Which parts fail
Components named in complaints (service brakes, ABS, rotors and pads, parking brake).
Mileage when the problem started
Owner reports
Selected complaints filed with NHTSA by 2002 Ford Expedition owners, lightly cleaned up (personal details are redacted by NHTSA).
The contact's fianc e owns a 2002 Ford Expedition. The contact stated that there was smoke coming from the driver's side front end of the vehicle. The contact stated that while his fianc e was attempting to drive the vehicle the following day, the brake pedal was depressed but was firm, requiring the contact's fianc e to step on the brake pedal to drive. The brake pedal remained on the floorboard and was inoperable, causing the contact's fianc e to shift to park(P) to stop the vehicle. The vehicle was towed to the dealer, where it was diagnosed that the speed control deactivation switch (SCDS) connectors had burned, and the brake fluid had leaked from the brake fluid reservoir. The dealer replaced the SCDS sensor and harness under NHTSA Campaign Number: 05V388000 (Vehicle Speed Control). The dealer declined to perform repairs for collateral damages. …
My spark plugs are going bad, I bought three tires. But now I'm having to take it to the shop because it's weird noises coming from the tire it may be the wheel baring or sway bar link and bushing the mechanic say.
Tl* the contact owned a 2002 Ford Expedition. While the vehicle was parked, the contact smelled a burning odor. The contact found that the master cylinder caught fire. The fire department was not contacted. A fire report was not filed. There were no injuries. The vehicle was towed to crowley Ford Lincoln (225 new britain ave, plainville, ct 06062) where it was deemed destroyed. The dealer did not give a diagnosis, but contacted the manufacturer multiple times to determine what Ford should cover. The manufacturer was made aware of the failure and stated that the VIN was included in NHTSA campaign number: 05V017000 (vehicle speed control). The manufacturer provided case number: cas12637815 and advised the contact to call his insurance company. The manufacturer stated that they would send an inspector. The approximate failure mileage was 183,000. Updated 09/07/17
5 amp fuse popped. Replaced with another 5 amp fuse. Shift lock solenoid attached to brake master cylinder caught fire. Fire was contained and controlled. Minimal damages. Unsure of vehicle drivability. Could have happened during transit. Condition unsafe.
About two weeks before my car wouldn't go into drive I had it towed to the dealers. They fixed the problem it was a brake switch and solenoid. That needed replacing $300.00 later its fixed. During the weekend my cruise control light kept flashing. My mother, daughter and I were waiting for my son who was at track practice on Monday 4-25-2011. We were waiting in the car and listening to the radio. I started my car to make sure it was going to start. As I started it was full of smoke so I open the hood and there was a little spark fire. I look into my car to find water and I returned to attend to the problem and it was in full flame. I called the fire department to report fire. The parking lot was full of parents and children also waiting for there children. There's serious fire damage under the hood wires and sensors. I have taken pictures as proof. Oil spills from the reservoir. …
Tl* the contact owns a 2002 Ford Expedition. The contact stated that smoke emitted from the driver's side of the vehicle. The vehicle was taken to an independent mechanic who replaced the engine and the timing belt. The contact also stated that the vehicle failed to respond to deceleration attempts and that it caught on fire while it was parked and unoccupied. The vehicle was destroyed. A police report was filed. The manufacturer was notified of the failure. The approximate failure mileage was 100,000.
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.
2002 expedition mfg date 12/2001 right front brake separated at swagged fitting to short tubing to caliper. had just parked, stopped fine. next day all fluid had drained through separated hose.
Brake line ruptured in rear of vehicle when pulling into service station hauling my travel trailer. Was told the line was completely rusted through and this is a common problem on these model year vehicles. I find totally crazy to find brake lines rusting on a vehicle of this age. I was also told the rear control arms need to be replaced because of the rust. I know this was an issue on the windstars and it was recalled Ford need to take care of this. Thank god it happened at the station and not hauling my kids to the campground. This needs to be addressed due to the fact there are thousands of these vehicles still on the roads.I know if I call Ford they will tell me its not in warranty that's why I contacted you. They cover airbags and seatbelts for life they should cover brake lines.
2002 Ford Expedition: right front brake(s) making grinding noise when driving and is exaggerated when braking. Called dealer to schedule service. Asked service advisor why wear indicator(s) did not work. Service advisor informed me that Ford has not installed brakes with wear indicators for years. I told the service advisor that it is unbelievable that a $30K vehicle would not have bps with wear indicators especially since my 1992 vw jetta has brake pads with wear indicators. I removed the rf tire to examine the brake pad(s) and discovered that the brake pad(s) do in fact have wear indicators however, the brake caliper is stuck which caused the inside brake pad to wear prematurely. This has scarred the rotor.
Brake complaints in other Expedition years
Frequently asked questions
How common are brake problems on the 2002 Ford Expedition?
NHTSA has 22 complaints about the brakes of the 2002 Ford Expedition, 6% of the model year's 340 complaints. The component named most often is antilock/traction control/electronic limited slip (3 mentions).
Is there a recall for 2002 Ford Expedition brake problems?
No. NHTSA lists no brakes recall for the 2002 Ford Expedition, though it has 2 recalls for other components. If the problem is widespread, a repair may still be covered by an extended warranty or a manufacturer service bulletin — ask a dealer.
At what mileage do 2002 Ford Expedition brake problems start?
Half of the complaints with a recorded mileage happened before about 94,000 miles, and 7% before 25,000 miles.
Is it dangerous?
Owners linked 1 crash, 5 fires and 1 injury to brakes problems on this model year. If you notice symptoms, have the car checked before driving further.
Source: U.S. National Highway Traffic Safety Administration (NHTSA) — owner complaints through October 20, 2026, recalls and defect investigations; fuel economy from the EPA. Complaints are unverified reports and are not proof of a defect. How we rate model years.