2002 Ford F Series
Safety record from NHTSA: recalls, owner complaints, investigations and service bulletins.
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Vehicles › Ford › F Series › 2002
These records cover every 2002 Ford F Series. To see whether one car still needs a recall repair, decode its VIN or check it with NHTSA.
Recalls
1 recall names the 2002 Ford F Series. Newest first.
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
34 complaints1 involved a crash1 involved a fire
What owners report most
Latest complaints
- Fuel/propulsion system
I was driving my truck and it began vibrating; shortly thereafter it was running as if half the engine was working , with a loss of power. I pulled the fuel filter and there was trash all in the filter. I bought another filter and replaced it and ran the truck again and it was working fine.…
I was driving my truck and it began vibrating; shortly thereafter it was running as if half the engine was working , with a loss of power. I pulled the fuel filter and there was trash all in the filter. I bought another filter and replaced it and ran the truck again and it was working fine. Shortly thereafter the same thing happened again, loss of power, running like half the engine was working and then stalled. After a few minutes it started up but ran terrible. I got it home. I pulled the fuel filter and it was loaded with trash again. I called the Ford dealer and spoke to a mechanic and he advised he has fixed numerous trucks like mine and the gas tank was deteriorating from the inside and clogging my fuel filter. He said there is a recall for the truck and that the fuel tank needs to be replaced. Please help me as this truck only has 75,000 miles and is like brand new, garage kept and well taken care of. Thank you for your time in this matter and I look forward to hearing from you soon.
- Engine
Driving on the freeway a spark plug came out of the engine causing the vehicle to shake and loose power. the dealer and a shop I took the vehicle to stated that this IS a frequent problem with this engine. *tr
- Power train · Steering · Structure › Body
While backing into my truck started making a load noise, it was obvious it was in the front end. Trying to turn the steering wheel, it was stuck. Stopped the truck, looked under the front of truck at steering, I noticed that there was a hole in the frame, it was then that I saw the steering link…
While backing into my truck started making a load noise, it was obvious it was in the front end. Trying to turn the steering wheel, it was stuck. Stopped the truck, looked under the front of truck at steering, I noticed that there was a hole in the frame, it was then that I saw the steering link, against the right cv axle. The idler arm had some how ripped off the frame, leaving na hole where the idler arm was, the frame of the truck had weakened, causing the metal to weaken and separate, thank again ford. *tr
- Electronic stability control (esc) · Service brakes
Failure of the ABS module has led to a near miss accident that was avoided via steering around the obstruction instead of braking. the obdii module IS throwing code c1185 as a part of the failure of the ABS controller.. *tr
- Vehicle speed control › Accelerator pedal
Gas petal sticks and when pushed on truck accelerates rapidly, this happens when starting out from a stop and during all driving. *js
- Engine
Was driving down the road at 35 mph and heard a pop then the engine started to run rough. Took to the mechanic said that I had a blown spark plug. *tr
- Fuel system, gasoline · Vehicle speed control
Throttle body linkage "plastic cover clamshell" cracked in half at plastic hinge (oxidized plastic) . loose plastic cover wedged open throttle fully causing "dangerous life threatening" driving stuck at full throttle. I have the cover and photos if you want me to send them. *tr
- Engine
A spark plug ejected from the right side head of the engine head while running down the hwy at 60 mph. the head might be damaged. I haven't had a chance to get it fixed. been a ford truck guy all my life & I can't believe ford hasn't accepted any responsibility of any portion or kind for this.…
A spark plug ejected from the right side head of the engine head while running down the hwy at 60 mph. the head might be damaged. I haven't had a chance to get it fixed. been a ford truck guy all my life & I can't believe ford hasn't accepted any responsibility of any portion or kind for this. My estimated expense to repair this IS $1,000 to $3,000 depending on any damage to the head etc.. I paid $4200 for the truck in april of 2013...it IS in very good condition & to good to junk in my opinion. Besides I can't afford to buy another truck so I have to try to fix it. this IS beyond disappointing, it IS a major blow to the budget etc. Etc. Etc...... *tr
- Electrical system · Engine · Fuel/propulsion system
Spark plug ejected while driving on high way. This IS the second time a plug has ejected. The first time the truck had 39000 miles, original factory torqued spark plugs. *tr
- Electrical system · Engine
Spark plug blew out of engine. This IS the second time in a year on two different plugs. These are the original plugs. *tr
- Engine
Driving on highway 30 mph and #3 spark plug blew out . *tr
- Fuel system, diesel › Storage › Tank assembly
The fuel tank straps on my 2002 ford F350 rotted out to were the fuel tank was hanging all most hitting the ground, could have been a major diesel spill with 38 gallon of fuel. *js
- Engine and engine cooling
Blew spark plug out of head while accelerating to get on highway. Had gas spill on motor. It has the 5.4 triton motor. *Tr
- Engine and engine cooling
My truck threw a spark plug while driving down the road. This IS the second time it has done this and the same exact one as before. *tr
- Fuel system, gasoline
Fuel tank straps failed while driving resulting in the tank dropping. the front of the tank contacted the road surface resulting in a leak and spilling of approximately 21 gals of fuel on the road. no fire resulted but the hazmat team was required to clean up the spilled fuel. the 2002 f 150 was towed to a ford dealer for repair. *Tr
- Fuel system, other
I have a 2002 ford f 150 xlt supercrew with the 139 inch wheelbase. Upon arriving home my wife said she noticed something hanging below the truck.. I went out to inspect. The front fuel tank retaining strap was hanging there. The bolt side had rotted away approximately 6 inches down from top. Rear…
I have a 2002 ford f 150 xlt supercrew with the 139 inch wheelbase. Upon arriving home my wife said she noticed something hanging below the truck.. I went out to inspect. The front fuel tank retaining strap was hanging there. The bolt side had rotted away approximately 6 inches down from top. Rear strap was inspected and showed signs of rust but still in place and functioning as intended..i have moved the vehicle inside to avoid using it and will order new strap in morning. I had heard ford was looking into this problem has it been resolved ? Do I have recourse ? thanks. *tr
- Fuel system, gasoline
Fuel tank straps rusted and broken causing tank to almost fall out
- Engine and engine cooling
Spark plug blew out of engine while driving. *Tr
- Electrical system › Ignition
Was having problems starting the vehicle. Sometimes it would start, sometimes it wouldn't. *tr
- Engine and engine cooling › Engine
I bought my truck under the assumption that I wouldn't need to do a major tuneup until 100,000 miles. prior to that, I had to get one at 60,000 miles, 3-5 months after that one of my spark plugs shot out of the motor, leading to having to have the head replace. I received no reasonable…
I bought my truck under the assumption that I wouldn't need to do a major tuneup until 100,000 miles. prior to that, I had to get one at 60,000 miles, 3-5 months after that one of my spark plugs shot out of the motor, leading to having to have the head replace. I received no reasonable explanation on what would have caused that or why would it happened. the dealership and ford wanted to charge me 3,600 dollars to fix it. I was wondering if anyone else had this problem with a ford F150 or had there been some kind of recall? if so, IS there some kind of legal action I can take against ford for this . *tr
- Engine and engine cooling › Engine
2002 ford F150 5.4 liter engine 2 months ago I had a spark plug thread failure on my F150. It cost 400.00 to repr the vehicle so that it could be driven. 1500 miles later I have another thread failure causing another plug to be spit out of MY6 cylinder head. I have been told by dealerships and…
2002 ford F150 5.4 liter engine 2 months ago I had a spark plug thread failure on my F150. It cost 400.00 to repr the vehicle so that it could be driven. 1500 miles later I have another thread failure causing another plug to be spit out of MY6 cylinder head. I have been told by dealerships and mechanics that this IS a common problem and that I can replace the heads with new ones but that they can not guarantee that it would not happen again. or I can have both heads removed and have inserts machined into the heads to prevent anything from failing again. the cost of this process IS 2200.00. I have now spent 2600.00 on the engine in 2 months time due to a improper manufacturing of the heads that were made for this engine. I would like to see a defect recall made on the heads and possibly be reimbursed for some of the expense. *tr
- Engine and engine cooling
I woke up last week to the sound of a car alarm. I looked outside and the front of my ford f 150 was engulfed in flames. It was so hot the tires melted into the driveway. We had not driven the truck in several days. It appears the fire started in the engine as the entire front of the vehicle IS incinerated. *Tr
- Engine and engine cooling › Engine › Gasoline
Ford triton V8 spark plug blew out of head 2002 F250. *nm
- Power train › Automatic transmission
We have owned our 2002 F150 4 door truck for 5 months now purchased in dec 04', we have 34,000 miles on this truck which was purchased used. On saturday 4/23/05 our transmission completely slipped out leaving us no power on a busy, hilly, country road. The truck's rmp's would go up however, the…
We have owned our 2002 F150 4 door truck for 5 months now purchased in dec 04', we have 34,000 miles on this truck which was purchased used. On saturday 4/23/05 our transmission completely slipped out leaving us no power on a busy, hilly, country road. The truck's rmp's would go up however, the truck was not gaining speed only losing speed, we are very lucky that no one came over the hill, or this would have caused a major wreck. Once we got us and vehicle to safety we called our ford dealership chuck anderson ford, who told us to have it towed in. However, they would not cover the tow since it was out of warranty. The vehicle evidently went out of warranty on feb. 14TH of this year 2005. I don't believe a truck with only 34,000 miles on it should have a transmission blown in it. We then had the truck taken to the dealership. I have spoken with the dealership today, which we we're told we would have to cover the deductible of $400/500.00 for this repair. They are now tearing the transmission apart. *Ak
- Steering › Column
No warning-upon attempt to engage shift selector into "r", the entire shift selector broke in half at the shaft connection inside the column . The structure appears to have been manufactured from a material often referred to as "pot-lead". Had to have vehicle towed home at my personal expense. Could not disengage transmission from the "park" position and could not remove the ignition key. *jb
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.
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.
- 10029029Jerr-dan: anti stall feature for ford f series light duty chassis with V10 gas engine and an engine drive clutch pump. Model years unknown.
- 10013116Malfunction indicator lamp (mil) illuminated - system lean diagnostic trouble codes (dtc's) - service tips. Various models including 2004 f-series.
- 10008279New service part - number 5 needle bearing and race kit - 4r70w transmission - service tip.
- 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.
- 10002606Clear gel-like substance in the hydraulic brake master cylinder reservoir. This substance IS a silicone base lubricant used during assembly of the master cylinder.
- 10001937False failure of the vapor management valve (vmv).
- 636408Some dedicated CNG vehicles may exhibit driveability conditions of hard start / no start / rough running.
- 636399Subject regarding vehicles exhibiting cold start rolling idle.
- 636344Some vehicles may exhibit wheels that seize to the hubs and are difficult to remove during service.
- 636330Subject regarding connecting rod commonization for 2002 super duty and light duty.
- 636110Some vehicles may exhibit fuel diagnostic trouble codes p0171, p0172, p0174, p0175 or mass air flow diagnostic trouble codes p0102, p0103, p0112, p0113.
- 630653Some vehicles may exhibit driveability conditions and / or check engine lamp illuminated with a diagnostic trouble p0455 (gross leak detected).
- 630645Super duty erratic coolant temperature gauge readings - concerns.
- 630412Some vehicles may exhibit a condition of oil contamination in cooling system.
- 630354Some vehicles may run rough at cruise or momentarily after stopping, a check engine light,and p030x codes.
- 630273Some vehicles equipped with 7.3L di engine may exhibit false diagnostic trouble codes p1105, p1106 (upper and lower alternator faults).
- 630026Some vehicles may exhibit driveabilty conditions and/or check engine lamp illuminated with a diagnostic trouble code p0455 (gross leak detected).
- 624617Some vehicles may exhibit a condition where the transmisison temperature gauge reads in the middle at start up.
Every Ford F Series model year
Bars are owner complaints, dots mark years with recalls. Select a year to open its report.