the gas to get the transmission to switch.”
NHTSA complaint #10297227, filed 2009-12, 74,000 miles - Body and structure
Rear liftgate glass shatters or hinge fails
- 421 complaints (13%)
- median 68,450 mi at 5.5 yrs old (286 state mileage)
- 59 mention a crash, fire or injury
- owner-quoted repair $585 (median of 34 quotes)
- filed 2001–2025
Owners report the rear liftgate glass breaking or shattering while opening, closing or simply releasing the hatch, sometimes in cold weather, and the hinge or strut coming loose so the glass drops. Some found a vertical crack in the panel below the rear window that grew over time. Dealers typically replaced the hinges or glass; owners note some repairs were done at their own cost. Reported from about 45,000 miles to beyond 180,000 miles, several mentions in cold or freezing conditions.
What to check: Open and close the liftgate glass several times and look at the hinges and strut mounts for looseness or cracks, and check the panel below the window for hairline cracks.
2 excerpts from owner complaints in NHTSA records
“Exploding rear window - my truck was parked in front of my house and I went out to get something out of it. I simply opened the hatch and the rear window exploded in my face.”
NHTSA complaint #10928105, filed 2016-11, 156,000 miles“Rear defroster had been on to un fog the glass. Rear liftgate glass shattered after pressing the release button to release the liftgate. Vehicle is a 2002 Ford Explorer. Weather was 19 degrees f with windchill of 10 degrees f.”
NHTSA complaint #10297754, filed 2010-01, 99,675 miles - Suspension
Wheel bearing noise and failure, rear coil spring breakage
- 566 complaints (17%)
- median 76,000 mi at 6.4 yrs old (473 state mileage)
- 20 mention a crash, fire or injury
- owner-quoted repair $1,000 (median of 93 quotes)
- filed 2001–2022
Complaints describe a whine, hum or roar that rises with speed, wheel play when the vehicle is jacked up, and in some cases a wheel locking or the vehicle feeling loose and hard to steer. Owners also report rear coil springs found broken or cracked, sometimes discovered during brake work or a failed inspection. Dealers replaced hub and bearing assemblies, and some owners say bearings failed again after replacement. Mostly reported between about 50,000 and 100,000 miles, with some vehicles showing repeat bearing failures.
What to check: Have the vehicle raised and check each wheel for play and roughness, and listen for bearing noise at highway speed. Inspect both rear coil springs for cracks or breaks before purchase.
2 excerpts from owner complaints in NHTSA records
“1) could hear high pitch noise while driving. 2) jacked up rear of Explorer and rear wheel(s) could wobble on the axle. 3) by 70,000 miles, both left and right rear wheel bearings have now failed and have been replaced by a Ford dealer. I now have 77000 miles on the Explorer and I am beginning to hear the high pitch sound again.”
NHTSA complaint #10143776, filed 2005-11, 70,000 miles“Have a 2002 Ford Explorer have had several problems, but while I was out driving today my car began to pop as I turned the wheel. I have gotten my tie rods replaced and there seems to continue to be a problem with my vehicle. My husband drove the car home for me slowly but will not drive for fear that the wheel may pop off. Contacted Ford and am waiting on a response, this problem has been noted on the internet by several owners of this model and year. …”
NHTSA complaint #10283681, filed 2009-09, 107,912 miles - Steering
Gear shift lever breaks off the steering column
- 188 complaints (6%)
- median 99,310 mi at 8.5 yrs old (159 state mileage)
- 4 mention a crash, fire or injury
- owner-quoted repair $1,232 (median of 52 quotes)
- filed 2004–2018
Owners describe the column-mounted shift lever snapping or detaching when moving between drive, reverse and park, sometimes leaving the lever dangling and the key stuck. Many say it became progressively harder to shift out of park beforehand. Dealers usually replaced the entire steering column assembly, with owners quoting costs from several hundred to nearly $2,000. Mostly reported between about 55,000 and 150,000 miles.
What to check: Try shifting in and out of park several times, including on a slight incline — a sticky or vague lever is worth investigating before the column has to be replaced.
2 excerpts from owner complaints in NHTSA records
“There is a common thread with gearshift selector breakage on Ford explorers which indicates that recall is urgently needed. In the driveway of my house, with car in park, I tried to shift into reverse to back out. The gearshift selector on the steering column broke off and just dangled. I removed the rubber cover on the steering column to have a look, and I could see rough metal where end of gearshift selector rod meets with joint inside the steering column, indicating that the metal simply broke there. …”
NHTSA complaint #10289714, filed 2009-10, 92,300 miles“About a year ago, the gear shifter in my 2002 Ford Explorer started getting harder to shift out of park especially on inclines. After a short period of time, I took it to our local Ford dealer for them to look at it. They said they could find nothing wrong but that it did stick a little. Gradually over several months it got worse. Eventually, it got stuck in park and I actually broke off the gear shifter trying to go from park to reverse. We had to pay almost $1,200 to replace the steering column and shifter. …”
NHTSA complaint #10273319, filed 2009-06, 86,000 miles
Buying note. This generation has known weak points in the transmission, rear wheel bearings and liftgate hardware, and repairs tend to be expensive, so service records and a thorough test drive matter more than mileage alone. A pre-purchase inspection by a shop familiar with these trucks is a reasonable step before committing.
Summary written with AI from a sample of 80 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.
NHTSA recorded 3,295 consumer complaints for the 2002 Ford Explorer. 2,521 of the complaints include a mileage, and 22% of those were filed for vehicles with under 50,000 miles; the median is 79,000 miles. Of all complaints, 144 involved a crash, 57 a fire, 187 an injury, 5 a death, according to the filers. NHTSA lists 4 recall campaigns and 40 technical service bulletins for this model year.
Not compared (before 2008). Model years 2008–2023 of the same vehicle that have at least 25 complaints are compared, and a model needs at least 3 of them.
Which parts are reported most
Complaints can name more than one part, so the counts add up to more than the total. Select a part to see its complaints, recalls and bulletins.
- Transmission and drivetrain1,502 46%
- Body and structure486 15%
- Suspension422 13%
- Engine cooling163 5.0%
- Air bags162 4.9%
- Steering155 4.7%
- Vehicle speed control152 4.6%
- Electrical system148 4.5%
- Brakes132 4.0%
Also reported: Wheels (78), Fuel system (72), Equipment (60), Latches, locks and linkages (50), Engine (49), Other or unknown (44), Tires (38), Seat belts (34), Seats (30), Exterior lighting (19), Interior lighting (6), Electronic stability control (3), Back-over prevention (rear camera) (1).
Example complaints
Transmission and drivetrain: “Upon beginning to drive home from work the transmission failed when shifting from second to third gear. There is no longer a third gear in my automatic transmission. In order to get home I had to manually shift with gear shifter and attempt to skip over third gear. Was driving on city streets. Vehicle has 174000 miles on it.”
NHTSA complaint #10991870, filed 2017-05, 174,000 milesBody and structure: “I was driving my Ford on the highway and the next thing I know my feet were really hot and black smoke started coming up. Then the black smoke started coming from the engine and I nearly crashed trying to get to the edge of the highway before the fire took over the whole front of the car. Luckily the fire department was right there for another accident. It was incredibly disturbing experience. Luckily my 3 small children were not in the car.”
NHTSA complaint #10837161, filed 2016-02, 130,000 milesSuspension: “My Ford Explorer started making a sound like there was something rolling around in back gate. First mechanic couldn't find problem. I worked on this for three months. Looks as if it is the bushings are worn and body is touching frame. I also understand that several others have had this problem.”
NHTSA complaint #10712719, filed 2015-04, 100,000 milesEngine cooling: “I was driving home from a friends came to a stop sign. Began to accelerate, I was going 25 MPH and all of a sudden my 2002 Ford Explorer sounded like my 4 wheeler. My spark plug had shot out of its threads and blew the coil to pieces. This is the second time this has happened in the last 6 months.”
NHTSA complaint #10261364, filed 2009-03, 68,792 milesMileage when problems were reported
22% of the 2,521 complaints with a mileage were filed for vehicles with under 50,000 miles; the middle half falls between 53,000 and 108,000 miles.
Complaints by year filed
Trend: falling. Complaints filed in the last 3 full calendar years are at least 25% lower than in the 3 years before.
Crash test ratings
NHTSA's 5-Star Safety Ratings for the 2002 Ford Explorer. Frontal results are shown driver / passenger; rollover shows the star rating and NHTSA's estimated risk of rolling over in a single-vehicle crash.
| Version | Overall | Frontal | Side | Side pole | Rollover |
|---|---|---|---|---|---|
| Explorer · sedan | not rated | 4 / 5 | — | — | 3 |
Ratings before the 2011 model year come from an older, less demanding test and are not comparable with ratings for 2011 and later.
Source: NHTSA New Car Assessment Program (5-Star Safety Ratings), nhtsa.gov/ratings.
Fuel economy and running cost
EPA ratings for each 2002 Ford Explorer version. Annual fuel cost is the EPA's estimate at its current fuel prices for 15,000 miles a year (55% city driving); for electric versions it is the cost of electricity and the rating is in MPGe.
| Version | Engine | Transmission | City | Hwy | Comb. | Fuel / yr |
|---|---|---|---|---|---|---|
| Explorer 2WD | 4.0L 6-cyl | 5-speed manual | 15 | 20 | 17 | $3,950 |
| Explorer 2WD | 4.0L 6-cyl | 5-speed automatic | 14 | 19 | 16 | $4,200 |
| Explorer 2WD | 4.6L 8-cyl | 5-speed automatic | 13 | 18 | 15 | $4,450 |
| Explorer 4WD | 4.0L 6-cyl | 5-speed manual | 14 | 18 | 16 | $4,200 |
| Explorer 4WD | 4.0L 6-cyl | 5-speed automatic | 13 | 18 | 15 | $4,450 |
| Explorer 4WD | 4.6L 8-cyl | 5-speed automatic | 13 | 17 | 14 | $4,800 |
| Explorer USPS Electric 2WD | Electric | 45 | 33 | 39 MPGe | $1,950 | |
| Explorer 2WD FFV | 4.0L 6-cyl · flex-fuel | 5-speed automatic | 14 | 19 | 16 | $4,200 |
| Explorer 4WD FFV | 4.0L 6-cyl · flex-fuel | 5-speed automatic | 14 | 19 | 16 | $4,200 |
Source: U.S. EPA and Department of Energy, fueleconomy.gov. Ratings are for comparing vehicles; real-world mileage varies with driving and conditions.
Recalls and investigations
- 09V399000Oct 13, 2009Vehicle speed controlCovers: Ford Explorer 1995–2002, E-150 1992–2003, E-350 1992–2003 +12 more
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…
- 04V442000Sep 13, 2004Structure › Body › Hatchback/liftgate › Hinge and attachmentsCovers: Ford Explorer 2002–2003, Mountaineer 2002–2003
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.
- 03V094000Mar 7, 2003Body and structureCovers: Ford Explorer 2000–2003, Dodge Grand Caravan 2000–2003, Ford Expedition 2000–2003 +9 more
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…
- 01V171000May 24, 2001Tires › SidewallCovers: Ford Explorer 2002, Mercury Mountaineer 2002
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.
Recall details for the 2002 Ford Explorer → · Check a VIN at nhtsa.gov/recalls
NHTSA investigations
- EA09013Vehicle Rollaway AllegationsClosed · Aug 18, 2009
- PE09020Vehicle rollaway allegationsClosed · Apr 21, 2009
- PE05037Stuck engine throttleClosed · Jul 7, 2005
- PE04045Rear liftgate glass assemblyClosed · Jun 2, 2004
- PE03020Front seat back recliner attachmentClosed · May 21, 2003
Technical service bulletins
TSBs are manufacturer notes to dealers about known repair procedures. They are not recalls and do not by themselves mean a vehicle has a fault. 40 on record; the latest 10 are shown.
- 10156863Feb 7, 2019Equipment, Body and 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…
- 10155551Feb 7, 2019Body and 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…
- 10028736May 1, 2009Transmission and drivetrain. 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.
- 10023943Oct 1, 2007Engine 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…
- 10019800Apr 29, 2006Electrical system. Low oil pressure indication/warning, a/c compressor inoperative and/or no crank condition on 4.6l equipped vehicles.
- 10019379Jan 1, 2006Fuel system. 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.
- 10014100Jan 1, 2006Transmission and drivetrain. Limited slip axle chatter, shudder, binding sensation, or vibration during low speed turning maneuvers.
- 10018959Dec 14, 2005Engine 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…
- 10018745Nov 14, 2005Engine cooling. Wds cop kit diagnostic tip - coil on plug (cop) ignition systems - engine misfire or rough running.
- 10013388Oct 31, 2005Fuel system. Fuel gauge slow to update after refueling.
Other model years of the Ford Explorer
| Year | Complaints | Median mi | Recalls | Crash ★ | MPG | Score (50 = typical) | Trend |
|---|---|---|---|---|---|---|---|
| 2026 | 42 | 2,600 | 14 | 5 | 24 | Too new to compare | Too new |
| 2025 | 107 | 3,000 | 20 | 5 | 21 | Too new to compare | Too new |
| 2024 | 21 | 8,832 | 10 | 5 | 21 | — | Too new |
| 2023 | 111 | 17,000 | 15 | 5 | 23 | 19 · Fewer | Too new |
| 2022 | 271 | 37,000 | 25 | — | 23 | 39 · Typical | Rising |
| 2021 | 448 | 44,000 | 27 | 5 | 24 | 54 · Typical | Rising |
| 2020 | 1,244 | 23,750 | 34 | 5 | 24 | 100 · More | Rising |
| 2019 | 300 | 54,000 | 6 | 5 | 20 | 2 · Fewer | Rising |
| 2018 | 734 | 50,000 | 7 | 5 | 20 | 42 · Typical | Rising |
| 2017 | 1,704 | 50,000 | 13 | 5 | 20 | 86 · More | Rising |
| 2016 | 2,463 | 48,850 | 14 | 5 | 20 | 100 · More | Rising |
| 2015 | 1,812 | 57,000 | 8 | 5 | 20 | 91 · More | Rising |
| 2014 | 1,684 | 66,000 | 6 | 5 | 20 | 71 · More | Rising |
| 2013 | 2,237 | 76,439 | 11 | 5 | 20 | 73 · More | Rising |
| 2012 | 830 | 70,000 | 5 | 4 | 23 | 46 · Typical | Rising |
| 2011 | 1,197 | 70,000 | 6 | — | 20 | 76 · More | Rising |
| 2010 | 115 | 40,707 | 1 | — | 17 | 0 · Fewer | Falling |
| 2009 | 33 | 77,000 | 0 | — | 17 | 0 · Fewer | Falling |
| 2008 | 148 | 77,000 | 1 | — | 16 | 0 · Fewer | Falling |
| 2007 | 208 | 67,250 | 1 | — | 16 | Not compared (before 2008) | Rising |
| 2006 | 630 | 55,000 | 1 | — | 16 | Not compared (before 2008) | Falling |
| 2005 | 497 | 70,000 | 0 | — | 15 | Not compared (before 2008) | Falling |
| 2004 | 1,304 | 65,000 | 0 | — | 16 | Not compared (before 2008) | Falling |
| 2003 | 1,131 | 73,000 | 2 | — | 16 | Not compared (before 2008) | Falling |
| 2002 | 3,295 | 79,000 | 4 | — | 16 | Not compared (before 2008) | Falling |
| 2001 | 375 | 90,000 | 6 | — | 17 | Not compared (before 2008) | Falling |
| 2000 | 952 | 77,419 | 9 | — | 16 | Not compared (before 2008) | Falling |
| 1999 | 1,348 | 82,193 | 9 | — | 16 | Not compared (before 2008) | Falling |
| 1998 | 1,959 | 100,000 | 9 | — | 16 | Not compared (before 2008) | Falling |
| 1997 | 1,731 | 99,500 | 7 | — | 16 | Not compared (before 2008) | Falling |
| 1996 | 1,450 | 120,208 | 6 | — | 16 | Not compared (before 2008) | Falling |
| 1995 | 843 | 121,585 | 5 | — | 18 | Not compared (before 2008) | Stable |
| 1994 | 1,207 | 99,041 | 4 | — | 18 | Not compared (before 2008) | Falling |
| 1993 | 939 | 117,494 | 6 | — | 18 | Not compared (before 2008) | Falling |
| 1992 | 633 | 108,065 | 4 | — | 17 | Not compared (before 2008) | Stable |
| 1991 | 609 | 121,902 | 8 | — | 18 | Not compared (before 2008) | Falling |
| 1990 | 12 | 58,410 | 0 | — | — | — | Not enough data |
All Ford Explorer model years · Best and worst years by complaints
Frequently asked questions
What are the most common problems with the 2002 Ford Explorer?
Owners of the 2002 Explorer most often report transmission trouble — slipping, hard or delayed shifts, a flashing overdrive light, and in some cases a unit that stops driving altogether — typically between 50,000 and 150,000 miles. The issues reported most often: Transmission slipping, harsh shifts and flashing overdrive; Rear liftgate glass shatters or hinge fails; Wheel bearing noise and failure, rear coil spring breakage.
How many NHTSA complaints does the 2002 Ford Explorer have?
NHTSA recorded 3,295 consumer complaints for the 2002 Ford Explorer as of Oct 27, 2026. Complaints are unverified consumer reports and may be duplicated or inaccurate.
What part of the 2002 Ford Explorer is reported most often?
Transmission and drivetrain is named most often, in 1,502 complaints (46% of the total), followed by body and structure with 486.
Has the 2002 Ford Explorer been recalled?
NHTSA lists 4 recall campaigns for this model year. To check a specific vehicle, enter its VIN at nhtsa.gov/recalls.
What gas mileage does the 2002 Ford Explorer get?
The EPA rates the 2002 Ford Explorer (Explorer 2WD, 4.0L 6-cyl) at 16 mpg combined, 14 city and 19 highway, with an estimated annual fuel cost of $4,200 at 15,000 miles a year. Other engine and drive versions are rated differently.
At what mileage are problems with the 2002 Ford Explorer reported?
Among the 2,521 complaints that include a mileage, the median is 79,000 miles and the middle half falls between 53,000 and 108,000 miles; 22% were filed for vehicles with under 50,000 miles.
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. Crash ratings are from NHTSA’s New Car Assessment Program. Fuel economy is from the EPA and DOE (fueleconomy.gov).
Complaint counts come from NHTSA’s public complaint database; we count each complaint once. The source records for this vehicle are on nhtsa.gov. Scores and trends are our own summaries of that data, described in the methodology. This page is not legal, safety or repair advice: for a specific vehicle, check its VIN at nhtsa.gov/recalls and ask a qualified mechanic. See an error? Tell us.