2002 Ford Explorer
Safety record from NHTSA: recalls, owner complaints, investigations and service bulletins.
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Vehicles › Ford › Explorer › 2002
These records cover every 2002 Ford Explorer. To see whether one car still needs a recall repair, decode its VIN or check it with NHTSA.
Recalls
10 recalls name the 2002 Ford Explorer. Newest first.
Ford IS recalling model years 1995-2003 windstar, 2000-2003 excursion diesel, 1993-1997 and 1999-2003 F-250 sd through F-550 sd diesel, 1992-2003 E-150 through E-550, 1995-2002 explorer, 1997 and 2002 mercury mountaineer, 1995-1997 and 2001-2003 ranger, and 1994 F53 vehicles equipped with the texas instruments speed control deactivation switch (scds). the…
Risk and remedy
Risk
A vehicle fire could occur with or without the engine running.
Remedy
Ford will notify owners that dealers will install a fused wiring harness in line with the scds. on 1999-2003 windstar vehicles with a leaking scds, dealers will also inspect the ABS control module connector and repair as necessary. repairs will be completed free of charge. the safety recall began on october 27, 2009. owners may contact ford at 1-888-222-2751.
Dope, inc. IS recalling 42,540 combination corner and bumper lamp assemblies of various part numbers sold for use as aftermarket equipment for various passenger vehicles. these headlamps fail to conform to the requirements of federal motor vehicle safety standard no. 108, "lamps, reflective devices, and associated equipment." these lamps do not contain…
Risk and remedy
Risk
Decreased lighting visibility may result in a vehicle crash.
Remedy
Dope, inc. Will notify owners and offer a full refund for the noncompliant combination lamps. the safety recall began on july 28, 2009. owners may contact dope, inc. At 1-626-272-1798.
Sabersport IS recalling 16,270 combination corner and bumper lamp assemblies of various part numbers sold for use as aftermarket equipment for various passenger vehicles. these headlamps fail to conform to the requirements of federal motor vehicle safety standard no. 108, "lamps, reflective devices, and associated equipment." these lamps do not contain…
Risk and remedy
Risk
Decreased lighting visibility may result in a vehicle crash.
Remedy
Sabersport will notify owners and offer a full refund for the noncompliant combination lamps. the safety recall began on may 11, 2009. owners may contact sabersport at 1-909-598-7589.
Certain curved tempered replacement glass manufactured by hangzhou safety glass ltd and supplied to safelite by auto temp inc., identified as dot-430, and sold for use on certain domestic and foreign vehicles may not break into small pieces as expected of tempered glass and fails to conform to federal motor vehicle safety standard no. 205, "glazing…
Risk and remedy
Risk
In the event of a vehicle crash, the occupant(s) may be seriously injured by shattered glass.
Remedy
Safelite will notify its retail customers and replace the glass free of charge. Retail customers can contact safelite toll free at 1-888-843-2906. Safelite will notify its wholesale customers and reimburse wholesale customers for current inventory and at a specified rate for replacing their customer's glass. Wholesale customers can contact safelite's wholesale division, service autoglass toll free at 1-888-246-6298. The recall began on january 15, 2008.
Certain ck motorsports combination headlights, clear corner, bumper, and side marker lights sold as replacement lamps for use on the passenger vehicles listed above. some combination lamps that are not equipped with amber side reflectors fail to conform to federal motor vehicle safety standard no. 108, lamps, reflective devices, and associated equipment.
Risk and remedy
Risk
Without the amber reflectors, the vehicle will be poorly illuminated, possibly resulting in a vehicle crash without warning.
Remedy
Ck motorsport will notify owners and replace the noncompliant lamps free of charge. the recall began on july 1, 2006. owners may contact ck motorsport at 1-909-610-7211.
Certain pro-a motors corner lamps, turn signals, and headlights sold as replacement lamps for use on certain passenger vehicles listed above. some combination lamps that are not equipped with amber side reflectors fail to conform to federal motor vehicle safety standard no. 108, lamps, reflective devices, and associated equipment.
Risk and remedy
Risk
Without the amber reflectors, the vehicle will be poorly illuminated, possibly resulting in a vehicle crash without warning.
Remedy
Pro-a motors will notify owners and offer to repurchase the lamps. the recall began on april 3, 2006. owners may contact pro-a motors at 323-838-2988.
On certain sport utility vehicles, the liftgate glass strut may become disengaged or the hinge may fracture allowing the glass to fall and possibly break.
Risk and remedy
Risk
If the hinge should fracture, there IS a potential for the glass to fall and ultimately break and personal injuries could occur.
Remedy
Dealers will have the liftgate glass strut brackets and glass hinges replaced. for the vehicles built from august 1, 2000 through march 3, 2002, the dealers will replace the hinges and liftgate strut bracket. on vehicles built from march 3, 2002 through june 23, 2003, the dealers will only replace the hinges. the recall began on september 30, 2004. a postcard was sent to owners on december 27, 2004, advising them that parts are now available. owners should contact ford at 1-800-392-3673.
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.
Vehicle description: sport utility vehicles. the right side tires may have horizontal cuts on the edge of the tread that could have occurred during vehicle assembly.
Risk and remedy
Risk
Over time, the tire could fail, increasing the risk of a crash.
Remedy
Dealers will inspect the tires and, if any slices are found, the cut tires will be replaced. owner notification began june 7, 2001. 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 ford at 1-800-392-3673.
This IS not a safety recall in accordance with the safety act. however, it IS deemed a safety improvement campaign by the agency. vehicle description: 2002 ford explorer and mercury montaineer sport utility vehicles. the brackets connecting the left cylinders to each side of the liftgate glass could rotate out of position if either the urethane bond or…
Risk and remedy
Risk
Rotation of the brackets could potentially cause the lift cylinders to detach from the glass or, in some cases, could potentially cause the liftgate glass to break. either condition IS most likely to occur when the glass IS being closed.
Remedy
Ford dealers will inspect the vehicles for the position of both the left and right liftgatge glass lift cylinder brackets. if the brackets are in the proper position, the bracket retainers will be tightened to a higher torque. in cases where the bracket IS not properly position, the bracket must be re-aligned.
Owner complaints
3,295 complaints144 involved a crash57 involved a fire187 injuries5 deaths
What owners report most
Latest complaints
- Service brakes · Suspension · Wheels
The rear toe arms came unhinged or disconnected from their placement and sank down to continuously rub a groove in the inner rim. The suspension was affected, the steering was effecting especially when turning, it made the brakes stick, and made loud crunching and rolling noises. It is quite…
The rear toe arms came unhinged or disconnected from their placement and sank down to continuously rub a groove in the inner rim. The suspension was affected, the steering was effecting especially when turning, it made the brakes stick, and made loud crunching and rolling noises. It is quite frankly dangerous. It was through no fault of mine that this happened, just weak design. I took it to a shop and they charged me all my money, but nothing was fixed.
- Air bags
I was driving down the road and my airbag instantly deployed in my face without cause or notice. I became completely disoriented as it hit my hand and face with severe force and was extremely loud and shocking. I thank God that I had just let off the gas and didn't hurt anyone else. If I had…
I was driving down the road and my airbag instantly deployed in my face without cause or notice. I became completely disoriented as it hit my hand and face with severe force and was extremely loud and shocking. I thank God that I had just let off the gas and didn't hurt anyone else. If I had panicked or was going through an intersection, experiencing a turn, coming to a stop, or someone in front of me stopped I could have struck another vehicle or object and caused death or injuries. I have not brought the vehicle anywhere to be checked out yet. My insurance refuses to cover it. There were no warning signs of this airbag deployment.
- Structure › Body · Unknown or other
September 2, 2023 at about 6 pm I pulled over to grab a couple water bottles from the rear of my 2002 Ford Explorer Sport cause my engine was overheating. I got out walked to the rear of my vehicle pushed my unlatch button on the tailgate and I lifted the glass part of the rear hatch. Both air…
September 2, 2023 at about 6 pm I pulled over to grab a couple water bottles from the rear of my 2002 Ford Explorer Sport cause my engine was overheating. I got out walked to the rear of my vehicle pushed my unlatch button on the tailgate and I lifted the glass part of the rear hatch. Both air hinges were not working correctly to keep it up so I gently rested the glass on my hair that was put up in a bun and just a little bit of the glass was resting on the very top of my head where my hair was slicked back for my bun so my hands were free to grab the bottles of water. (My hair was the softest of resting place's). As I reached in the back to grab the water bottles I heard the loudest bang and hundreds of little pieces of glass fell everywhere around me. I was in so much distrot that I actually thought someone had shot at me with a fire arm but missed me and hit the rear glass instead. The top of my head was stinging and it felt like I had just been smacked with a tree branch and the glass had went all over me causing a few minor cuts and scrapes as I fell to my knees in shock my heart racing faster than I had even imagined a heart could beat while histaraclly crying from the trauma that just occurred I fell to the ground and for a full 15 minutes i sat there surrounded by glass and tears in so much shock, dazed and confused before I stood up and looked around at everything that then I only realized I WASN'T shot at because there was no bullet or bullet hole nor did a vehicle drive by nor was there any people closer than a mile to me when I realized that the glass had shattered for some UNKNOWN reason ON ITS OWN that it scared me so bad it traumatized me. After that day I was pulled over multiple times by numerous police agency's (sheriff, Medford PD, Central Point PD and State Police) because I didn't have the money to fix it let alone have the knowledge that it had a recall so I could get it replaced. I have pictures but it will not allow me to upload them.
- Air bags
The contact owns a 2002 Ford Explorer. The contact stated that while her fiancé was driving 45 MPH, the driver’s side and passenger’s side air bags inadvertently deployed without an impact or a crash, causing the contact’s fiancé to swerve and drive down into a ditch. No warning lights were…
The contact owns a 2002 Ford Explorer. The contact stated that while her fiancé was driving 45 MPH, the driver’s side and passenger’s side air bags inadvertently deployed without an impact or a crash, causing the contact’s fiancé to swerve and drive down into a ditch. No warning lights were illuminated. The front bumper, windshield, and passenger’s side taillight were cracked. No injuries were sustained. A Police report was not filed. The vehicle was not diagnosed or repaired by an independent mechanic or dealer. The manufacturer was not made aware of the failure. The failure mileage was 118,583.
- Engine
The contact owns a 2002 Ford Explorer. The contact stated while driving 45 MPH, the vehicle shut off. The contact was able to coast off the freeway. There were no warning lights illuminated. The contact called an independent mechanic, but the mechanic declined to service the vehicle. The local…
The contact owns a 2002 Ford Explorer. The contact stated while driving 45 MPH, the vehicle shut off. The contact was able to coast off the freeway. There were no warning lights illuminated. The contact called an independent mechanic, but the mechanic declined to service the vehicle. The local dealer was not contacted. The vehicle was not diagnosed or repaired. The manufacturer was notified about the failure and opened a case. The approximate failure mileage was 88,000.
- Engine · Steering
The contact owns a 2002 Ford Explorer. The contact stated that the steering wheel intermittently seized while driving at various speeds without warning. After finding a replacement part at a salvage yard, the contact had the steering wheel replaced by an independent mechanic; however, the failure…
The contact owns a 2002 Ford Explorer. The contact stated that the steering wheel intermittently seized while driving at various speeds without warning. After finding a replacement part at a salvage yard, the contact had the steering wheel replaced by an independent mechanic; however, the failure persisted. The contact also stated that an abnormal ticking noise was coming from the engine with the ABS warning light illuminated. The vehicle was taken back to the same independent mechanic and the contact was informed that the engine needed to be replaced. Neither the dealer nor the manufacturer was notified of the failure. The vehicle was not repaired. The failure mileage was unknown.
- Latches/locks/linkages › Hood › Latch
The contact owns a 2002 Ford Explorer. The contact stated that while driving 55 MPH, the hood latch independently released, causing the hood to strike the windshield. The contact was able to get to the side of the roadway and closed the hood. The contact had not taken the vehicle to a dealer. The…
The contact owns a 2002 Ford Explorer. The contact stated that while driving 55 MPH, the hood latch independently released, causing the hood to strike the windshield. The contact was able to get to the side of the roadway and closed the hood. The contact had not taken the vehicle to a dealer. The vehicle had not been diagnosed or repaired. The manufacturer was made aware of the failure. The approximate failure mileage was 137,000.
- Power train
Overdrive light flashes after driving a little bit hard shifting doesn't shift into overdrive 4x4 lights indicate that it's working when the buttons are pushed but doesn't go into 4x4
- Vehicle speed control › Accelerator pedal
The contact owns a 2002 Ford Explorer. The contact stated while entering the highway at approximately 45 MPH and accelerating to overtake the next vehicle, the accelerator pedal went to the floorboard however, the vehicle did not respond. The contact was able to pull over safely off the highway.…
The contact owns a 2002 Ford Explorer. The contact stated while entering the highway at approximately 45 MPH and accelerating to overtake the next vehicle, the accelerator pedal went to the floorboard however, the vehicle did not respond. The contact was able to pull over safely off the highway. There were no warning lights on the instrument panel. The contact stated that the failure was related to NHTSA Campaign Number: 00V422000 (Vehicle Speed Control). The vehicle was not diagnosed or repaired. The manufacturer was notified of the failure but did not assist. The approximate failure mileage was 115,000.
- Air bags
The light form air bad juts got on when I was driving
- Air bags
I was on motion when the air bag light turn on but I went to check and they say I have to take to the dealer to repair
- Power train
TL* the contact owns a 2002 ford explorer. The contact stated while driving at various speeds, the transmission experienced hard shifting with a clunking noise present coming from the transmission. The vehicle was taken to an independent mechanic who diagnosed that the transmission gear ratio was…
TL* the contact owns a 2002 ford explorer. The contact stated while driving at various speeds, the transmission experienced hard shifting with a clunking noise present coming from the transmission. The vehicle was taken to an independent mechanic who diagnosed that the transmission gear ratio was faulty. The vehicle was not repaired. The local dealer jacob george ford located at 125 spring st, houtzdale, pa 16651 and the manufacturer were notified of the failure. The failure mileage was 100,000.
- Tires
TL* the contact stated the when driving a 2002 ford explorer at approximately 20 mph, equipped with cooper tire, tire line solaris as, tire size 225-70-r16, dot information was not available. The front passenger tire wall blew and the tire separated from the rim. The vehicle was towed to a…
TL* the contact stated the when driving a 2002 ford explorer at approximately 20 mph, equipped with cooper tire, tire line solaris as, tire size 225-70-r16, dot information was not available. The front passenger tire wall blew and the tire separated from the rim. The vehicle was towed to a mechanic. The vehicle vin, mileage, information was not available. The vehicle was not repaired. The manufacturer was not contacted.
- Electrical system · Power train · Vehicle speed control
The issues that I'm having IS the exhilaration (picking up speed) on a public street as well as in the expressway it hesitates to do so. When the vehicle IS parked and I go to switch gears it does not want to switch. The gauge indicator comes on and the gas idle be stuck on empty when it has a full…
The issues that I'm having IS the exhilaration (picking up speed) on a public street as well as in the expressway it hesitates to do so. When the vehicle IS parked and I go to switch gears it does not want to switch. The gauge indicator comes on and the gas idle be stuck on empty when it has a full tank of gas. While the vehicle IS in motion the radio volume goes up and down on its own. And the vehicle did not want to start for me one day the very next day it started right on up (like it want to start but didn't catch). All of this started happening at the beginning of october 2020
- Structure › Body › Hatchback/liftgate
TL* the contact owns a 2002 ford explorer. The contact stated that while opening the real lift gate, the rear lift gate glass window suddenly shattered. During the incident, the person sustained a facial laceration which required medical treatment. The cause of the failure was not determined. The…
TL* the contact owns a 2002 ford explorer. The contact stated that while opening the real lift gate, the rear lift gate glass window suddenly shattered. During the incident, the person sustained a facial laceration which required medical treatment. The cause of the failure was not determined. The local dealer (future ford located at 650 automall dr, roseville, ca 95661) was notified of the failure. The manufacturer was not notified of the failure. The failure mileage was 184,000.
- Electrical system · Structure › Body
Summer,spring weather, all four, clear, glass windows do not slide up or down through its' power button, electronically.
- Exterior lighting · Seats · Suspension
Makes a rattling noise when a bump IS hit driver side seat stop working
- Exterior lighting · Steering · Suspension
The car always feels like IS about to jump off the road or the lane im in whenever I drive over any rough road or pot holes. %ģ
- Fuel/propulsion system · Wheels
I had had this 2018 jeep renegade not even 2.5 months and it needed an oil change and the tires were completely worn out they were every one slick as could get and dangerous. I called the dealer because the tires went bad and I hadn't had the first 50K miles on it yet and they did nothing. Called…
I had had this 2018 jeep renegade not even 2.5 months and it needed an oil change and the tires were completely worn out they were every one slick as could get and dangerous. I called the dealer because the tires went bad and I hadn't had the first 50K miles on it yet and they did nothing. Called the tire company they did nothing. So I replaced them and another almost 3 months go by and the tires are completely worn out and slick again. This has repeatedly happened every 2-3 months to where they are so dangerous you either drive 30 mph or get them changed. 3 times I've replaced the tires and and the oil goes so fast. And now I am stuck with this vehicle I don't feel safe in. I shouldn't have to pay these prices for a 30K vehicle that's not worth 10K.
- Electrical system · Engine
Was driving on hwy and my vehicle just shut down as I was turning off the main road, lost all control of steering. When I raised the hood I saw my radiator smoking and all of a sudden it popped. Had to have it towed in to the shop and was told that the radiator had exploded and the engine seized…
Was driving on hwy and my vehicle just shut down as I was turning off the main road, lost all control of steering. When I raised the hood I saw my radiator smoking and all of a sudden it popped. Had to have it towed in to the shop and was told that the radiator had exploded and the engine seized up! How could this happen? I never even had it to over heat or the light never even alerted me. Just blew up and left me stranded. I was told after the fact that there IS a recall on the radiator! *tr
- Electrical system · Power train
TL* the contact owns a 2002 ford explorer. The contact stated that while driving at various speeds the transmission independently switched to 4 wheel drive and the vehicle stalled. The failure recurred several times. The vehicle was towed to an independent mechanic who diagnosed that the transfer…
TL* the contact owns a 2002 ford explorer. The contact stated that while driving at various speeds the transmission independently switched to 4 wheel drive and the vehicle stalled. The failure recurred several times. The vehicle was towed to an independent mechanic who diagnosed that the transfer casing and ignition coils needed to be replaced. The ignition coil was replaced and the transfer casing was repaired however the failure recurred. An unknown dealer and the manufacturer were notified of the failures. No assistance was provided. The failure mileage was 80,000.
- Electrical system · Engine · Unknown or other
The radiator started going out on me. I had to fix it twice. The breakes I keep having the continued fixing them every 4 months. Recently october 25, 2019 it started smelling like burnt rubber came thru the air vents. Things with the electricity oe a shortage. With the tires they put wrong tire…
The radiator started going out on me. I had to fix it twice. The breakes I keep having the continued fixing them every 4 months. Recently october 25, 2019 it started smelling like burnt rubber came thru the air vents. Things with the electricity oe a shortage. With the tires they put wrong tire size. They told me to sign and go because they didn't have my actual tire size. Its always on the smalls streets and on freeway or. Highway it smells like burnt rubber. The owner didn't notify me or bother to tell me it was on recall already.
- Electrical system · Engine · Fuel/propulsion system
I was driving down the highway I went to make a left hand turn when smoke started coming out of the grill, so I pulled over to check under the hood, smoke started boiling out from under the hood
- Structure › Body
TL* the contact owns a 2002 ford explorer. While driving at an unknown speed, the contact heard an abnormal rattling noise coming from the rear of the vehicle. The contact inspected the vehicle and noticed that the rear driver's side upper hinge was fractured. The vehicle was not repaired. Perry…
TL* the contact owns a 2002 ford explorer. While driving at an unknown speed, the contact heard an abnormal rattling noise coming from the rear of the vehicle. The contact inspected the vehicle and noticed that the rear driver's side upper hinge was fractured. The vehicle was not repaired. Perry ford of santa barbara (440 hitchcock way, santa barbara, ca 93105, (805) 682-2411) was contacted by phone and informed of the failure. The vehicle was not included in nhtsa campaign number: 04v442000 (structure). The manufacturer was notified. The approximate failure mileage was 204,000.
- Power train
The car gets stuck in park and will not into reverse, neutral or drive. it doesn't happen often but has been happening at infrequent periods since 2007. It's a nuisance when it does happen but after multiple attempts, depressing the brake and repeatedly attempting to shift; shutting down the…
The car gets stuck in park and will not into reverse, neutral or drive. it doesn't happen often but has been happening at infrequent periods since 2007. It's a nuisance when it does happen but after multiple attempts, depressing the brake and repeatedly attempting to shift; shutting down the engine and restarting and repeating the process; usually does shift into gear. The last incident was more than 4 years ago. Now since saturday, 9/28/19; can't shift out of park. I never reported the problem because it was always resolved and I forgot to report it to the dealership because I was always in a rush to get to my destination. My car IS in good running condition. Original owner. 93964Mi. Always serviced at dealership.
Defect investigations
NHTSA’s Office of Defects Investigation opened these reviews into vehicles including this one.
- Vehicle Rollaway Allegations
This investigation is being closed based on several considerations.By the most inclusive counting of all alleged rollaway incidents (i.e., counting all alleged rollaway incidents and assuming a singular failure mechanism), the incident rate is low, however during EA09-013, ODI identified a number of different failure…
This investigation is being closed based on several considerations.By the most inclusive counting of all alleged rollaway incidents (i.e., counting all alleged rollaway incidents and assuming a singular failure mechanism), the incident rate is low, however during EA09-013, ODI identified a number of different failure mechanisms in 180 incidents related to the alleged defect.The highest rate for any particular failure mechanism, the failure of the Automatic Transmission Parking System, was 4.4/100K.The next-highest failure rate was for the BSI System, at 3.4/100K.For all identified failure mechanisms there has been a drastically declining trend including very few incidents occurring in recent years.Accordingly, this investigation is closed.The closing of this investigation does not constitute a finding by NHTSA that a safety-related defect does not exist.For additional information regarding this investigation, see the complete closing resume in the document file for EA09-013. The ODI reports cited above can be reviewed at www-odi.nhtsa.dot.gov/owners/SearchNHTSAID under the following identification (ODI) numbers:10168454, 10279630, 10280078.
- Vehicle rollaway allegations
In response to an information request (ir) letter sent by the office of defects investigation (odi), ford stated consumer reports of higher than expected efforts when shifting into and out of park could be a result of a groove being worn into the swing arm ramp of the steering column. The swing arm IS a component…
In response to an information request (ir) letter sent by the office of defects investigation (odi), ford stated consumer reports of higher than expected efforts when shifting into and out of park could be a result of a groove being worn into the swing arm ramp of the steering column. The swing arm IS a component bolted to the steering column that assists in shifting through the transmission gears.an engineering evaluation conducted by ford of returned steering columns found the groove could be created over time if consumer shift more quickly from the drive or reverse to park than the brake shift interlock (bsi) solenoid pin retracts after the brake pedal IS applied. In november of 2004, ford released a redesigned bsi solenoid with a shorter pin retracting time as a serviceable component. Ford has noted the shorter retraction time significantly lessens the likelihood of bsi solenoid pin to swing arm contact even with rapid consumer shifts.ford also issued a technical service bulletin, tsb 04-22-12, to instruct service technicians on the proper diagnosis and vehicle repair. Reviewing complaints to odi and data submitted by ford, odi has identified 200 alleged incidents of unintended vehicle movement after consumers believe they have shifted the vehicle into park, resulting in 85 alleged crashes and 32 alleged injuries.in addition to the reports of alleged incidents of unintended vehicle movement, odi has also identified 883 reports of consumers alleging difficulty or the inability to shift the vehicle into park.this preliminary evaluation has been upgraded to an engineering analysis (ea09-013) to further assess the scope, frequency and risk to motor vehicle safety of the alleged defect in the subject vehicles.
- 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.
- Stuck engine throttle
On july 7, 2005, the office of defects investigation (odi) opened a preliminary evaluation to investigate alleged stuck throttle complaints in certain model year (my) 2002 ford explorer and mercury mountaineer vehicles equipped with the standard available 4.0L SOHC V6 engine.at that time, odi was aware of 15…
On july 7, 2005, the office of defects investigation (odi) opened a preliminary evaluation to investigate alleged stuck throttle complaints in certain model year (my) 2002 ford explorer and mercury mountaineer vehicles equipped with the standard available 4.0L SOHC V6 engine.at that time, odi was aware of 15 complaints that alleged stuck engine throttle causing unwanted vehicle acceleration and 1 alleged crash as a result.six complainants reported that throttle control cable replacement remedied the alleged stuck throttle condition.additionally, odi was aware of a technical service bulletin issued by the manufacturer that referred to an accelerator cable design change.odi sent a letter to the manufacturer on july 18, 2005 requesting certain information about these vehicles. According to ford, approximately 234,092 subject vehicles built from august 14, 2000 (?job 1?) through october 31, 2001 used a particular accelerator cable known as a 16 lay wire design.this design IS comprised of the throttle cable surrounded by a conduit made of several concentric layers including a teflon liner, a nylon tube extruded over the teflon liner, 16 lay wires wrapped around the nylon tube, and finally a nylon jacket extruded over and around the lay wires. Ford reports that throttle control concerns related to the accelerator cable are likely caused by a migration of the inner teflon liner out of the conduit at the dash panel fitting.should the teflon liner migrate outward sufficiently to contact the accelerator pedal arm it could interfere with the pedal?s ability to return to idle.in november 2001, ford began using a new 12 lay wire design accelerator cable.this change was implemented to allow for installation of optionally available power-adjustable pedals. Field data suggests that the condition with the subject cable IS more prevalent in cold (winter) climates.of the 396 warranty claims related to the alleged defect, nearly 68% occurred in winter months and most warranty claims are associated with vehicles sold in the northeastern, northern interior (midwest), and rocky mountain regions of the united states.this seasonal trend appears to be in decline with fewer warranty claims paid in winter 2005 than in previous winters.there are no known crashes related to the alleged defect on the subject vehicles, the complaint rate IS low after approximately four years in service (3.0 incidents per 100,000 vehicles) and the failure trend IS declining.there have been no new complaints since january 2005.a safety-related defect trend has not been identified at this time and further use of agency resources does not appear to be warranted.accordingly, this investigation IS closed.the closing of this investigation does not constitute a finding by nhtsa that a safety-related defect does not exist.odi will continue to monitor its complaint database and will receive updated complaint and warranty data from ford in spring 2006 to verify the trend analysis.the agency will take further action if warranted by the circumstances.
- Rear liftgate glass assembly
Complaints report failure of the rear liftgate glass support while the operator IS opening or closing the glass.the falling glass can strike the operator or bystander.the injuries reported are bruises to the head, neck or back, cuts to the face, arm or hand.on september 9, 2004, ford notified the agency that it will…
Complaints report failure of the rear liftgate glass support while the operator IS opening or closing the glass.the falling glass can strike the operator or bystander.the injuries reported are bruises to the head, neck or back, cuts to the face, arm or hand.on september 9, 2004, ford notified the agency that it will recall approximately 955,732 my 2002 and 2003 ford explorer and mercury mountaineer vehicles to replace the liftgate glass strut brackets and/or hinges.see nhtsa recall 04v442 for details. This investigation IS closed.
- Mis-assembled airbag clockspring
In july 2001, ford issued a special service message announcing that some air bagclockspring devices may produce noise when the steering wheel IS turned full left or right.ford was aware that some clocksprings may have been improperly installed.the improper installation may also cause an open circuit and the air bag…
In july 2001, ford issued a special service message announcing that some air bagclockspring devices may produce noise when the steering wheel IS turned full left or right.ford was aware that some clocksprings may have been improperly installed.the improper installation may also cause an open circuit and the air bag warning light to illuminate.starting with vehicles produced in september 2001, ford adding length to the clockspring wire to reduce the likelihood of damage from improper installation.odi's investigation revealed 32 comlaints (vehicle built prior to sept. 2001) of warning light but no crashes, injuries, lawsuits or claims.a safety defect has not been identified at this time and further use of agency resources does not appear to be warranted.accordingly, this investigation IS closed. The closing of this investigation does not constitute a finding by nhtsa that a safety-related defect does not exist.the agency will take further action if warranted by the circumstances.see attached summary report.
- Inoperative air bag system
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.
- 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
- 10028736Ford: some vehicles may exhibit oil separation from the internal lube found in the unitized cartridge seal. Oil separation appears to be and IS often misdiagnosed, as an axle lube leak.
- 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.
- 10019800Low oil pressure indication/warning, a/c compressor inoperative and/or no crank condition on 4.6L equipped vehicles.
- 10019379Malfunction indicator lamp on with pcm diagnostic trouble code p0463 and/or ic diagnostic trouble code b1201 - fuel gauge drops to empty or slow to update after refueling.
- 10018959Extended coverage program 05n04 - extended coverage for composite intake manifold. This program IS being provided as a settlement to a class action lawsuit. The terms of the settlement extend the coverage of the all-composite intake manifold to 7 years from the original warranty start date of the vehicle, with no limit on the number of miles that the vehicle has been driven.
- 10018745Wds cop kit diagnostic tip - coil on plug (cop) ignition systems - engine misfire or rough running.
- 10018064Noise from rear wheel hub bearings.
- 10017892Rear axle noise repair.
- 10017881No start/hard start n hot soak restart.
- 10017860Malfunction indicator lamp coming on with diagnostic trouble codes (dtcs) p0171, p0172, p0174 and/or p0175 (fuel system too rich or lean).
- 10016832Backglass difficult to close and an intermittent door ajar lamp.
- 10016798Hard start/no start condition during cold ambeint temperatures after short hot soak period-4.0l engine.
- 10016789Rear axle noise repair.
- 10014668Axle seal leaks.
- 10014664Front seat(s) slight movement when accelerating and/or decelerating.
- 10014659Axle whine howl. This includes 1997-05 ford vehicles.
- 10014165Aluminum corrosion - service tip.
- 10014138Safety belt retraction speed.
- 10014100Limited slip axle chatter, shudder, binding sensation, or vibration during low speed turning maneuvers.
- 100140895R55w transmission - no 3RD gear or slipping 2-3 shift - diagnostic trouble code p0733 and p0745 - vehicles built prior to 3/4/2002.
- 10014086General (pcm) power train control module programming procedures.
- 10014062Rear window defroster grid/integral antenna diagnosis and repair - terminal tab repair.
- 10013398Gear selector lever - increased effort to shift from drive to park.
- 10013388Fuel gauge slow to update after refueling.
- 10013319Open fuse F2.20 (5 amp) and/or F2.1 (30 amp) which may result in loss of function of several systems including power seats, adjustable pedals and power door locks.
- 10013303Rear power window(s) inoperative.
- 10013116Malfunction indicator lamp (mil) illuminated - system lean diagnostic trouble codes (dtc's) - service tips. Various models including 2004 f-series.
- 10013078High side pressure fluctuations on vehicles equipped with a fixed scroll a/c compressor.
- 10013074Sun visor rattle / detroit area dealers contact request.
- 10013064Excessive sulfur smell from exhaust.
- 10012959Axle whine howl service with individual parts instead of an axle assembly.
- 10012952Driveline 1ST order vibration/boom/drone.
- 10011342No crank/no start condition when vehicle temperature IS below freezing (32f/0c).
- 10011333Updated rear halfshaft removal procedure.
- 10011332Fuel gauge slow to update.
- 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.
- 10011150Rattle noise from primary chain drive area 2000-3000 rpm - 4.0L SOHC engine.
Every Ford Explorer model year
Bars are owner complaints, dots mark years with recalls. Select a year to open its report.