2002 Ford Explorer Engine cooling Problems
- Complaints
- 163about this part
- Share
- 5%of 3,295 total for the year
- Median mileage
- 74,000miles
- Trend
- StableComplaints filed in the last 3 full calendar years are within 25% of the 3 years before.
NHTSA recorded 163 complaints about the engine cooling of the 2002 Ford Explorer, 5% of the 3,295 complaints for this model year. Where a mileage was given, the median is 74,000 miles. 2 of these say a crash was involved and 11 a fire, according to the filers.
Example complaints
Selected from NHTSA records; personal details are removed. They are consumer reports, not findings.
“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 miles“While driving our 2002 Ford Explorer it stalled without any warning and would not start. Car had to be pushed off to the side and towed to dealer. The mechanic said it probably broke a valve spring which caused massive internal engine damage. The truck has only 49,000 miles on it and Ford basically told us it's our problem. They refuse to contribute anything to the estimated repair of $4,800.00.”
NHTSA complaint #10228808, filed 2008-05, 49,000 miles“August 10,2009 while driving notice smoke wasn't sure if it was me then pull over to notice when hood was lift up their was fire. I then call fire department along with police. My insurance nationwide then had it place in to auto body shop which it couldn't be fixed.”
NHTSA complaint #10290509, filed 2009-11, 100,325 miles“I have a 2002 Ford Explorer with a 4.6 liter v8 was driving to work this morning and the engine ejected a factory installed spark plug I have read on the internet that this is a common problem and was informed by the dealers there was no recall on it.”
NHTSA complaint #10268167, filed 2009-05, 112,061 miles“Driving on I-65 nashville, tn. Vehicle experienced a loud and abrupt sound in the engine with significant loss of power. Narrowly missed having an accident due to the loss of power. We managed to drive the vehicle home where upon inspection, a spark plug had obviously blown out of the left side of the engine (left side of the engine from the perspective of sitting in the driver seat).”
NHTSA complaint #10142534, filed 2005-11, 66,000 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…
- 10018959Dec 14, 2005Extended 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…
- 10018745Nov 14, 2005Wds cop kit diagnostic tip - coil on plug (cop) ignition systems - engine misfire or rough running.
- 10017881Apr 1, 2005No start/hard start n hot soak restart.
- 10016798Jan 1, 2005Hard start/no start condition during cold ambeint temperatures after short hot soak period-4.0l engine.
- 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.
- 10011150Aug 9, 2004Rattle noise from primary chain drive area 2000-3000 rpm - 4.0l sohc engine.
- 10013064Oct 28, 2002Excessive sulfur smell from exhaust.
Engine cooling: other model years
| Year | Complaints | Share of year |
|---|---|---|
| 2025 | 1 | 1% |
| 2023 | 1 | 1% |
| 2022 | 2 | 1% |
| 2021 | 10 | 2% |
| 2020 | 21 | 2% |
| 2019 | 6 | 2% |
| 2018 | 29 | 4% |
| 2017 | 77 | 5% |
| 2016 | 114 | 5% |
| 2015 | 66 | 4% |
| 2014 | 67 | 4% |
| 2013 | 67 | 3% |
| 2012 | 14 | 2% |
| 2011 | 21 | 2% |
| 2010 | 3 | 3% |
| 2009 | 1 | 3% |
| 2008 | 4 | 3% |
| 2007 | 10 | 5% |
| 2006 | 164 | 26% |
| 2005 | 29 | 6% |
| 2004 | 71 | 5% |
| 2003 | 69 | 6% |
| 2002 | 163 | 5% |
| 2001 | 39 | 10% |
| 2000 | 90 | 9% |
| 1999 | 100 | 7% |
| 1998 | 189 | 10% |
| 1997 | 198 | 11% |
| 1996 | 81 | 6% |
| 1995 | 45 | 5% |
| 1994 | 74 | 6% |
| 1993 | 55 | 6% |
| 1992 | 64 | 10% |
| 1991 | 52 | 9% |
| 1990 | 2 | 17% |
Other parts of the 2002 Ford Explorer
1,502 complaintsBody and structure
486 complaintsSuspension
422 complaintsAir bags
162 complaintsSteering
155 complaintsVehicle speed control
152 complaintsElectrical system
148 complaintsVisibility (wipers, defrost, mirrors)
138 complaintsBrakes
132 complaintsWheels
78 complaintsFuel system
72 complaintsEquipment
60 complaints
← All problems reported for the 2002 Ford Explorer
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