Problems owners report
Complaints filed with NHTSA about the 2002 Ford Expedition, by the system named in each complaint. One complaint can name several.
- Engine and engine cooling95
- Vehicle speed control58
- Electrical system46
- Engine27
- Tires26
- Seat belts20
- Power train18
- Air bags16
- Service brakes, hydraulic16
- Fuel system, gasoline15
NHTSA ODI complaints (public domain) · updated 23 Oct 2026 · 27 injuries and 2 deaths reported
Compared with other years
NHTSA ODI complaints by model year
Fatal crashes in the US
From 2020 to 2023, 49 2002 Expedition vehicles were involved in crashes on US public roads in which someone died; 39 people died inside them, and 19 of the vehicles rolled over. This is a count, not a crash rate: it grows with the number of cars on the road.
NHTSA Fatality Analysis Reporting System (FARS), crash years 2020–2023 (public domain)
New York safety inspections
At its first New York inspection the 2002 Ford Expedition failed the safety check 1.84% of the time — 8% less often than the average 2002 passenger car (2.00%). Median odometer at inspection: 158,700 miles.
NY DMV Vehicle Inspections (vezn-fmmk), initial inspections since Aug 2021 · how we count
Fuel consumption
Official Canadian test results for 2 variants: combined 17.1–18.8 L/100 km (about 13–14 mpg US), CO₂ 393–432 g/km.
| Variant | City | Highway | Combined |
|---|---|---|---|
| Expedition 4X4 · Sport utility vehicle · Regular gasoline | 19.1 | 14.6 | 17.1 |
| Expedition 4X4 · Sport utility vehicle · Regular gasoline | 21.5 | 15.4 | 18.8 |
Litres per 100 km. Natural Resources Canada, Fuel consumption ratings (open.canada.ca) · Open Government Licence – Canada
Recalls in Canada
2 Transport Canada recalls for the 2002 Ford Expedition.
| 2005028 14 Feb 2005 | Electrical On certain vehicles, the speed control deactivation switch may overheat, smoke, or burn, potentially resulting in an underhood fire. The condition may occur ei… |
| 2004164 18 May 2004 | Steering On certain vehicles, Ford has issued a scheduled maintenance guide update which specifies that every 20 000 kms, the steering linkage, which includes tie-rod en… |
Transport Canada Vehicle Recalls Database · Contains information licensed under the Open Government Licence – Canada
Recalls
ON CERTAIN PICKUP TRUCKS AND SPORT UTILITY VEHICLES EQUIPPED WITH SPEED CONTROL, THE SPEED CONTROL DEACTIVATION SWITCH MAY OVERHEAT, SMOKE, OR BURN.
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.
Whether a recall was fixed on a particular car is known only to the manufacturer: check the VIN at nhtsa.gov/recalls.
NHTSA recalls · summaries in NHTSA's own words
Service bulletins
What Ford told its dealers about the 2002 Ford Expedition: known faults, fixes and updates.
| Bulletin | Summary |
|---|---|
| 637882 | WHITE FLAKES COMING FROM THE AIR CONDITIONER VENTS WHEN THE BLOWER MOTOR IS ENGAGED. *TT |
| 637848 | CONCERNS WITH SPEED BODY BOOM. *TT |
| 637779 | SUBJECT REGARDING DRIVELINE ANGLE-RELATED VIBRATION AT VARIOUS SPEEDS AND LOAD CONDITIONS. *TT |
| 637511 | SOME 4X2 VEHICLES EQUIPPED WITH P275/60/R17 CONTINENTAL-GENERAL TIRES MAY EXHIBIT A HIGHWAY SPEED TIRE VIBRATION. *TT |
| 636384 | SOME VEHICLES EQUIPPED WITH 4 WHEEL DRIVE MAY EXHIBIT A NOTCHY OR STICKING FEELING IN SLOW SPEED TURNS WITH NO EFFECT ON STEERING EFFORTS OR ASSIST WHILE IN THE AUTOMATIC 4X4 POSITION. *TT |
| 636371 | SOME 4X2 VEHICLES EQUIPPED WITH P275/60/R17 CONTINENTAL GENERAL TIRES MAY EXHIBIT A HIGHWAY SPEED TIRE VIBRATION. *TT |
| 636344 | SOME VEHICLES MAY EXHIBIT WHEELS THAT SEIZE TO THE HUBS AND ARE DIFFICULT TO REMOVE DURING SERVICE. *TT |
| 636326 | SOME VEHICLES MAY EXHIBIT A SQUEAK, SNAP, RATTLE, OR CLUNK IN THE FRONT END WHEN TURNING OR GOING OVER BUMPS. *TT |
| 636289 | SOME VEHICLES MAY EXHIBIT A FLASHING TRANSMISSION CONTROL INDICATOR LAMP (TCIL) AND DIAGNOSTIC TROUBLE CODES P0740, P0741, P0743, AND P1744 (TORQUE CONVERTER CLUTCH). *TT |
| 636226 | SOME VEHICLES WITH ELECTRONIC SHIFT-ON-THE FLY MAY EXHIBIT AN INADVERTENT 4X4 LOW ENGAGEMENT WHILE DRIVING. *TT |
| 636202 | SOME VEHICLES WITH AIR SUSPENSION MAY EXHIBIT AN INITIAL OR REPEAT COMPRESSOR DRYER FAILURE. *TT |
| 636178 | SOME VEHICLES EQUIPPED WITH A 4R100 TRANSMISSION AND BUILT BETWEEN JANUARY 1, 2001 AND MAY 1, 2002 MAY EXHIBIT FLASHING TRANSMISSION CONTROL INDICATOR LAMP AND ANY OR ALL TORQUE CONVERTER CLUTCH DIAGNOSTIC TROUBLE CODES P0740, P0741, P0743, P1744. *TT |
| 636083 | SOME VEHICLES EQUIPPED WITH THE 5.4L 2V ENGINE MAY EXHIBIT A WHISTLING NOISE FROMTHE FORMED NYLON TUBE INTHE IDLE-AIR BYPASS FLOW CIRCUIT. *TT |
| 636065 | INFORMATION REGARDING DISCHARGED BATTERY CHARGING SERVICE TIPS AND GUIDELINES. *TT |
| 636054 | SUBJECT REGARDING IDLER ARM REPLACEMENT SPECIFICATIONS. *TT |
| 636052 | INOPERATIVE OR INACURRATE SPEEDOMETER, 4X4 LAMP ILLUMINATD, AND / OR DIAGNOSTIC TROUBLE CODE P1635 OR P1639. *TT |
| 636049 | THIS BULLETIN INVOLVES PROPER PROCEDURES FOR PREPARATION OF SERVICE SHEET METAL PARTS COATED WITH ELECTRO DEPOSITION PRIMER (E-COAT). *TT |
| 630706 | CONCERNS WITH CLIMATE CONTROL SYSTEM AIR DISCHARGED THROUGH THE DEFROSTER DUCTS ONLY, REGARDLESS OF SETTING. *TT |
| 630704 | SOME VEHICLES EQUIPPED WITH AIR SUSPENSION MAY EXHIBIT AN AIR LEAK AND/OR OVERNIGHT BLEED DOWN OF THE AIR SUSPENSION. *TT |
| 630702 | SOME VEHICLES MAY EXHIBIT A SLOW FUEL FILL CONDITION AND/OR PREMATURE SHUTOFF OF THE GAS PUMP WHEN THE VEHICLE IS BEING REFUELED. *TT |
| 630679 | CONCERNS WITH VEHICLES WITH A 5.4L 2V ENGINE EXHIBITINGNG A LACK OF POWER CONDITION. *TT |
| 630653 | SOME VEHICLES MAY EXHIBIT DRIVEABILITY CONDITIONS AND / OR CHECK ENGINE LAMP ILLUMINATED WITH A DIAGNOSTIC TROUBLE P0455 (GROSS LEAK DETECTED). *TT |
| 630612 | CONCERNS WITH POP/CLUNK/CLICK NOISE FROM THE FRONT SUSPENSION WHEN MAKING LOW-SPEED TURNS IN FORWARD OR REVERSE GEARS. *TT |
| 630585 | SOME VEHICLES MAY EXHIBIT A SLOW FUEL FILL CONDITION AND/OR PREMATURE SHUTOFF OF THE GAS PUMP WHEN THE VEHICLE IS BEING RE-FUELED. *TT |
| 630515 | ENGINE OIL SYSTEM PRIMING PROCEDURES, SERVICE TIPS FOR REPORTS OF PREMATURE ENGINE FAILURE. *TT |
NHTSA manufacturer communications (public domain)
NHTSA investigations
SPARK PLUG EJECTION FROM CYLINDER HEAD
ENGINE COMPARTMENT FIRES
NHTSA Office of Defects Investigation