Which parts fail
Components named in complaints (fuel pump, injectors, fuel tank, hybrid and EV propulsion).
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).
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 owns a 2002 Ford Expedition. While driving approximately 30 MPH, there was an abnormal odor in the vehicle and it caught fire. The fire was able to be extinguished by the fire department. The vehicle was destroyed and towed from the scene. A police report was not filed. There were no injuries. The manufacturer was not notified of the failure. The contact believed that the VIN was included in NHTSA campaign number: 06e056000 (fuel system, gasoline). The failure mileage was approximately 200,000. The VIN was not provided.
Ford triton engine spitting spark-plugs out of engine resulting in gasoline being sprayed all over engine. Costly repairs are minimum $400+. This has happened 4 times to me and I can anticipate it happening on the remaining 4 cylinders in my 2002 Ford Expedition. As a result of this problem Ford is aware of, gasoline is being sprayed on 1000's of engines when this happens. Bad design by Ford. Aluminum heads on iron engine. Duh. My investigation has determined that there are 1000's of Ford owner who have experienced this same problem yet Ford is unwilling to do anything about it. Their repair shops will charge anywhere from $400 to $1600 to repair the problem. Please address this issue before my remaining 4 cylinders go and I will have to pay to get this bad design repaired. Thank you.
Tl* the contact owns a 2002 Ford Expedition. The vehicle was parked and a neighbor notified the contacxt that vehicle was on fire. The fire fighters and police departments were called. The hood burned off the vehicle. The paint on the driver's side burned off the vehicle, the driver's side windshieldwas missing, and the interior was completely destroyed. The driveway was also damaged, and a tree burned. A police report was filed. Ford stated that there was nothing that they could do. However, he gave them his VIN and never received a call to confirm if this vehicle was affected by the recall NHTSA recall number: 06e056000). The failure and current mileage were 75,000.
On the 2002 Ford Expedition I have found that there is a problem with the pick up in the gas tank if the vehicle it is mounted in the center of the tank and if the vehicle is below or at a 1/4 of a tank and parked on a grade at all the fuel will not pick up and run out of fuel causing the vehicle to stall this very dangerous especially if you work down town and park on a grade then you have 2 choices coast to a level area with no brakes or call for help. Luckily my wife's Expedition has only done it here at the house where she parks on a hill but most of the time I try to keep it above a 1/2 of a tank to combat the problem. I would very much appreciate it if you would check into this problem and let me know what happens.
Tl* the contact owns a 2002 Ford Expedition. The contact stated that while inspecting the vehicle, he noticed that the fuel tank straps were fraying and coming apart, but the failure was not due to corrosion. An authorized dealer was notified and they stated that the 2002 Ford Expedition was not included in the recall associated with NHTSA campaign id number 11V385000 (fuel system, gasoline: storage: tank assembly: mounting). The vehicle had not been repaired. The failure and the current mileages were 70,328. Updated 9/13/11 the consumer was informed his VIN was not included in the recall. Updated 10/28/11
My 2002 Expedition 4.6 has for the past year stalled out on an incline with 1/4 tank of gas. It will also revved up and lurch forward when restarted, even while standing on brakes. The dealership has replaced many things and has no reason why it does this. I have had enough. This is a 2002 automobile and the 21st century, this shoudl not be happening to a new car. A dealership should not be unable to correct this problem. Ford needs to find the problem and issue a recall, before a lawsuit ensues.
On every fillup of gasoline I have gasoline vapors inside the car which necessitates my opening windows to rid the interior of the strong fumes. There is no spilled liquid and my shoes are clean and all windows are closed and the car is not running and the havoc is off. I am in fear of fire. The service department has not been able to find a problem. This has been present for more than 4 years and has been reported over 10 times to the service department.
Over a course of one year of purchasing vehicle, it has been in the shop 7 times for an engine/transmission issue, unsure as Ford has not been able to identify the problem. When I contacted Ford, they denied to buy the vehicle back due to the mileage on the vehicle. As of today, the vehicle has not been fixed although drivable, for how long until it gives out?
Spark plug popped out my iginition coil and the threading section is stripped. When I started my car an exploration sound occurred. Also, my driver side head light won't stay lite even with replacement light unit. Also car stalls when car is facing down a hill, even with a full tank of gas.
Fuel System complaints in other Expedition years
Frequently asked questions
How common are fuel system problems on the 2002 Ford Expedition?
NHTSA has 21 complaints about the fuel & propulsion system of the 2002 Ford Expedition, 6% of the model year's 340 complaints. The component named most often is delivery (3 mentions).
Is there a recall for 2002 Ford Expedition fuel system problems?
No. NHTSA lists no fuel & propulsion system 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 fuel system problems start?
Half of the complaints with a recorded mileage happened before about 62,000 miles, and 7% before 25,000 miles.
Is it dangerous?
Owners linked 0 crashes, 3 fires and 0 injuries to fuel & propulsion system 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.