2002 Ford Explorer Body and structure Problems
- Complaints
- 486about this part
- Share
- 15%of 3,295 total for the year
- Median mileage
- 66,400miles
- Trend
- FallingComplaints filed in the last 3 full calendar years are at least 25% lower than in the 3 years before.
NHTSA recorded 486 complaints about the body and structure of the 2002 Ford Explorer, 15% of the 3,295 complaints for this model year. Where a mileage was given, the median is 66,400 miles. 4 of these say a crash was involved and 2 a fire, according to the filers. 2 recall campaigns on record are filed under a similar system.
Example complaints
Selected from NHTSA records; personal details are removed. They are consumer reports, not findings.
“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 miles“We opened the rear window to get something out of the trunk, lifted the window and the window exploded and crashed on my husband's head. It seems as if the hydrolics failed on each side of the rear window. Glass just shattered and was everywhere. My husband's hands were cut and his head was banged up.”
NHTSA complaint #10497794, filed 2013-02, 98,559 miles“After loading my luggage I closed my trunk and the whole back window completely shattered the struts broke and the little black thing that holds the window up top broke too. I got a cut on my hand, glass went everywhere. So stressed..”
NHTSA complaint #10909661, filed 2016-09, 218,000 miles“About a year after I purchased my Explorer ltd, the rear logo panel started coming loose. I used special adhesive to attach it, but it just wouldn't stick. I tried pulling it off, but it wouldn't budge on the other side, so I tried a different adhesive. It stuck for a while, but as I was going down a busy street, it flew off almost hitting the car behind me. This very easily could have caused an accident and serious injury.”
NHTSA complaint #10455588, filed 2012-04, 182 miles“Ford Explorer 2002 rear panel cracked, and I traveled around the country and I saw several cars with the same problem. I visited too many websites and there's more people complaining on that issue. The back door panel is cracked and getting worse everyday, and someday the glass is going to explode.”
NHTSA complaint #10357288, filed 2010-09, 85,000 milesRelated recalls
- 04V442000Sep 13, 2004On certain sport utility vehicles, the liftgate glass strut may become disengaged or the hinge may fracture allowing the glass to fall and possibly break.Covers: Ford Explorer 2002–2003, Mountaineer 2002–2003
- 03V094000Mar 7, 2003Certain pickup truck, van, and mini van conversions equipped with southern comfort built running boards that contain certain courtesy lights manufactured by…Covers: Ford Explorer 2000–2003, Dodge Grand Caravan 2000–2003, Ford Expedition 2000–2003 +9 more
Related service bulletins
- 10156863Feb 7, 2019Some 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…
- 10155551Feb 7, 2019Some 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…
- 10014165Dec 27, 2004Aluminum corrosion - service tip.
- 10013074Oct 1, 2002Sun visor rattle / detroit area dealers contact request.
Body and structure: other model years
| Year | Complaints | Share of year |
|---|---|---|
| 2026 | 2 | 5% |
| 2025 | 7 | 7% |
| 2023 | 10 | 9% |
| 2022 | 11 | 4% |
| 2021 | 25 | 6% |
| 2020 | 45 | 4% |
| 2019 | 150 | 50% |
| 2018 | 288 | 39% |
| 2017 | 659 | 39% |
| 2016 | 591 | 24% |
| 2015 | 411 | 23% |
| 2014 | 276 | 16% |
| 2013 | 439 | 20% |
| 2012 | 144 | 17% |
| 2011 | 110 | 9% |
| 2010 | 1 | 1% |
| 2009 | 2 | 6% |
| 2008 | 1 | 1% |
| 2007 | 11 | 5% |
| 2006 | 11 | 2% |
| 2005 | 151 | 30% |
| 2004 | 426 | 33% |
| 2003 | 354 | 31% |
| 2002 | 486 | 15% |
| 2001 | 29 | 8% |
| 2000 | 29 | 3% |
| 1999 | 47 | 3% |
| 1998 | 48 | 2% |
| 1997 | 50 | 3% |
| 1996 | 63 | 4% |
| 1995 | 39 | 5% |
| 1994 | 158 | 13% |
| 1993 | 86 | 9% |
| 1992 | 62 | 10% |
| 1991 | 31 | 5% |
Other parts of the 2002 Ford Explorer
1,502 complaintsSuspension
422 complaintsEngine cooling
163 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