2002 Ford F-250 Problems

What owners report

Complaints on this model year cluster around a few recurring themes: spark plugs blowing out of the cylinder head on gasoline engines, tires that blow out or lose tread, brake problems including rotors and rusty lines, and cruise control problems tied to the speed-control deactivation switch. Many reports come in between roughly 60,000 and 150,000 miles, with tire complaints tending to arrive at lower mileage and steering and transmission complaints at higher mileage.

1. 1
   Tires

   Tire blowouts and tread separation

   • 22 complaints (14%)
   • median 56,500 mi at 4.2 yrs old (18 state mileage)
   • 1 mention a crash, fire or injury
   • filed 2002–2015

   Owners describe rear or front tires blowing out at highway speed, and in several cases tread separated from the casing and wrapped around the axle or damaged the truck. Reports name a mix of brands and sizes, and some concern replacement tires rather than the originals. Owners say dealers or tire sellers often declined to replace the tires, and some noted the tires were run at the recommended pressure. Mostly reported under about 60,000 miles on the truck, sometimes with only a few thousand miles on the tire itself.

   What to check: Check tire date codes and brand, look for cracking or bulging sidewalls, and confirm the load range matches the truck's towing use.

   2 excerpts from owner complaints in NHTSA records

   “I bought a set of new firestone destination at 285-75-r16. On july 24, 2007. Were I bought the tires they didn't have road hazard, and we didn't know that till they all ready had them on. The cost of those were $673.52. On november 5, 2007 I had a blow out going to work with one of the tires in front and I had to buy a brand new one. To replace that tire, it cost me $155.06 for a new one, and they would not give us a road hazard on that one sense we didn't buy it from them. Then on january 22, 2008 I had another flat blow out, on the back tire. …”

   NHTSA complaint #10215836, filed 2008-01, 97,265 miles

   “While driving at 70 MPH vehicle trembled violently. Consumer parked and checked the vehicle, there was no noticeable problems. Consumer drove at highway speeds, and the trembling started again. Several seconds there was a loud explosion. Consumer examined the left rear tire and determined that tread had separated and wrapped around the axle.”

   NHTSA complaint #10062984, filed 2004-03, 18,900 miles
2. 2
   Vehicle speed control

   Cruise control switch and wiring problems

   • 10 complaints (6%)
   • median 87,008 mi at 7.5 yrs old (10 state mileage)
   • 3 mention a crash, fire or injury
   • filed 2003–2017

   Owners report cruise control quitting, unexpected acceleration or failure to respond while cruise is engaged, and burning smells or smoke traced to the speed-control deactivation switch, harness or fuse box. Some say the dealer replaced the switch, harness or fuse box and charged for it, and a few note their vehicle was not covered by the speed-control recall despite matching symptoms. Others describe the brake lights staying on or lighting failures alongside the cruise problem. Reported across a wide mileage range, from about 20,000 to 160,000 miles.

   Recall 06V286000

   What to check: Ask whether recall 06V286000 was completed on this vehicle, and have the speed-control deactivation switch and its harness inspected for heat damage or scorching.

   2 excerpts from owner complaints in NHTSA records

   “1st cruise control quit working. 3 weeks later a new problem began. To start vehicle I had to turn key to accessory, move gear shift from park to neutral, then turned key the rest of the way to start. After arriving anywhere could not leave vehicle in park and could not move gear shift back to drive. I had to turn vehicle off and restart it with the above procedure. Within a week after the shifting problem began I could not shut overdrive off. …”

   NHTSA complaint #10191080, filed 2007-05, 149,000 miles

   “While driving up a hill with the cruise control activated the consumer applied the brakes and the vehicle accelerated. The dealer was notified. The motor continued to rev until the consumer shut the vehicle completely off. (larry d. Is the second consumer in re to complaint)”

   NHTSA complaint #10017235, filed 2003-04, 20,000 miles
3. 3
   Engine

   Spark plug blows out of cylinder head

   • 12 complaints (8%)
   • median 107,587 mi at 8.8 yrs old (8 state mileage, few)
   • 1 mention a crash, fire or injury
   • filed 2004–2022

   Owners of gasoline trucks describe a loud pop followed by an exhaust-type noise, after which the engine misfires and runs poorly. In several reports the spark plug and its coil are found dislodged from the head, and owners say the aluminum threads in the spark plug port were damaged, sometimes on more than one cylinder. Dealers and shops are described as replacing the head or repairing the threads, and owners note the repair is costly and that they were told no recall or warranty coverage applied. Reported from about 50,000 to 160,000 miles, often during acceleration or ordinary driving.

   What to check: Ask whether any cylinder head has been repaired or replaced for a blown spark plug, and have a mechanic check plug torque and thread condition before buying.

   2 excerpts from owner complaints in NHTSA records

   “On 03/16/2012 at 10:30pm while on my way home from work, I came to a stop at a stop sign. Truck was running fine. As I pulled away from the stop sign and accelerating I heard a loud pop and what sounded like an exhaust leak. I immediately pulled over and looked under the hood. I found that the coil on the #3 spark plug was out and the exhaust sound was coming from the hole where the spark plug should have been. Only living 2 miles from work, I drove the truck home and parked it til morning. …”

   NHTSA complaint #10452118, filed 2012-03, 88,715 miles

   “The #3 spark plug blew out of the engine head. This is the second time this has happened on the same side of the engine. By blowing out, it is a fire hazard ,as the engine still pumps gas through this piston. This is an expensive problem to fix and Ford needs to take responsibility for its bad head problem.”

   NHTSA complaint #10478498, filed 2012-10, 156,000 miles
4. 4
   Electrical system

   Seat belt unlatches or locks up

   • 8 complaints (5%)
   • median 104,500 mi at 12.9 yrs old (6 state mileage, few)
   • filed 2003–2023

   Owners say the driver or passenger seat belt releases on its own while driving, even after being pushed in firmly and tugged to confirm it was latched, at speeds from a crawl to highway speed. Others report belts that lock up, fail to retract, or intermittently will not release. Dealers are described as replacing the belt or buckle receptacle, and owners say no recall or warranty covered it. Reported from roughly 60,000 to 180,000 miles, during normal driving.

   What to check: Buckle each belt and pull firmly to test the latch, and check that the belts retract and release smoothly.

   2 excerpts from owner complaints in NHTSA records

   “Drivers seat belt keeps coming unlatched for no reason while driving. Nothing is stuck inside. I latch it and tug hard to make sure fully latched. Then after a few minutes of driving, it releases for no reason. My best friends 2006 f250 also has the same problem.”

   NHTSA complaint #10824326, filed 2016-02, 80,000 miles

   “On several occasions, without any reason, my driver-side seat belt has unbuckled itself while the vehicle is moving (speed does not seem to be a factor). After experiencing this a few times I began inserting the buckle and jiggling it and pulling it to make sure it locked firmly before driving. Even after having done this, there have still been times when it unbuckled itself while driving. If I get into in an accident the seat belt may not offer any restraint/protection.”

   NHTSA complaint #10562287, filed 2014-01, 93,000 miles
5. 5
   Engine

   Oil pan rust and leaks

   • 5 complaints (3%)
   • median 95,000 mi at 12.4 yrs old (5 state mileage, few)
   • filed 2010–2025

   Owners describe oil spots under the truck and a burning oil smell, traced to a rusted-through oil pan that leaked onto the exhaust. In one report the dealer called the rust cosmetic while a second shop found a hole in the pan; another owner had the pan replaced and later saw leaks again from the gasket. Repair costs reported by owners run into the hundreds to over a thousand dollars. Reported from about 86,000 to 140,000 miles, including on trucks used in road-salt areas.

   What to check: Look under the truck for a rusted or weeping oil pan and gasket, and check for oil residue on the exhaust and garage floor.

   2 excerpts from owner complaints in NHTSA records

   “Have had approximately $8000 in car repair bills in last few months for our 2002 Ford f250 diesel truck and 2005 Ford explorer xlt. Tremendous financial burden 2002 Ford f250 diesel truck - hubs seized, loss of control of vehicle premature rusting of vehicle body, tailgate but most importantly the oil pan in which replacing the old pan became an approximately $3,000 repair bill. 2005 Ford explorer - transmission went at 80,000 miles! Hubs seize.”

   NHTSA complaint #10421166, filed 2011-08, 70,000 miles

   “Rust out of oil pan, 2002 Ford f250 diesel causing major oil leakage onto exhaust. Ford indicated this is a cosmetic problem but issued a service bulletin to dealers. Vehicle has been serviced by dealer since new. Ford indicates there is not a problem as it is cosmetic. It cost over $1400.00 to fix this cosmetic problem which resulted in totally oil covered exhaust system. Repair was not done by dealer that indicated the problem was a pan gasket. A second opinion showed a large hole in the pan from rusting. Could have been a major fire.”

   NHTSA complaint #10316085, filed 2010-03, 95,000 miles

Buying note. Check the cylinder head history on gasoline trucks and the condition of the oil pan, brake lines and tires before committing, and confirm whether the speed-control recall was performed. A pre-purchase inspection by a mechanic familiar with these trucks is worthwhile given the age.

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.