2002 Ford Expedition
Safety record from NHTSA: recalls, owner complaints, investigations and service bulletins.
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These records cover every 2002 Ford Expedition. To see whether one car still needs a recall repair, decode its VIN or check it with NHTSA.
Recalls
4 recalls name the 2002 Ford Expedition. Newest first.
Certain maxzone headlight assemblies, depo brand, p/nos. 331-1129L-asn and 331-1129r-asn, sold for use as aftermarket equipment for the above listed passenger vehicles. these headlamps fail to conform to the photometric requirements of federal motor vehicle safety standard no. 108, lamps, reflective devices, and associated equipment.
Risk and remedy
Risk
Decreased lighting visibility may result in a vehicle crash.
Remedy
Maxzone will notify owners and offer reimbursement for any noncompliant headlights. the recall began on july 28, 2006. owners may contact maxzone at 909-822-3288.
Certain aftermarket fuel filters sold under the purolator brand name, p/n f65277, shipped from january 16 through june 2, 2006, for use on the above listed passenger vehicles. due to incorrect design, the quick connectors may not fully seat with the tube interface, even though the person making the connection may believe that the quick connector IS fully…
Risk and remedy
Risk
Failure of this connection could lead to fuel spillage and, in the presence of an ignition source, a fire could occur.
Remedy
Ufi will notify owners and replace the filters free of charge. the recall began on august 4, 2006. owners may contact ufi filters USA at 800-230-5876.
On certain pickup trucks and sport utility vehicles equipped with speed control, the speed control deactivation switch may overheat, smoke, or burn.
Risk and remedy
Risk
A fire at the switch could occur.
Remedy
By letter dated september 12, 2005, owners were instructed to return their vehicles to their dealers to have the speed control deactivation switch disconnected. owners who have had their speed control deactivated are being notified that parts will be available and advised to make an appointment to reconnect the speed control beginning in february 2006. owners who did not have their speed control deactivated are being notified to have their system remedied beginning in february 2006. owners are urged to avail themselves of the free disconnect service as soon as possible because of the significant risk of fire. Owners may contact ford at 1-800-392-3673. (note: also see recalls 05v017 and 06v286)
Certain pickup truck, van, and MINI van conversions equipped with southern comfort built running boards that contain certain courtesy lights manufactured by american technology components, inc. these units contain a courtesy light or lights that might overheat when the wire harness IS exposed to excessive moisture and road salt.
Risk and remedy
Risk
This overheating condition can cause the running board to melt or cause a fire.
Remedy
Dealers will replace the wiring harness on these running boards. owner notification began march 7, 2003. owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the free remedy within a reasonable time should contact southern comfort at 1-800-745-6096.
Owner complaints
340 complaints19 involved a crash69 involved a fire27 injuries2 deaths
What owners report most
Latest complaints
- Vehicle speed control
Cruise control deactivation switch. I was getting in my truck on my way to work in the early morning. as I walked by the hood I could smell what seemed like burning wire, so I opened the hood & right as I got it all the way up flames started shooting up. I put the fire out and had to wait to call my mechanic he came and told me it was definitely the deactivation switch that had caught fire.
- Service brakes, hydraulic · Vehicle speed control
The contact's fiancée owns a 2002 Ford Expedition. The contact stated that there was smoke coming from the driver's side front end of the vehicle. The contact stated that while his fiancée was attempting to drive the vehicle the following day, the brake pedal was depressed but was firm, requiring…
The contact's fiancée owns a 2002 Ford Expedition. The contact stated that there was smoke coming from the driver's side front end of the vehicle. The contact stated that while his fiancée was attempting to drive the vehicle the following day, the brake pedal was depressed but was firm, requiring the contact's fiancée to step on the brake pedal to drive. The brake pedal remained on the floorboard and was inoperable, causing the contact's fiancée to shift to park(P) to stop the vehicle. The vehicle was towed to the dealer, where it was diagnosed that the speed control deactivation switch (SCDS) connectors had burned, and the brake fluid had leaked from the brake fluid reservoir. The dealer replaced the SCDS sensor and harness under NHTSA Campaign Number: 05V388000 (Vehicle Speed Control). The dealer declined to perform repairs for collateral damages. The contact stated that he was an auto-electrician mechanic who owned an auto shop. The vehicle was then towed to the contact's auto repair shop, where mechanics replaced the brake master cylinder and cleaned the brake fluid off the engine bay. The vehicle was repaired. The manufacturer was notified of the failure and referred the contact to the NHTSA Hotline for assistance. The failure mileage was approximately 163,745.
- Fuel/propulsion system · Service brakes · Vehicle speed control
My spark plugs are going bad, I bought three tires. But now I'm having to take it to the shop because it's weird noises coming from the tire it may be the wheel baring or sway bar link and bushing the mechanic say.
- Service brakes
re: IR 11467550. See attached photo.
- Service brakes
2002 expedition mfg date 12/2001 right front brake separated at swagged fitting to short tubing to caliper. had just parked, stopped fine. next day all fluid had drained through separated hose.
- Firerelated · Vehicle speed control
The contact owns a 2002 Ford Expedition. The contact stated that while the vehicle was parked, it caught fire. The fire started from under the hood of the vehicle. The contact was able to extinguish the fire with water. An independent mechanic came to the contact's residence and diagnosed that the…
The contact owns a 2002 Ford Expedition. The contact stated that while the vehicle was parked, it caught fire. The fire started from under the hood of the vehicle. The contact was able to extinguish the fire with water. An independent mechanic came to the contact's residence and diagnosed that the failure was related to NHTSA Campaign Number: 05V017000 (Vehicle Speed Control) however, the contact did not receive notification of the recall. The mechanic informed the contact that the speed control deactivation switch caused the fire that damaged the hydraulic control unit and the pigtail. The vehicle was towed to the dealer. The dealer confirmed that the failure was related to the recall. However, the dealer denied the recall repair since the recall was open for many years but was left unrepaired. The contact stated that she had owned the vehicle for a couple of months and was not aware there was a recall. The vehicle was not repaired and remained at the dealer. The manufacturer was not made aware of the failure. The failure mileage was approximately 146,457.
- Engine
I have replace the drive belt 2 times this month. The belt keep messing up now I have get another belt because it IS twisted around the tensioner. I don't know hiw it happen I drive all that day.
- Seat belts
The driver's seat belt disconnects at random times.
- Fuel/propulsion system · Seat belts · Suspension
Two weeks before this problem happen ,the truck starts making tomuch noise and air supention didn't go up no more . And stop making noise .
- Electrical system · Vehicle speed control
Cruse control not working and no horn
- Service brakes, hydraulic › Foundation components › Master cylinder · Vehicle speed control
TL* the contact owned a 2002 ford expedition. While the vehicle was parked, the contact smelled a burning odor. The contact found that the master cylinder caught fire. The fire department was not contacted. A fire report was not filed. There were no injuries. The vehicle was towed to crowley ford…
TL* the contact owned a 2002 ford expedition. While the vehicle was parked, the contact smelled a burning odor. The contact found that the master cylinder caught fire. The fire department was not contacted. A fire report was not filed. There were no injuries. The vehicle was towed to crowley ford lincoln (225 new britain ave, plainville, ct 06062) where it was deemed destroyed. The dealer did not give a diagnosis, but contacted the manufacturer multiple times to determine what ford should cover. The manufacturer was made aware of the failure and stated that the vin was included in nhtsa campaign number: 05v017000 (vehicle speed control). The manufacturer provided case number: cas12637815 and advised the contact to call his insurance company. The manufacturer stated that they would send an inspector. The approximate failure mileage was 183,000. updated 09/07/17*lj *cn
- Engine
Two spark plugs blew out of the head. pain in the butt to fix. ford needs to stand behind its name and fix the known problem.
- Engine
I went to get an oil change I was told by worker at shop that everything under hood was rusty and chances are that this truck was in the new orleans flood (katrina) it was down hill from then. Everything started to malfunction.
- Suspension
Takata recall during an inspection of my suspension for worn bushings, I noted severe corrosion on my rear trailing arms for the rear axle. The lower arm on the passenger side actually had a quarter size hole in the inboard side of the web. This obviously greatly reduces the strength of the arms and could cause axle separation from the vehicle and an obvious control hazard.
- Seat belts
The seat belts front, passenger side unlock by themselves while in motion. It can happen during city or highway driving. This has not been repaired by anyone and IS factory original. Seems like a danger to passengers.
- Engine
This IS about a blown out spark plug. the blown out spark plug (#4 on passenger side)) happened when my family & I were traveling in highway near stockton ca at around 5 pm. There was no shop open and I had to call aaa to tow the 2002 ford expedition to our friend's house about 30 miles away. It…
This IS about a blown out spark plug. the blown out spark plug (#4 on passenger side)) happened when my family & I were traveling in highway near stockton ca at around 5 pm. There was no shop open and I had to call aaa to tow the 2002 ford expedition to our friend's house about 30 miles away. It was also a very cold night and we waited for about 1 hr for the tow truck to arrive. It was incredibly inconvenient for this incident to happen on the freeway/highway. I heard that this IS a common problem for the older expedition with triton engine. I love ford trucks/suvs and I hope they can fix this problem with the engine before somebody gets in serious trouble. I would rather want to see a recall than a class action suit in the future.
- Engine
Just want to add my car to the list of ford expedition 5.6L engines that have experienced the spark plug ejection issue. Thankfully, this occured when starting the vehicle, so it did not cause any accident or injury. This IS our son's car and we intended it to be the vehicle our 15 year old used as…
Just want to add my car to the list of ford expedition 5.6L engines that have experienced the spark plug ejection issue. Thankfully, this occured when starting the vehicle, so it did not cause any accident or injury. This IS our son's car and we intended it to be the vehicle our 15 year old used as well. However, now that we know about the spark plug problem, we no longer feel it's safe and hope to trade it in. It's extremely disappointing and disheartening to know that ford has not taken responsibility for this issue. Our vehicle had all original factory-installed spark plugs.
- Engine
TL* the contact owns a 2002 ford expedition. While the vehicle was parked in a residential driveway, the engine compartment erupted into flames without warning and a loud explosion sound emitted from the vehicle. The contact mentioned that the vehicle was completely burned and part of the garage…
TL* the contact owns a 2002 ford expedition. While the vehicle was parked in a residential driveway, the engine compartment erupted into flames without warning and a loud explosion sound emitted from the vehicle. The contact mentioned that the vehicle was completely burned and part of the garage was damaged. The police and fire departments filed reports. There were no injuries. The vehicle was not taken to the dealer. The manufacturer was not made aware of the failure. The vehicle was not repaired. The vin was not available. The failure mileage was 180,000.
- Engine
Idling at a metered ramp I experienced unintended acceleration while in line waiting for my turn at the metered light.the car in front of me rolled forward and I following suit. I did not touch the accelerator but merely released my foot from the brake pedal. The truck surged forward unexpectedly.…
Idling at a metered ramp I experienced unintended acceleration while in line waiting for my turn at the metered light.the car in front of me rolled forward and I following suit. I did not touch the accelerator but merely released my foot from the brake pedal. The truck surged forward unexpectedly. I was able to apply the brakes before impacting the car in front of me. As I sternly applied the brakes the engine settled down and all systems worked as expected for the remainder of my commute. 5/23/2016 approx. 7:25 am cdt. Sunny and clear weather approx 63 degrees f. "Normal" humidity. My daughter IS the primary driver of this vehicle and when asked if this has happened to her the answer to my surprise was yes.
- Engine · Structure › Body · Wheels
The vehicle was driven earlier that day for about 2 to 3 miles and then it was parked inside a private mobile home park. after 30 to 45 minutes had passed, an explosion was heard outside the mobile home park; the vehicle exploded and was on fire. the explosion occurred in the hood and now it IS a…
The vehicle was driven earlier that day for about 2 to 3 miles and then it was parked inside a private mobile home park. after 30 to 45 minutes had passed, an explosion was heard outside the mobile home park; the vehicle exploded and was on fire. the explosion occurred in the hood and now it IS a total loss. this occurred on april 18TH, 2016. We contacted the national highway traffic safety administration and they informed us that a recall back in 2005 was issued. the ford motor company has not helped us out in this accident.
- Electrical system › Ignition · Engine
TL* the contact owns a 2002 ford expedition. While starting the vehicle, an abnormal noise was heard from the engine. In addition, the vehicle stuttered without warning. The vehicle was taken to a dealer where it was diagnosed that the plug and ignition coil were replaced. The vehicle was repaired…
TL* the contact owns a 2002 ford expedition. While starting the vehicle, an abnormal noise was heard from the engine. In addition, the vehicle stuttered without warning. The vehicle was taken to a dealer where it was diagnosed that the plug and ignition coil were replaced. The vehicle was repaired; however, the failure persisted eight months later. The vehicle was taken back to the dealer where it was diagnosed with the same failure. The vehicle was repaired, but the failure persisted. The manufacturer was notified of the failure. The approximate failure mileage was 89,000.
- Engine
I was driving my truck, when it started to make a crazy noise coming from the engine. I had to pull over and pop the hood and I noticed that my plug on right side head, had blew out. I was on the side of the road and ended up having it towed because I didn't want to drive it in the condition that…
I was driving my truck, when it started to make a crazy noise coming from the engine. I had to pull over and pop the hood and I noticed that my plug on right side head, had blew out. I was on the side of the road and ended up having it towed because I didn't want to drive it in the condition that it was in. I understand most will say this IS not a safety issue, however, when this happens in the middle of traffic or going down the interstate, it could very well be a big safety issue. This IS a very common issue that I feel ford should be held responsible for.
- Exterior lighting
The passenger side turn signal will not work. I have changed fuses, bulb( even though both were good), and have checked wiring and can not get it to work. this IS very much a safety issue and I can't imagine that I am the only one this has happen to.
- Engine
Spark plug shot from engine. has 112500 miles on SUV. was ice and snow on back road 30 miles from home at 14 degrees. sounded like engine blowing up. then load ping sound in motor and lack of power. engine shut off on idle. was stuck. have not serviced yet. ford needs to fix this issue…
Spark plug shot from engine. has 112500 miles on SUV. was ice and snow on back road 30 miles from home at 14 degrees. sounded like engine blowing up. then load ping sound in motor and lack of power. engine shut off on idle. was stuck. have not serviced yet. ford needs to fix this issue immediately. this 5.4 l triton should run for longer than 110,000 miles. my old dodge would not and did not have any issue and it had 130,000 miles when it was wrecked.
- Seat belts
TL* the contact owns a 2002 ford expedition. The contact stated that the vehicle's driver side seat belts would unlatch independently. The failure occurred without warning. The vehicle was not taken to an independent mechanic or dealer to be diagnosed or repaired. The manufacturer was not made aware of the failure. The failure mileage was approximately 123,000.
Defect investigations
NHTSA’s Office of Defects Investigation opened these reviews into vehicles including this one.
- Spark plug ejection from cylinder head
On september 6, 2005, odi received a petition requesting that the agency investigate allegations of engine spark plug ejection in certain model year 1997 through 2004 ford vehicles with triton V-8 and V-10 engines.odi received a total of 474 non-duplicative complaints on the subject vehicles where the complainant, or…
On september 6, 2005, odi received a petition requesting that the agency investigate allegations of engine spark plug ejection in certain model year 1997 through 2004 ford vehicles with triton V-8 and V-10 engines.odi received a total of 474 non-duplicative complaints on the subject vehicles where the complainant, or the dealer repairing the vehicle, reported that a spark plug detached from the cylinder and/or ejected from the engine.as of december 8, 2005, odi IS not aware of any allegations where the alleged defect resulted in a loss of vehicle control, a crash, an injury, or a fatality in any of the 10,319,810 subject vehicles.in addition, odi IS aware of only two incidents where the vehicle stalled without restart.information contained in the odi consumer complaints and obtained from 72 telephone interviews with complainants showed the following:(1) 99% of the complaints were on my 1997 to 2002 subject vehicles.(2) most the complainants reported hearing a loud pop while driving or upon starting up the vehicle followed by a loud, repetitive clicking or popping sound.(3) many of the complainants reported that the popping sound was accompanied by some loss of vehicle power; however, in 99% of the incidents reported, the vehicle did not stall.in the very few incidents where the vehicle did stall, most vehicles could be restarted.(4) only a small percentage of the complainants cited that they smelled gas or a slight burning smell when the incident occurred.(5) in all but a very few incidents, vehicle damage was limited to the engine.in one incident, the complaint reported that the fuel rail was damaged and replaced after one of the spark plugs ejected from the engine; however, the complainant reported that the damage did not result in any type of fuel leak or fire.in another incident, the only incident where a fire was alleged, the complainant reported that no fluid leak was observed, but that a fire resulted after the spark plug had ejected from the engine and he had restarted the vehicle and driven to another location.none of the complainants reported any damage to the vehicle hood.(6) only two complainants reported that they observed what appeared to be some drops of fuel coming from the cylinder where the spark plug had failed or on the spark plug itself; however, each of these complainants reported that there was no smoke or flames as a result of his incident.as the petitioner noted, and odi?s analysis showed, it IS possible for a spark plug to detach from the engine cylinder threads in the subject vehicles.however, odi?s analysis of 474 complaints describing such incidents found only a very few alleged any safety-related consequences.none of these showed any evidence of a serious safety consequence.given the large population and relatively long exposure time of the subject vehicles, the complaint analysis indicates that the risk to motor vehicle safety from the alleged defect IS very low.in view of the foregoing, it IS unlikely that nhtsa would issue an order for the notification and remedy of the alleged defect at the conclusion of the investigation requested in the petition.therefore, in view of the need to allocate and prioritize nhtsa?s limited resources to best accomplish the agency?s safety mission, the petition IS denied.
- Engine compartment fires
Ea05-005 IS closed with ford?s actions in recalls 05v-017, 05v-388, and 06v-286, recalling approximately 6.7 million vehicles equipped with texas instruments speed control deactivation switches (scds).the brake systems in these recalled vehicles generate a vacuum that can potentially cause the scds to fail and, in…
Ea05-005 IS closed with ford?s actions in recalls 05v-017, 05v-388, and 06v-286, recalling approximately 6.7 million vehicles equipped with texas instruments speed control deactivation switches (scds).the brake systems in these recalled vehicles generate a vacuum that can potentially cause the scds to fail and, in certain switch installation orientations, catch fire.ford IS also including the entire population of 1998 explorers.ford has informed odi that testing to determine the cause of failures in the 1998 explorers will continue after this investigation IS closed.odi believes that the vehicles exhibiting the factors causing scds failure described in this report correlate well with the observed failure rates on these vehicles by model and model year.the closing of this investigation does not constitute a finding by nhtsa that a safety-related defect does not exist in the non-recalled vehicles manufactured with scds that are not included in ford?s recalls.odi will continue to monitor the non-recalled population for incidence of engine compartment fires.the agency reserves the right to take further action if warranted by the circumstances.see attached closing report for details.
Service bulletins
Technical service bulletins and other communications the manufacturer sent dealers about this vehicle. Ask a dealer for the full document by its number.
- 10177863This article supersedes TSB 19-2026 to update the vehicle model years affected. Some 2000 and newer Ford/Lincoln/Mercury vehicles equipped with aluminum body panels may exhibit corrosion concerns appearing as bubbled and/or peeling paint with or without accompanying white dust. Panel replacement is recommended.
- 10156863Some 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 accompanying white dust. Panel replacement is recommended. Follow the Service Procedure steps to correct the condition
- 10155551Some 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 accompanying white dust. Panel replacement is recommended. Follow the Service Procedure steps to correct the condition
- 10023943Some 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. This includes F-53 motorhome chassis. Updated 2/23/10.
- 10018745Wds cop kit diagnostic tip - coil on plug (cop) ignition systems - engine misfire or rough running.
- 10017892Rear axle noise repair.
- 10016789Rear axle noise repair.
- 10014685Use of stainless steel exhaust studs in service for 5.4L 2V engine.
- 10014666Intermittent rough idle - non-commanded egr (exhaust gas recirculation valve) flow.
- 10014165Aluminum corrosion - service tip.
- 10014138Safety belt retraction speed.
- 10014086General (pcm) power train control module programming procedures.
- 10014062Rear window defroster grid/integral antenna diagnosis and repair - terminal tab repair.
- 10013116Malfunction indicator lamp (mil) illuminated - system lean diagnostic trouble codes (dtc's) - service tips. Various models including 2004 f-series.
- 10013060Climate control a/c service tech tips.
- 10011162Engine 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.
- 10011159Rear window defroster grid/integral antenna diagnosis and repair - terminal tab repair.
- 10010731Multiple vehicles - fuel level indication concerns - service tip. Various models including 2005 super duty f-series, excursion, expedition, explorer, mountaineer and aviator.
- 10010001Customer maintenance reminder - literature program 04l19 - tie rod inspection procedure.
- 10009332Multiple vehicles using fehp rear axle fluid. Fluid usage change.
- 10009321Inoperative electric rear window defroster (heated backlite) grid lines, integral antenna concerns.
- 10008588Driveability-idle-high idle speeds-throttle sticks after steady state driving in extreme cold ambient temperatures-vehicles built through 12/31/01 equipped with 4.6L engine.
- 10008580Lamp-brake-invadvertent disabling of brake shift interlock.
- 10008542Pop/thump noise at end of window movement and/or driver's window bounce back and reverse to mid-position.
- 10008539Air suspension compressor noise.
- 10008334Engine-light tick or rattle type noise from engine after cold start.
- 10008331Rear axle seal leak - contact request.
- 10008310Engine-cylinder head deck leak-4.6 and 5.4L engines-new service-only gasket and cylinder head kits availability.
- 10008278Engine-romeo built 4.6L 2v-tick noise from engine-engines built before 9/17/2003.
- 10008252Streamlined diagnostic procedure for vehicles with malfunction indicator lamp (mil) on and diagnostic trouble codes (dtcs) p0401, p0402, p1400 or p1401. Additional symptoms may include runs rough, lacks power, surge, poor fuel economy.
- 10008225Airbag warning lamp on with diagnostic trouble code (dtc) b1994/b1998 on vehicles without side air bags.
- 10008201Warning indicators-parking aid-reverse sensing system (rss) and forward sensing system (fss)-false activation of warning tone-service tips. Update.
- 10008177Steering idler arm noise.
- 10008169Broken exhaust manifold studs.
- 10008166Fuel signal to instrument cluster service tip.
- 10008157Correct lug nut torque specifications - increase wheel nut and stud size - service tip.
- 10007360Streamlined diagnostic procedure for vehicles with malfunction indicator lamp on and diagnostic trouble codes (dtcs) p0401, p0402, p1400 or p1401. Additional symptoms may include runs rough, lacks power, surge, poor fuel economy.
- 10007316Courtesy rail lamps do not operate correctly or cause a battery draw.
- 10007207Customer satisfaction program 02m01 supplement #4. Certain ford 2000 through 2003 vehicles equipped with a tube-mounted egr pressure sensor - additional egr pressure sensor warranty coverage. Supplement #3. Supplement #6.
- 10004027Remote keyless entry (rke) - service tips.
Every Ford Expedition model year
Bars are owner complaints, dots mark years with recalls. Select a year to open its report.