2002 Ford F-350 Problems

What owners report

Owners of this model year most often report problems with tires, engine cooling, and power steering. Many complaints come from trucks at moderate mileage, roughly 40,000 to 70,000 miles, though several tire and steering reports arrive at much higher mileage. Issues described range from sudden events, such as tire tread separation and loss of power assist, to gradual ones, like fluid leaks and corrosion of brake lines and the oil pan.

1. 1
   Tires

   Tire tread separation and blowouts

   • 14 complaints (12%)
   • median 82,500 mi at 4.9 yrs old (10 state mileage)
   • filed 2002–2017

   Complaints describe rear or front tires that vibrate, then come apart at speed, with tread peeling or the sidewall failing while the vehicle was moving. Owners say the tires still had substantial tread when this happened, and several mention the vehicle shaking or being difficult to control afterwards. Tires named in the reports are various brands and sizes, both original and replacement, and owners report that tire makers generally declined warranty help. Reported across the mileage range, from around 15,000 to over 190,000 miles, often at highway speeds.

   What to check: Inspect all tires, including the spare, for cracks, bubbles or uneven tread wear, and check the DOT date codes for age. Ask when the tires were last replaced and whether any were subject to a tire recall.

   2 excerpts from owner complaints in NHTSA records

   “My husband and I have 2 Ford f350s that came with general tires of the 12 tires we have had 5 blow outs, the most recent was 4/23/2015 on I-80, in which my truck sustained over 2500.00 dollars in damage. Just wondering if we are lucky or if general tire company is just trying to kill people. The tires are 235x85x16 load range e and all had substantial tread when they blew. Thank you for looking into this.”

   NHTSA complaint #10713251, filed 2015-04, 50,000 miles

   “Dt: three of the 6 tires blew out. Two on the front and one on the rear. Contacted general tires ,they said they would send a form to fill out. First the front tire blewout and about 50 feet further the left front tire blewout. The sidewalls were still intact. The front two blew out on july 9,2005, the rear blew out on july 19, 2005. The blowoutds caused damage to the vehicle”

   NHTSA complaint #10129535, filed 2005-07, 37,000 miles
2. 2
   Steering

   Power steering loss or heavy steering effort

   • 19 complaints (16%)
   • median 63,000 mi at 2.5 yrs old (7 state mileage, few)
   • 3 mention a crash, fire or injury
   • filed 2001–2019

   Owners describe the steering becoming very heavy or the power assist dropping out, sometimes with a whining noise from the pump area. Several trace it to a leaking power steering hose or fitting, and one notes the hose rubbing against a nearby pipe. Others describe the steering refusing to follow the wheel during braking or evasive maneuvers, and dealers reportedly replaced the steering gearbox in at least one case without curing it. Mostly reported between about 23,000 and 90,000 miles, with some cases at much higher mileage.

   What to check: Check the power steering fluid level and look for wet or oily hoses and fittings under the front of the engine. Turn the wheel lock to lock while stationary and listen for whining or grinding.

   2 excerpts from owner complaints in NHTSA records

   “Hard steering with wineing noise. I was not able to steer the truck. Lucky for me I was going slow at the time. I traced the leaking fluid to a fitting on the power steering hose. Looks like a insulated steel pipe coming from the tubo rests on this steering hose. Constant rubbing and movement of this pipe causes damage to the hose fitting. Hose was repaired, however less than six months later it happend again same problem. I recognized the simptoms and was able to pull off the road safely. …”

   NHTSA complaint #10323471, filed 2010-04, 260,000 miles

   “I have a 2002 Ford F-350. I have just had to replace my alternator for the second time. I called Ford customer relations and they said there was nothing they would do to help with the costs at this time. It is a part that should last many years and for me to be on my third with a truck this new means to me that there is a problem. The dealer did tell me that they were replacing a lot of them. I have numerous problems with this truck. I kept having high pressure oil line problems until the block cracked and they replaced the motor.”

   NHTSA complaint #10046013, filed 2003-11, 70,500 miles
3. 3
   Brakes

   Brake and clutch pedal problems, rollaway in park

   • 16 complaints (14%)
   • median 66,000 mi at 6.5 yrs old (10 state mileage)
   • 4 mention a crash, fire or injury
   • filed 2001–2025

   Complaints describe the brake pedal going to the floor, traced by dealers to corroded and leaking brake lines, or brakes dragging at low speed. Some describe the clutch pedal dropping to the floor or detaching, leaving the truck unable to shift. Other reports say the vehicle rolled while left in park, in one case because the shift cable bracket was loose. Reported from low mileage up to around 160,000 miles, with several cases between 30,000 and 90,000 miles.

   What to check: Inspect the brake lines underneath for rust and wet spots, and check pedal feel on a test drive. With the truck in park on a slope, confirm it holds without rolling, and ask whether the shift cable bracket has been checked.

   2 excerpts from owner complaints in NHTSA records

   “Failure of the clutch master cylinder resulted in a stalled vehicle in the number 1 lane of I-80w out of sacramento, ca. Very heavy labor day traffic prevented an accident. (stop and go traffic). As a result of the failure, the truck wouldn't shift into gear after the gear shift lever was placed in neutral.”

   NHTSA complaint #10474013, filed 2012-09, 89,560 miles

   “While driving/braking low speeds, the consumer can hear/see the front passenger side brakes dragging/squeaking noise. The dealerships mechanic inform the consumer that the problem was pertaining to the brake caliper bolt failure , but did not resolve the problem. Please provide more information”

   NHTSA complaint #10066632, filed 2004-04, 64,000 miles
4. 4
   Electrical system

   Starter engages without key; wiring and electrical faults

   • 11 complaints (9%)
   • median 88,000 mi at 7.3 yrs old (9 state mileage, few)
   • 5 mention a crash, fire or injury
   • filed 2003–2019

   Complaints describe the starter turning over or engaging with no key in the ignition, in some cases with a burnt wiring smell and repeated starter replacement. Others report the security module that controls door locks, interior lights and headlights failing, so locks stop working or headlights turn off while driving. Some mention fuse panel or turn signal and brake light faults, and a few describe electrical fires in the firewall area. Spread from very low mileage up to about 230,000, with several reports between 50,000 and 140,000 miles.

   What to check: Ask whether the starter, alternator or vehicle security module has been replaced, and check for a burnt smell near the starter and fuse box. Test that every door lock, headlight and turn signal works, and confirm the battery holds a charge.

   2 excerpts from owner complaints in NHTSA records

   “1.on march 24, 2005 I started my 2002 Ford 350 truck and drove about 15' when all of a sudden the truck died. Upon trying to start it again several people came over to tell me flames were shooting down on the ground from the engine. I immediately got out of the vehicle and the flames had stopped shortly thereafter. 2.I had just recently had my vehicle serviced on 2.21.05 knowing I was driving to texas I had them check everything as well as whatever mileage maintenance that was due. Mileage at service date was 51,304. …”

   NHTSA complaint #10114789, filed 2005-03, 55,000 miles

   “Consumer states: 3 times now, the starter burned up while setting in the garage and the wiring burnt out in the starter. After consumer had driven the vehicle, when you come back out, you can smell burnt wiring. Dealer can not pin point the problem. The starter is engaging when there are no keys in the ignition.”

   NHTSA complaint #10121013, filed 2005-05, 55,000 miles
5. 5
   Engine cooling

   Spark plugs ejecting and misfires

   • 7 complaints (6%)
   • median 91,700 mi at 8.0 yrs old (6 state mileage, few)
   • filed 2004–2014

   Owners report a loud bang from the engine bay followed by rough running, and on inspection a spark plug has come out of the cylinder head. Some say a mechanic attributed it to compression blowing the plug out, and one complaint notes plugs that were improperly installed during earlier service. Others describe manifold bolts rusting and breaking off, and an oil pan rusting through and leaking. Reported from about 8,500 miles up to around 180,000, with several cases under 65,000 miles.

   What to check: Listen for a ticking or popping noise from the engine at idle, and check the oil pan and manifold fasteners for rust. Ask whether the spark plugs have been replaced and whether any plug threads have been repaired.

   2 excerpts from owner complaints in NHTSA records

   “I have a 2002 Ford f 350 with v10 engine. The manifold bolts keep rusting off and breaking. I only have about 11,000 miles on the truck now. Ford fixed the bolts on the right side on may 8, 2007 as I had purchased the extended warranty. They should have fixed both sides at the same time as this is an obvious problem. The truck only had 8500 miles on it then. They actually brought a rep in from Ford on may 2, 2007 to photograph my truck during the repair at whited truck center in bangor, maine. …”

   NHTSA complaint #10321365, filed 2010-03, 8,500 miles

   “Consumer took vehicle to a dealership due to loss of power and unknown ticking noise from the engine. This had been a problem twice since the 3,000 mile checkup. Dealership cleaned the engine, and returned the vehicle. Dealership states noise was normal, and should not affect the engine's performance. Took vehicle back to dealer, and was told that the engine blew out. Another mechanic looked at the engine, and found the spark plugs were improperly installed. Consumer was aware of other complaints on NHTSA's website. …”

   NHTSA complaint #10099477, filed 2004-12, 20,000 miles

Buying note. Have a mechanic inspect the tires and date codes, the brake and power steering lines for corrosion or leaks, and the front end before purchase, since these account for most of the owner reports here. Service records showing recent starter, brake line and steering work are worth asking for.

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.