2002 Ford Explorer: Recalls, Problems & MPG
Here are the deets on the 2002 Ford Explorer: 4 recalls, 3295 owner complaints and up to 17 mpg combined.
Recalls
4 vehicle recalls from the manufacturer, plus 6 equipment/tire recalls that can apply. Repairs are free. Check your VIN to see if one is still open on your car.
Tires Vehicle recall #01V171000 · 2001 · 52,000 vehicles
What's wrong: The right side tires May have horizontal cuts on the edge of the tread that could have occurred during vehicle assembly.
Why it matters: Over time, the tire could fail, increasing the risk of a crash.
The fix: Dealers will inspect the tires and, if any slices are found, the cut tires will be replaced. Owner notification began June 7, 2001.
Body & structure Vehicle recall #03V094000 · 2003 · 3,674 vehicles
What's wrong: 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.
Why it matters: This overheating condition can cause the running board to melt or cause a fire.
The fix: Dealers will replace the wiring harness on these running boards. Owner notification began March 7, 2003.
Body & structure Vehicle recall #04V442000 · 2004 · 955,732 vehicles
What's wrong: 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.
Why it matters: If the hinge should fracture, there is a potential for the glass to fall and ultimately break and personal injuries could occur.
The fix: 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…
Speed control / throttle Vehicle recall #09V399000 · 2009 · 4,500,000 vehicles
What's wrong: The scds May leak internally and then overheat, smoke, or burn.
Why it matters: A vehicle fire could occur with or without the engine running.
The fix: 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…
6 aftermarket equipment / tire recalls replacement parts sold to fit this car, not the car itself
Visibility (wipers, glass) Recall #01I010000 · 2001 · 50,224 vehicles
What's wrong: 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 torque are not sufficient.
Why it matters: 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.
The fix: 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…
Exterior lights Equipment recall #06E026000 · 2006 · 61,944 vehicles
What's wrong: 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.
Why it matters: Without the amber reflectors, the vehicle will be poorly illuminated, possibly resulting in a vehicle crash without warning.
The fix: Pro-a motors will notify owners and offer to repurchase the lamps. The recall began on April 3, 2006.
Exterior lights Equipment recall #06E049000 · 2006 · 27,176 vehicles
What's wrong: 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.
Why it matters: Without the amber reflectors, the vehicle will be poorly illuminated, possibly resulting in a vehicle crash without warning.
The fix: Ck motorsport will notify owners and replace the noncompliant lamps free of charge. The recall began on July 1, 2006.
Visibility (wipers, glass) Equipment recall #07E104000 · 2007 · 1,657 vehicles
What's wrong: 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 materials."
Why it matters: In the event of a vehicle crash, the occupant(s) May be seriously injured by shattered glass.
The fix: 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…
Exterior lights Equipment recall #09E012000 · 2009 · 16,270 vehicles
What's wrong: 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 the required amber side reflectors.
Why it matters: Decreased lighting visibility May result in a vehicle crash.
The fix: Sabersport will notify owners and offer a full refund for the noncompliant combination lamps. The safety recall began on May 11, 2009.
Exterior lights Equipment recall #09E025000 · 2009 · 42,540 vehicles
What's wrong: 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 the required amber side reflectors.
Why it matters: Decreased lighting visibility May result in a vehicle crash.
The fix: Dope, Inc. will notify owners and offer a full refund for the noncompliant combination lamps. The safety recall began on July 28, 2009.
Most-reported problems
Owner complaints filed with NHTSA, by component. One complaint can list several components. 57 mention a fire, 187 injuries and 5 deaths were reported.
What owners describe
- Transmission & drivetrain (1502): the most common themes are hard / delayed shifting (714), noise or vibration (301), warning light on (134).
- Body & structure (486): the most common themes are door / lock issues (86), noise or vibration (21).
- Suspension (422): the most common themes are noise or vibration (145), rust / corrosion (26).
- Engine & cooling (163): the most common themes are stalls / loses power (49), noise or vibration (38), fire / smoke (19).
The 2002 Ford Explorer has 3295 owner complaints, ranking #1 of 38 Explorer model years for complaints (3.6× the average Explorer year). Complaints peaked in 2008 (493 filed that year). The typical problem showed up when the car was about 6 years old, at a median of 79,000 miles. Neighboring years: 2001 (375 complaints, 6 recalls), 2003 (1131 complaints, 2 recalls).
Engines & fuel economy (EPA)
| Engine | Transmission | Drive | City | Hwy | Comb. | Fuel |
|---|---|---|---|---|---|---|
| 4.0 L 6-cyl | Manual 5-spd | Rear-Wheel Drive | 15 | 20 | 17 | Regular |
| 4.0 L 6-cyl | Automatic 5-spd | Rear-Wheel Drive | 14 | 19 | 16 | Regular |
| 4.0 L 6-cyl | Manual 5-spd | 4-Wheel or All-Wheel Drive | 14 | 18 | 16 | Regular |
| 4.0 L 6-cyl | Automatic 5-spd | 4-Wheel or All-Wheel Drive | 14 | 19 | 16 | Gasoline or E85 |
| 4.0 L 6-cyl | Automatic 5-spd | Rear-Wheel Drive | 14 | 19 | 16 | Gasoline or E85 |
| 4.6 L 8-cyl | Automatic 5-spd | Rear-Wheel Drive | 13 | 18 | 15 | Regular |
| 4.0 L 6-cyl | Automatic 5-spd | 4-Wheel or All-Wheel Drive | 13 | 18 | 15 | Regular |
| 4.6 L 8-cyl | Automatic 5-spd | 4-Wheel or All-Wheel Drive | 13 | 17 | 14 | Regular |
Want the full repair deets? Get the factory manual.
Recall and complaint data tells you what goes wrong. A service manual tells you how to fix it: torque specs, wiring diagrams, fluid capacities and step-by-step procedures for the 2002 Ford Explorer.
Closest thing to the factory manual for most years. Pay once, keep it.
Most $25–$78, one-timePro-shop repair procedures, wiring diagrams and TSBs for your exact car.
From $19.99/mo · $39.99/yrOEM procedures, specs and recall/TSB info, the same source many shops use.
From $19.99/mo · $59.99/yrStep-by-step photos written from a real teardown. Great for first-timers.
Books ~$30–$40 · AllAccess $34.99/moHeads up: we may earn a commission if you buy through these links, at no extra cost to you. Prices checked 2026-10 and can change. We never host or link to pirated manuals. Disclosure
FAQ
Does the 2002 Ford Explorer have any recalls?
Yes. NHTSA lists 4 vehicle recalls for the 2002 Ford Explorer, plus 6 equipment or tire recalls that can apply. Recall repairs are free at any dealer, no matter how old the car is. Check your VIN at nhtsa.gov/recalls.
What are the most common 2002 Ford Explorer problems?
Owners have filed 3295 complaints with NHTSA. The most-reported areas are transmission & drivetrain (1502), body & structure (486), suspension (422).
What gas mileage does the 2002 Ford Explorer get?
EPA ratings run up to 17 mpg combined (4.0 L, Manual 5-spd), across 8 engine and transmission combos.
Where can I get a 2002 Ford Explorer repair manual?
eManualOnline sells downloadable manuals, Mitchell 1 DIY and ALLDATAdiy sell online access to factory repair data, and Haynes sells printed guides and online access. Pick a download if you want to keep it, or a subscription for wiring diagrams and TSBs.