Problems owners report
Complaints filed with NHTSA about the 2002 Ford Explorer, by the system named in each complaint. One complaint can name several.
- Power train1,502
- Structure486
- Suspension422
- Engine and engine cooling163
- Air bags162
- Steering155
- Vehicle speed control152
- Electrical system148
- Visibility129
- Service brakes, hydraulic89
NHTSA ODI complaints (public domain) · updated 23 Oct 2026 · 187 injuries and 5 deaths reported
Compared with other years
NHTSA ODI complaints by model year
Fatal crashes in the US
From 2020 to 2023, 157 2002 Explorer vehicles were involved in crashes on US public roads in which someone died; 111 people died inside them, and 78 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 Explorer failed the safety check 2.06% of the time — 3% more often than the average 2002 passenger car (2.00%). Median odometer at inspection: 164,485 miles.
NY DMV Vehicle Inspections (vezn-fmmk), initial inspections since Aug 2021 · how we count
In the United Kingdom
0 cars built in 2002 were licensed for the road at the end of 2025, and 1 more were declared off the road (SORN).
Department for Transport and DVLA, vehicle licensing statistics (table VEH0124, year of manufacture) · Open Government Licence v3.0
In New Zealand
298 2002 cars are on the New Zealand register; 19% arrived as used imports, 78% were sold new in New Zealand.
NZ Transport Agency Waka Kotahi, Motor Vehicle Register (March 2026) · CC BY 4.0
Fuel consumption
Official Canadian test results for 2 variants: combined 15.6–16.3 L/100 km (about 14–15 mpg US), CO₂ 359–375 g/km.
| Variant | City | Highway | Combined |
|---|---|---|---|
| Explorer 4X4 · Sport utility vehicle · Regular gasoline | 17.8 | 12.9 | 15.6 |
| Explorer 4X4 · Sport utility vehicle · Regular gasoline | 18.6 | 13.5 | 16.3 |
Litres per 100 km. Natural Resources Canada, Fuel consumption ratings (open.canada.ca) · Open Government Licence – Canada
Recalls in Canada
7 Transport Canada recalls for the 2002 Ford Explorer.
| 2019420 21 Aug 2019 | Other Issue: This recall is for aftermarket replacement rear window glass produced by Vitro Automotriz. Certain rear window glass may not have been properly tempere… |
| 2009292 14 Oct 2009 | Other On certain vehicles, the speed control deactivation switch may overheat, smoke, or burn, potentially resulting in an underhood fire. The condition may occur ei… |
| 2007258 7 Aug 2007 | Electrical On certain vehicles, the speed control deactivation switch may overheat, smoke, or burn, potentially resulting in an underhood fire. The failure mode appears t… |
| 2006079 18 Apr 2006 | Seats And Restraints On certain Explorer, Explorer Sport and Explorer Sport Trac vehicles, the upper bolt on the driver's high back seat that attaches the seat recliner mechanism to… |
| 2004328 10 Sept 2004 | Other On certain 2002 model year vehicles, the ball stud bracket located on the rear liftgate window could rotate out of position on the glass. If this occurs, the w… |
| 2003190 11 Aug 2003 | Seats And Restraints On certain Explorer, Explorer Sport and Explorer Sport Trac vehicles, the upper bolt on the driver's high back seat that attaches the seat recliner mechanism to… |
| 2001125 28 May 2001 | Other On certain vehicles, the right side tires may have horizontal cuts on the edge of the tread that could have occurred during vehicle assembly. Over time the tir… |
Transport Canada Vehicle Recalls Database · Contains information licensed under the Open Government Licence – Canada
Recalls
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 SCDS MAY LEAK INTERNALLY AND THEN OVERHEAT, SMOKE, OR BURN.
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.
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.
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.
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 Explorer: known faults, fixes and updates.
| Bulletin | Summary |
|---|---|
| 637920 | SOME VEHICLES EQUIPPED WITH THE 4.0 SOHC (SINGLE OVER-HEAD CAM) ENGINE MAY EXHIBIT A PRIMARY TIMING CHAIN RATTLE NOISE. *TT |
| 637846 | INFORMATION USED WHEN REPLACING THE DRIVERS SEAT MODULE. *TT |
| 637803 | CONCERNS WITH BRAKE VIBRATION, ROUGHNESS AND / OR GRINDING NOISE, AND EXCESSIVE BRAKE ROTOR CORROSION. *TT |
| 637796 | INFORMATION ON POWER STEERING LEAK CONDITION. *TT |
| 637783 | SUBJECT REGARDING THEFT LIGHT RELOCATION. *TT |
| 637771 | SUBJECT REGARDING REAR LIFTGATE APPLIQUE (TRIM PANEL) CRACKS. *TT |
| 637700 | SUBJECT REGARDING INTERMITTENT ENGINE QUIT DURING TRANSMISSION ENGAGEMENTS OR PARKING MANEUVERS. *TT |
| 637573 | SUBJECT REGARDING CIGAR LIGHTER REVISED INSTALLATION PROCEDURES. *TT |
| 637528 | SOME VEHICLES BUILT SINCE OCTOBER 1, 2001 MAY EXHIBIT A NO START CONDITION OR AN INTERMITTENT NO START CONDITION, AND / OR POSSIBLY NO COMMUNICATION FROM THE POWERTRAIN ELECTRONIC CONTROLLER WITH THE WDS / NGS DIAGNOSTIC EQUIPMENT. *TT |
| 637476 | SOME VEHICLES MAY EXHIBIT EXCESSIVE SULPHUR SMEEL FROM THE EXHAUST UNDER CERTAIN DRIVE MODES. *TT |
| 636316 | EXHIBITING SQUEAK / CREAK NOISES DURING FRONT SUSPENSION MOVEMENT. *TT |
| 636314 | SOME VEHICLES MAY EXHIBIT A NEED FOR HEADLAMP AIM ADJUST AFTER DRIVING ON ROUGH ROADS. *TT |
| 636221 | SOME VEHICLES MAY EXHIBIT UNINTENDED SMART UNLOCK ACTIVATION WITHOUT KEY IN IGNITION. *TT |
| 636110 | SOME VEHICLES MAY EXHIBIT FUEL DIAGNOSTIC TROUBLE CODES P0171, P0172, P0174, P0175 OR MASS AIR FLOW DIAGNOSTIC TROUBLE CODES P0102, P0103, P0112, P0113. *TT |
| 636106 | SOME 4DR VEHICLES MAY EXHIBIT SEATING APPEARANCE OR RELATED ISSUES. *TT |
| 636065 | INFORMATION REGARDING DISCHARGED BATTERY CHARGING SERVICE TIPS AND GUIDELINES. *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 |
| 636027 | SUBJECT REGARDING 5R55W AUTOMATIC TRANSMISSION HARSH UPSHIFTS DURING LIGHT TO MEDIUM THROTTLE CONCERNS. *TT |
| 636013 | INFORMATION ON DIAGNOSING ENGINE RATTLE NOISE FROM PRIMARY CHAIN DRIVE AREA BETWEEN 2000-3000 RPM ON COLD ENGINE OPERATION ONLY. *TT |
| 630700 | SOME VEHICLES EQUIPPED WITH A V6 ENGINE MAY EXHIBIT A STEERING RATTLE NOISE WHICH MAY BE HEARD AND FELT IN THE STEERING WHEEL AND COLUMN. *TT |
| 630698 | CONCERNS WITH CLUNK NOISE FROM FRONT AXLE AREA. *TT |
| 630653 | SOME VEHICLES MAY EXHIBIT DRIVEABILITY CONDITIONS AND / OR CHECK ENGINE LAMP ILLUMINATED WITH A DIAGNOSTIC TROUBLE P0455 (GROSS LEAK DETECTED). *TT |
| 630636 | SOME VEHICLES EQUIPPED WITH THE 4.0L SOHC ENGINE MAY EXHIBIT A CHECK ENGINE LIGHT ON WITH DIAGNOSTIC TROUBLE CODES P0300 (RANDOM MISFIRE) OR P0301. *TT |
| 630628 | SOME VEHICLES MAY EXHIBIT AN INTAKE MANIFOLD CROSSOVER (FIRST RUNNER) COOLANT SEEPAGE CONDITION. *TT |
NHTSA manufacturer communications (public domain)
NHTSA investigations
Vehicle Rollaway Allegations
VEHICLE ROLLAWAY ALLEGATIONS
SPARK PLUG EJECTION FROM CYLINDER HEAD
STUCK ENGINE THROTTLE
REAR LIFTGATE GLASS ASSEMBLY
MIS-ASSEMBLED AIRBAG CLOCKSPRING
INOPERATIVE AIR BAG SYSTEM
NHTSA Office of Defects Investigation