VehicleVerdict

2002 Ford Expedition problems

Verdict · NHTSA data

One of the years to avoid

With 415 complaints filed to NHTSA — about 2.0 times the median Expedition year — the 2002 model ranks #12 of 36 Expedition years for complaint volume. It lands on the years-to-avoid list. Reports tied to this model year include 4 deaths and 36 injuries, per the complaint records themselves.

Engine leads the complaint categories with 122 reports (29% of the total).

415

NHTSA complaints

4

Recalls

2

Investigations

25

Crash-involved

87

Fires reported

36

Injuries

4

Deaths

—

NCAP overall

How does 2002 compare to other Expedition years?

Expedition NHTSA complaints by model year, 2002 highlighted1,137 complaints1991: 1 complaints1993: 1 complaints1994: 4 complaints1995: 1 complaints1996: 3 complaints1997: 1,065 complaints1998: 1,022 complaints1999: 1,137 complaints2000: 1,134 complaints2001: 739 complaints2002: 415 complaints2003: 800 complaints2004: 381 complaints2005: 452 complaints2006: 395 complaints2007: 267 complaints2008: 179 complaints2009: 42 complaints2010: 74 complaints2011: 92 complaints2012: 163 complaints2013: 114 complaints2014: 96 complaints2015: 229 complaints2016: 274 complaints2017: 474 complaints2018: 452 complaints2019: 581 complaints2020: 473 complaints2021: 270 complaints2022: 156 complaints2023: 87 complaints2024: 106 complaints2025: 47 complaints2026: 13 complaints2027: 0 complaints
Expedition NHTSA complaints by model year, 2002 highlighted. Red bars are years to avoid.

See all Expedition years to avoid →

What are the most common 2002 Ford Expedition problems?

ComponentComplaintsShare
Engine12229%
Speed Control5814%
Electrical System4812%
Tires & Wheels297%
Brakes256%
Fuel System225%
Seat Belts205%
Transmission184%
Airbags164%
Suspension154%
Body & Structure143%
Other102%
Lighting72%
Steering41%
Visibility & Wipers31%
Latches & Locks31%
Seats10%

Does the 2002 Ford Expedition have recalls?

4 NHTSA recall campaigns on file. Recall repairs are free at franchised dealers.

06E067000LightingAugust 1, 2006 · 19,413 units

Defect

CERTAIN MAXZONE HEADLIGHT ASSEMBLIES, DEPO BRAND, P/NOS. 331-1129L-ASN AND 331-1129R-ASN, SOLD FOR USE AS AFTERMARKET EQUIPMENT FOR THE ABOVE LISTED PASSENGER VEHICLES. THESE HEADLAMPS FAIL TO CONFORM TO THE PHOTOMETRIC REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 108, LAMPS, REFLECTIVE DEVICES, AND ASSOCIATED EQUIPMENT.

Consequence

DECREASED LIGHTING VISIBILITY MAY RESULT IN A VEHICLE CRASH.

Remedy

MAXZONE WILL NOTIFY OWNERS AND OFFER REIMBURSEMENT FOR ANY NONCOMPLIANT HEADLIGHTS. THE RECALL BEGAN ON JULY 28, 2006. OWNERS MAY CONTACT MAXZONE AT 909-822-3288.

06E056000Fuel SystemJune 13, 2006 · 58,640 units

Defect

CERTAIN AFTERMARKET FUEL FILTERS SOLD UNDER THE PUROLATOR BRAND NAME, P/N F65277, SHIPPED FROM JANUARY 16 THROUGH JUNE 2, 2006, FOR USE ON THE ABOVE LISTED PASSENGER VEHICLES. DUE TO INCORRECT DESIGN, THE QUICK CONNECTORS MAY NOT FULLY SEAT WITH THE TUBE INTERFACE, EVEN THOUGH THE PERSON MAKING THE CONNECTION MAY BELIEVE THAT THE QUICK CONNECTOR IS FULLY ATTACHED.

Consequence

FAILURE OF THIS CONNECTION COULD LEAD TO FUEL SPILLAGE AND, IN THE PRESENCE OF AN IGNITION SOURCE, A FIRE COULD OCCUR.

Remedy

UFI WILL NOTIFY OWNERS AND REPLACE THE FILTERS FREE OF CHARGE. THE RECALL BEGAN ON AUGUST 4, 2006. OWNERS MAY CONTACT UFI FILTERS USA AT 800-230-5876.

05V388000Speed ControlSeptember 7, 2005 · 4,500,000 units

Defect

ON CERTAIN PICKUP TRUCKS AND SPORT UTILITY VEHICLES EQUIPPED WITH SPEED CONTROL, THE SPEED CONTROL DEACTIVATION SWITCH MAY OVERHEAT, SMOKE, OR BURN.

Consequence

A FIRE AT THE SWITCH COULD OCCUR.

Remedy

BY LETTER DATED SEPTEMBER 12, 2005, OWNERS WERE INSTRUCTED TO RETURN THEIR VEHICLES TO THEIR DEALERS TO HAVE THE SPEED CONTROL DEACTIVATION SWITCH DISCONNECTED. OWNERS WHO HAVE HAD THEIR SPEED CONTROL DEACTIVATED ARE BEING NOTIFIED THAT PARTS WILL BE AVAILABLE AND ADVISED TO MAKE AN APPOINTMENT TO RECONNECT THE SPEED CONTROL BEGINNING IN FEBRUARY 2006. OWNERS WHO DID NOT HAVE THEIR SPEED CONTROL DEACTIVATED ARE BEING NOTIFIED TO HAVE THEIR SYSTEM REMEDIED BEGINNING IN FEBRUARY 2006. OWNERS ARE URGED TO AVAIL THEMSELVES OF THE FREE DISCONNECT SERVICE AS SOON AS POSSIBLE BECAUSE OF THE SIGNIFICANT RISK OF FIRE. OWNERS MAY CONTACT FORD AT 1-800-392-3673. (NOTE: ALSO SEE RECALLS 05V017 AND 06V286)

03V094000Body & StructureMarch 7, 2003 · 3,674 units

Defect

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.

Consequence

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.

Consumer complaints filed with NHTSA

Representative excerpts, cleaned of personal information. These are consumer statements, not verified defects.

“TL*THE CONTACT OWNS A 2002 FORD EXPEDITION. AFTER PARKING THE VEHICLE, THE CONTACT CAME OUTSIDE TO SEE THE VEHICLE ENGULFED IN FLAMES WHICH WERE COMING FROM UNDER THE HOOD. THE FIRE DEPARTMENT EXTINGUISHED THE FIRE. THE VEHICLE HAD NOT BEEN INSPECTED OR REPAIRED AT THE TIME OF THE COMPLAINT. THE…”

Complaint filed with NHTSA · Engine · April 26, 2010 · fire

“DT*: THE CONTACT STATED WHILE PARKED AND UNATTENDED, THERE WAS A FIRE IN THE ENGINE COMPARTMENT. THE FIRE ENGULFED THE ENTIRE VEHICLE. THE FIRE DEPARTMENT WAS CALLED TO THE SCENE AND A REPORT WAS TAKEN. THE CONTACT WAS INFORMED THE FIRE BEGAN IN THE AREA OF THE VEHICLE SPEED CONTROL. PICTURES WERE…”

Complaint filed with NHTSA · Speed Control · October 10, 2006 · fire

“DT: NEIGHBOR WAS LEAVING FOR THE STORE AND SMELLED SMOKE. SAW FIRE AND KNOCKED ON THE DOOR AND TOLD CONSUMERTHAT THE TRUCK WAS ON FIRE. CALLED 911, AND EMPTIED TWO FIRE EXTINGUISHERS TRYING TO PUT OUT THE FIRE. THE FIRE DEPARTMENT STATED THAT THE FIRE WAS STARTED FROM AN ELECTRICAL SOURCE. ALSO,…”

Complaint filed with NHTSA · Electrical System · May 16, 2005 · fire

“THE VEHICLE WAS DRIVEN EARLIER THAT DAY FOR ABOUT 2 TO 3 MILES AND THEN IT WAS PARKED INSIDE A PRIVATE MOBILE HOME PARK. AFTER 30 TO 45 MINUTES HAD PASSED, AN EXPLOSION WAS HEARD OUTSIDE THE MOBILE HOME PARK; THE VEHICLE EXPLODED AND WAS ON FIRE. THE EXPLOSION OCCURRED IN THE HOOD AND NOW IT IS A…”

Complaint filed with NHTSA · Tires & Wheels · April 18, 2016 · fire

“VEHICLE WAS PARKED AND IT CAUGHT ON FIRE. OWNER WAS NOTIFIED BY NEPHEW THAT THE VEHICLE WAS ON FIRE. THE FIRE DEPARTMENT WAS NOTIFIED, AND EXTINGUISHED THE BLAZE. A REPORT WAS TAKEN, AND THE CAUSE WAS DETERMINE DTO BE THE ABS SENSOR AND OR THE CRUISE CONTROL WHERE THE FIRE ORIGINATED. *AK”

Complaint filed with NHTSA · Brakes · November 19, 2004 · fire

2002 Ford Expedition — common questions

Is the 2002 Ford Expedition reliable?

NHTSA data argues against it: 415 complaints put the 2002 model at #12 of 36 Expedition years. It is one of the Expedition years to avoid.

What are the most common 2002 Expedition problems?

According to NHTSA complaint data, the leading problem areas are engine (122 complaints), speed control (58 complaints), electrical system (48 complaints).

Does the 2002 Ford Expedition have recalls?

Yes — NHTSA lists 4 recall campaigns affecting the 2002 Ford Expedition. Recall repairs are free at franchised dealers; check the VIN at nhtsa.gov/recalls to confirm the work was done.

Is the 2002 Ford Expedition under NHTSA investigation?

NHTSA opened 2 investigations into this model year; all are now closed.

Which Ford Expedition years should you avoid?

Based on complaint rates and open investigations, the Expedition years to avoid are 1999, 2000, 1997, 1998, 2003, 2001, 2019, 2017, 2020, 2018, 2005, 2002, 2006, 2004, 2021. The cleanest record among Expedition years belongs to 2027.

Related

Based on NHTSA ODI data through June 2026. Complaints are consumer-reported and unverified. Updated July 5, 2026.

Compiled by Sharon Ben-Moshe, Founder.