2002 Ford F-150 Problems
- Complaints
- 821filed with NHTSA
- Median mileage
- 90,000miles, 638 complaints with mileage
- Recalls
- 2campaigns on record
- Trend
- StableComplaints filed in the last 3 full calendar years are within 25% of the 3 years before.
- NHTSA crash rating
- —overall rating starts with 2011 models
- EPA fuel economy
- 16 mpgcombined, 4.2L 6-cyl RWD · 14 city / 19 hwy
Sources: NHTSA records for the 2002 Ford F-150 (complaints, recalls, investigations), NHTSA crash tests, EPA fuel economy. Report an error
What owners report
Owners of this model year most often report spark plugs blowing out of the cylinder head, usually while driving at speed, with a loud bang followed by lost power; many say the head had to be replaced or re-threaded. Other recurring themes are the 4.2L V6 intake manifold gasket leak, corroded fuel tank straps, and unintended acceleration or stuck throttle complaints.
- Engine
Spark plug blows out of cylinder head
- 199 complaints (24%)
- median 95,677 mi at 7.8 yrs old (188 state mileage)
- 3 mention a crash, fire or injury
- owner-quoted repair $1,325 (median of 48 quotes)
- filed 2003–2024
Owners describe a loud pop or bang while driving, then a sudden loss of power and a ticking or rough-running engine. Complaints say the spark plug and its threads left the cylinder head, sometimes on the same cylinder more than once, with gas or exhaust odor in the engine bay. Owners report the dealer quoting a cylinder head replacement or a thread-insert repair, and several mention the work was not covered after warranty. Reported across a wide mileage range, from under 60,000 miles to well over 150,000, often during highway driving or acceleration.
What to check: Listen for a ticking or popping noise at cold start and at speed, and ask whether any cylinder head has been re-threaded, sleeved, or replaced. A compression or leak-down test can show a compromised plug hole.
2 excerpts from owner complaints in NHTSA records
“Right before the failure I was sitting at a stop sign. As I began pulling a way I heard a single loud popping sound followed by a complete loss of power and popping and ticking. I stopped the truck immediately -- I never made it out onto the cross street. The plug blew out of the head --blown plug. Ford has offered to replace the head for a cost of $3900.00.”
NHTSA complaint #10143006, filed 2005-11, 59,000 miles“On start up a sparkplug blew out of cylinder head .... 3rd plug to bow out in 8 months over 800.00 per plug to fix then caught on fire under hood......very dangerous to have happen may cause our house to burn down if in garage.... I called Ford 4 times no help what so ever.....bad company .....do not advise ......bad Ford products....they need to do a class action on Ford .....”
NHTSA complaint #10463649, filed 2012-06, 97,000 miles - Vehicle speed control
Unintended acceleration / stuck throttle
Mentioned in 7 of 60 sampled complaints
Owners describe the engine revving or accelerating on its own with the brake pedal pressed, and in some cases the accelerator pedal going to the floor and staying there. Complaints say shifting into neutral and braking hard was needed to stop, and that dealers either could not reproduce the problem or found nothing. Some also report under-hood fires while parked. Reported from about 90,000 to 150,000 miles, often during acceleration or at a stop.
What to check: Ask whether the speed control deactivation switch recall was performed, and have the throttle cable, pedal, and cruise control linkage checked for binding or sticking.
2 excerpts from owner complaints in NHTSA records
“On february 26, 2010 my girlfriend and I along with our kids were driving to san diego, ca. As we were speeding up to pass a slow semi-truck my truck got stuck on throttle, I started to panic asking my girlfriend to check and see if there was a water bottle stuck underneath the break pedal, she checked, also panicking because we had our children asleep in the truck. I tried to push on the brake but it was really tough to push down on and the truck wouldn't slow down, we started to panic even more. …”
NHTSA complaint #10317896, filed 2010-03, 92,500 miles“Loud noise spark plug blow out and caused sparks when opened the hood. Afraid it was going to catch fire so had it towed. According to mechanic is a Ford issue ongoing but no recall nor will Ford pay for it. 91120 miles on truck well maintained.”
NHTSA complaint #10852913, filed 2016-04, 91,000 miles - Fuel system
Corroded fuel tank straps
- 51 complaints (6%)
- median 122,000 mi at 9.7 yrs old (49 state mileage)
- 2 mention a crash, fire or injury
- filed 2010–2024
Owners in rust-belt areas describe fuel tank support straps rusting through, with the tank hanging down or dropping toward the road and fuel leaking while driving. Some say the strap broke without warning on city streets or that the tank was held by only the remaining hanger. Complaints note that some vehicles in this model year fall outside the recall build or registration criteria. Typically reported between about 95,000 and 175,000 miles, mostly on older trucks in high-corrosion areas.
Recall 11V3850004 related service bulletins
What to check: Inspect both fuel tank straps for heavy rust or thinning, and check with a dealer whether this vehicle was included in the fuel tank strap recall by VIN.
2 excerpts from owner complaints in NHTSA records
“The front gas tank support hanger broke due to corrosion. The rear hanger held the tank in place until I was able replace both units. The rear hanger did not break but was severely corroded also. I don't know what would have happen if I would have lost both units together while driving down the road.”
NHTSA complaint #10407830, filed 2011-06, 81,180 miles“After hearing about the f150 fuel strap problem I decided to report a rusted and busted strap on my 2002 f150. A friend noticed the strap hanging down so I was able to fix it before it fell. Mi.”
NHTSA complaint #10399740, filed 2011-05, 175,000 miles
Buying note. Have a mechanic check for a stripped or repaired spark plug hole and do a compression test, look closely at the fuel tank straps for rust, and confirm any open recalls by VIN. Ask for records of intake manifold gasket work and test the seat belts and throttle for proper operation.
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.
NHTSA recorded 821 consumer complaints for the 2002 Ford F-150. 638 of the complaints include a mileage, and 21% of those were filed for vehicles with under 50,000 miles; the median is 90,000 miles. Of all complaints, 51 involved a crash, 95 a fire, 60 an injury, according to the filers. NHTSA lists 2 recall campaigns and 21 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.
- Engine cooling196 24%
- Electrical system106 13%
- Fuel system86 10%
- Vehicle speed control86 10%
- Engine66 8.0%
- Transmission and drivetrain53 6.5%
- Seat belts50 6.1%
- Body and structure45 5.5%
- Brakes42 5.1%
- Air bags35 4.3%
Also reported: Visibility (wipers, defrost, mirrors) (30), Other or unknown (29), Steering (25), Tires (24), Suspension (20), Wheels (13), Equipment (10), Exterior lighting (10), Latches, locks and linkages (8), Seats (7), Electronic stability control (2), Forward collision avoidance (1), Interior lighting (1).
Example complaints
Engine cooling: “My 2002 Ford F-150 has in the past two months experienced three blown/ejected spark plugs causing the damage and necessary replacement of coils . This posed a possible safety hazard, and I am very unhappy at the time and cost I have incurred since the initial onset of this problem, that apparently Ford has been aware of all of this time.”
NHTSA complaint #10282448, filed 2009-08, 82,000 milesElectrical system: “Woke up at 1am one 4-1-2018 to my Ford f 150 on fire drivers side front under the hood. Unknow to us our local sheriff had spotted the fire and already called the fire department. Total loss. Bought the truck a few months back without any knowledge of a recall on the speed control switch. The vehicle was sitting in our drive next to our other cars for 3 hour with keys out of the ignition.”
NHTSA complaint #11082349, filed 2018-04, 190,000 milesFuel system: “Gas tank straps broke, gas tank fell onto pavement. Had my truck towed to my Ford dealer where they replaced the straps for about $200. If this had happened 5 minutes later, I would have been going 60 MPH! Updated 09/14/11 the tank fell to the ground, while the vehicle was sitting. There was no fuel spill. The dealer replaced the straps. Updated 09/21/11”
NHTSA complaint #10407761, filed 2011-06, 118,000 milesVehicle speed control: “Got home from work parked my vehicle in my carport available space in my apartment. Turn off the truck completely, nothing left on or anything suspicious to cause a incident. When to my apartment unit took a shower and not more than 20-30mins was alarmed that my vehicle was caught on fire. I immediately ran outside to the carport saw the engine on fire, tried to stop it with anything that I could find (water holes) or extinguisher. …”
NHTSA complaint #11046072, filed 2017-11, 190,000 milesMileage when problems were reported
21% of the 638 complaints with a mileage were filed for vehicles with under 50,000 miles; the middle half falls between 55,000 and 134,167 miles.
Complaints by year filed
Trend: stable. Complaints filed in the last 3 full calendar years are within 25% of the 3 years before.
Crash test ratings
NHTSA's 5-Star Safety Ratings for the 2002 Ford F-150. 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 |
|---|---|---|---|---|---|
| F-150 · extended cab | not rated | 4 / 5 | — | — | 3 |
| F-150 · coupe | not rated | — | — | — | 2 |
| F-150 · sedan | not rated | 5 / 5 | — | — | 2 |
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 F-150 version. Annual fuel cost is the EPA's estimate at its current fuel prices for 15,000 miles a year (55% city driving).
| Version | Engine | Transmission | City | Hwy | Comb. | Fuel / yr |
|---|---|---|---|---|---|---|
| F150 Pickup 2WD | 4.2L 6-cyl | 5-speed manual | 15 | 19 | 17 | $3,950 |
| F150 Pickup 2WD | 4.2L 6-cyl | 4-speed automatic | 14 | 19 | 16 | $4,200 |
| F150 Pickup 2WD | 4.6L 8-cyl | 4-speed automatic | 14 | 19 | 16 | $4,200 |
| F150 Pickup 2WD | 4.6L 8-cyl | 5-speed manual | 13 | 18 | 15 | $4,450 |
| F150 Pickup 2WD | 5.4L 8-cyl | 4-speed automatic | 13 | 18 | 15 | $4,450 |
| F150 Pickup 2WD | 5.4L 8-cyl | 4-speed automatic | 11 | 15 | 12 | $6,850 |
| F150 Pickup 4WD | 4.2L 6-cyl | 4-speed automatic | 14 | 18 | 15 | $4,450 |
| F150 Pickup 4WD | 4.2L 6-cyl | 5-speed manual | 14 | 18 | 15 | $4,450 |
| F150 Pickup 4WD | 4.6L 8-cyl | 4-speed automatic | 13 | 17 | 14 | $4,800 |
| F150 Pickup 4WD | 4.6L 8-cyl | 5-speed manual | 12 | 17 | 14 | $4,800 |
| F150 Pickup 4WD | 5.4L 8-cyl | 4-speed automatic | 12 | 16 | 14 | $4,800 |
| F150 Dual-fuel 2WD (CNG) | 5.4L 8-cyl · bifuel (cng) | 4-speed automatic | 10 | 14 | 11 | $6,100 |
| F150 Dual-fuel 4WD (CNG) | 5.4L 8-cyl · bifuel (cng) | 4-speed automatic | 10 | 14 | 11 | $6,100 |
| F150 Dual-fuel 2WD (LPG) | 5.4L 8-cyl · bifuel (lpg) | 4-speed automatic | 11 | 15 | 12 | $5,600 |
2 more EPA-rated versions are not shown.
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
- 11V385000Jul 29, 2011Fuel system, gasoline › Storage › Tank assembly › MountingCovers: Ford F-150 1997–2004, F-250 1997–1999, Lincoln Blackwood 2002–2003
Ford is recalling certain 1997 through 2003 model year ford f-150, 2004 model year ford f-150 heritage, 1997 through 1999 model year f-250 less than 8,500 lbs. Gross vehicle weight rating (gvwr), and 2002 and 2003 lincoln blackwood vehicles manufactured from…
- 05V388000Sep 7, 2005Vehicle speed controlCovers: Ford F-150 1994–2002, F-250 1994–1999, Expedition 1997–2002 +3 more
On certain pickup trucks and sport utility vehicles equipped with speed control, the speed control deactivation switch may overheat, smoke, or burn.
Recall details for the 2002 Ford F-150 → · Check a VIN at nhtsa.gov/recalls
NHTSA investigations
- EA11006Fuel Tank Strap Failure Due to CorrosionClosed · May 4, 2011
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. 21 on record; the latest 10 are shown.
- 10172885Feb 7, 2020Engine cooling. This SKU is an Oil Dipstick. The customer communication requested return of unsold inventory to inspect the dipstick tube. The dipstick tube inner diameter may be small enough that it prevents…
- 10205038Apr 21, 2016Fuel system. Safety recall 11S21 - Fuel tank strap fracture - requests for recall service action
- 10183774Apr 21, 2016Fuel system. For 1997-2003 F-150, 2004 F-150 Heritage, 1997-1999 F-250 Light Duty, or 2002-2003 Blackwood vehicles Safety Recall 11S21 has been issued for vehicles that are operated in high corrosion areas for…
- 10058101Sep 9, 2014Fuel system, Equipment. Ford/lincoln: safety recall regarding high corrosion areas for operating, for an extended time, vehicles where both or one strap of fuel tank can fracture, after contacting ground. Model 1997-99…
- 10056624Aug 11, 2014Fuel system. Ford/lincoln: safety recall issued due to one or both fuel tank straps fracturing due to being in high corrosion areas for an extended period and dislodging fuel tank. Model 1997-99 f250, 1997-03…
- 10024865Apr 1, 2008Engine cooling. 1999-2008 7.3l/6.0l/6.4l/4.5l diesel f-super duty - clean the charge air cooler (cac) system after certain turbo or engine failures - service tip.
- 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…
- 10018745Nov 14, 2005Engine cooling. Wds cop kit diagnostic tip - coil on plug (cop) ignition systems - engine misfire or rough running.
- 10018741Nov 14, 2005Engine cooling. Malfunction indicator lamp on with diagnostic trouble code p1131 and/or p1151 - 4.2l engine.
- 10014138Jun 7, 2005Seat belts. Safety belt retraction speed.
Other model years of the Ford F-150
| Year | Complaints | Median mi | Recalls | Crash ★ | MPG | Score (50 = typical) | Trend |
|---|---|---|---|---|---|---|---|
| 2026 | 12 | — | 8 | 5 | 20 | — | Too new |
| 2025 | 109 | 5,330 | 14 | 5 | 20 | Too new to compare | Too new |
| 2024 | 195 | 8,750 | 11 | 5 | 20 | Too new to compare | Too new |
| 2023 | 416 | 29,700 | 13 | 5 | 21 | 42 · Typical | Too new |
| 2022 | 601 | 27,882 | 23 | 5 | 20 | 53 · Typical | Rising |
| 2021 | 1,036 | 47,500 | 29 | 5 | 20 | 67 · More | Rising |
| 2020 | 741 | 38,000 | 11 | 4–5 | 19 | 45 · Typical | Rising |
| 2019 | 1,342 | 60,000 | 9 | 4–5 | 21 | 40 · Typical | Rising |
| 2018 | 2,325 | 40,000 | 18 | 4–5 | 21 | 74 · More | Rising |
| 2017 | 1,462 | 53,000 | 17 | 5 | 20 | 49 · Typical | Rising |
| 2016 | 2,086 | 45,478 | 13 | 5 | 20 | 74 · More | Rising |
| 2015 | 1,743 | 50,000 | 13 | 5 | 20 | 61 · Typical | Stable |
| 2014 | 1,538 | 65,000 | 8 | 4 | 18 | 51 · Typical | Rising |
| 2013 | 2,992 | 74,281 | 3 | 4 | 18 | 48 · Typical | Rising |
| 2012 | 1,784 | 63,000 | 4 | 4 | 18 | 56 · Typical | Stable |
| 2011 | 2,193 | 70,766 | 6 | 4 | 18 | 67 · More | Stable |
| 2010 | 843 | 58,150 | 1 | — | 16 | 6 · Fewer | Stable |
| 2009 | 324 | 50,525 | 2 | — | 17 | 0 · Fewer | Falling |
| 2008 | 369 | 61,500 | 1 | — | 15 | 0 · Fewer | Stable |
| 2007 | 488 | 57,426 | 2 | — | 15 | Not compared (before 2008) | Stable |
| 2006 | 585 | 60,500 | 4 | — | 15 | Not compared (before 2008) | Falling |
| 2005 | 1,112 | 61,000 | 3 | — | 15 | Not compared (before 2008) | Stable |
| 2004 | 2,029 | 61,000 | 5 | — | 15 | Not compared (before 2008) | Stable |
| 2003 | 423 | 63,946 | 4 | — | 16 | Not compared (before 2008) | Stable |
| 2002 | 821 | 90,000 | 2 | — | 16 | Not compared (before 2008) | Stable |
| 2001 | 1,236 | 95,000 | 8 | — | 16 | Not compared (before 2008) | Falling |
| 2000 | 1,075 | 91,843 | 6 | — | 16 | Not compared (before 2008) | Stable |
| 1999 | 1,044 | 100,000 | 7 | — | 15 | Not compared (before 2008) | Falling |
| 1998 | 1,381 | 113,070 | 8 | — | 15 | Not compared (before 2008) | Rising |
| 1997 | 2,758 | 107,360 | 14 | — | 16 | Not compared (before 2008) | Falling |
| 1996 | 324 | 110,000 | 2 | — | 14 | Not compared (before 2008) | Stable |
| 1995 | 626 | 117,000 | 2 | — | 15 | Not compared (before 2008) | Falling |
| 1994 | 676 | 132,835 | 6 | — | 15 | Not compared (before 2008) | Falling |
| 1993 | 586 | 136,500 | 7 | — | 15 | Not compared (before 2008) | Rising |
| 1992 | 470 | 133,000 | 3 | — | 14 | Not compared (before 2008) | Stable |
| 1991 | 304 | 107,000 | 3 | — | 14 | Not compared (before 2008) | Stable |
| 1990 | 275 | 97,900 | 4 | — | 14 | Not compared (before 2008) | Falling |
| 1989 | 224 | 106,000 | 4 | — | 14 | Not compared (before 2008) | Stable |
| 1988 | 139 | 99,061 | 2 | — | 15 | Not compared (before 2008) | Stable |
| 1987 | 91 | 128,013 | 3 | — | 14 | Not compared (before 2008) | Stable |
| 1986 | 61 | 120,500 | 1 | — | 16 | Not compared (before 2008) | Stable |
| 1985 | 28 | — | 1 | — | 16 | Not compared (before 2008) | Stable |
| 1984 | 15 | 192,035 | 1 | — | 14 | — | Stable |
| 1983 | 10 | — | 1 | — | — | — | Not enough data |
| 1982 | 5 | — | 0 | — | — | — | Not enough data |
All Ford F-150 model years · Best and worst years by complaints
Frequently asked questions
What are the most common problems with the 2002 Ford F-150?
Owners of this model year most often report spark plugs blowing out of the cylinder head, usually while driving at speed, with a loud bang followed by lost power; many say the head had to be replaced or re-threaded. The issues reported most often: Spark plug blows out of cylinder head; Unintended acceleration / stuck throttle; Corroded fuel tank straps.
How many NHTSA complaints does the 2002 Ford F-150 have?
NHTSA recorded 821 consumer complaints for the 2002 Ford F-150 as of Oct 27, 2026. Complaints are unverified consumer reports and may be duplicated or inaccurate.
What part of the 2002 Ford F-150 is reported most often?
Engine cooling is named most often, in 196 complaints (24% of the total), followed by electrical system with 106.
Has the 2002 Ford F-150 been recalled?
NHTSA lists 2 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 F-150 get?
The EPA rates the 2002 Ford F-150 (F150 Pickup 2WD, 4.2L 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 F-150 reported?
Among the 638 complaints that include a mileage, the median is 90,000 miles and the middle half falls between 55,000 and 134,167 miles; 21% 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.