Which parts fail
Components named in complaints (doors, hood, frame, rust, paint and trim).
Mileage when the problem started
Owner reports
Selected complaints filed with NHTSA by 2002 Ford Explorer Sport owners, lightly cleaned up (personal details are redacted by NHTSA).
I noticed the rear window lift gate was slightly ajar, so I closed it, and suddenly the hinge bracket on the right side, connecting the window at the roof, popped loose, extending the window lift support, making it now impossible to close the back lift gate glass. I checked into the issue, and found a recall, campaign # 04V442000. This hinge has never been replaced. I want to have this fixed under recall.
This is the second time this has happened. My rear tailgate window exploded. The car had been on for about ten minutes, warming up. I loaded my items into the car through the tailgate window. When I was done, I closed the window. Before it was even closed, the window exploded into thousands of pieces. There was glass all over. The window was recently replaced at the Ford dealership.
Rear window exploded overnight while parked in driveway. We live in southern ca and it was a rare cold night with lows in the 30's. Security camera's verified no one or no object damaged the window. It just exploded while parked the glass was strewn across a 3 car driveway.
I don't know if this is the right place to file this complaint but its worth a shot. My mother owned a 2002 Ford Explorer Sport. My brother was driving it home to kansas city from st. Louis missouri. The weather was perfect, the roadways were perfect, there was nothing wrong with the car, the air bags deployed, he wasn't speeding. However, he drove off the side of the highway, over corrected it to gain control and fish-tailed. Witnesses say that it looked like he had control again and then it rolled, killing him. Him and the passenger were both wearing seat belts; however, the top crushing him in is what killed him. These vehicles like other SUV's have a high roll-over rate yet people keep buying them. Something needs to be done to prevent any other families from experiencing this tragedy. …
Rear door glass hatch hinges came off.this was my wifes vehicle driven very little until she passed away 2009.then it was driven even less. Back hatch glass was never used as far as I know. She always used the metal door. I drove it to grocery store,put groceries in back using large door. When I got home I just grabbed glass hatch handle by mistake,it came off in my hand.both hinges were broken. I don't know for how long,the latch was all that kept it in place.when the latch opened it exploded outward ,resulting in badly damaged paint and both rear defroster wires to be torn off glass.luckily it was me and not my wife,could have been a lot worse.lift cylinders were so strong I could not put it back in place,had to yell for neighbors for help!had it repaired local Ford dealer.told me about recall for models except Sport.no recall for it.$150.50(not including paint) for repairs & 10 days …
While opening my rear hatch window to load groceries I noticed the top right hinge had detached from the car, leaving the glass hatch hanging by a single hinge. When I got home I googled the problem and discovered recall #04s20 and mentioned it to my dealer when I took my car in for servicing. They said my car was not included, so I called Ford and they agreed. Even though the recall specifies "all Ford Explorer models" they say mine is the 2-door "Sport" edition and so isn't included even though the hatch is identical (I've owned both). This is an expensive repair and this is the 2nd time I've had this problem (the other hinge broke 2 years ago). I'd appreciate it if you could determine if the 2-door models are sufficiently different that they can be exempted from this recall, and if they should be included tell me how to proceed. [redacted]
Part# 2l2z-98420a68-aa hinge and attachments for liftgate broke 08/04-2008. Recall campaign#pe04045-purchased another hinge from Ford parts dept. Invoice# 216039 on 08/04/2008-they did not tell me there was a recall on this part item- bought part and replaced it myself. 08/26-2012 the other hinge broke and called [phone] and was told recall was over- the Ford store never told me this part was recalled and charged me $43.95. Now the other side of the hatchback hinge has broken and have been told I have to pay to get it repaired myself again. Never received any postcard for recall notice. …
The Ford Explorer Sport has a rear hatch that includes a glass section that has the ability to be opened to load items into the trunk area of the vehicle. Three separate times the rear windshield has blown out as it has been opened / closed. The rear windshield is made of tempered glass and when it breaks it explodes into the person operating the window. There has not been any injuries besides a few small cuts, but having glass explode into a person is dangerous. After the first failure the glass was simply replaced. The first failure occurred as the rear glass was opened. After the second failure, the car was brought to a Ford dealership to fix the issue. The second failure occurred as the glass was closed. The third failure occurred 12/1/2013, it has yet to be fixed. This most recent failure occurred as the glass was closed.
Tl contact owns a 2002 Ford Explorer Sport. The contact noticed that the hinges in the liftgate were unscrewing. He locked the window to prevent it from falling. While driving approximately 65 MPH, the window fell down and shattered. The contact took the vehicle to the dealer, but they offered no assistance. The manufacturer stated that the VIN was not included in NHTSA campaign id number 04V442000 (structure:body:hatchback/liftgate:hinge and attachments). He also experienced issues with the armrest. It would not open unless he forced it, which eventually caused it to fail. The current mileage was 79,015 and failure mileage was approximately 74,000. Updated 11/17/08 updated 11/18/08.
The rear liftgate glass fell off the hinges. The falling glass damaged the rear defroster wires (can no longer be used) the hinge holding the glass broke off from the vehicle causing the glass to fall to the ground. It cost $130 at the Ford dealer. Nhtse recall 04V442 investigated this exact complaint and a recall was issued but Ford informed me that my 2002 Ford Explorer Sport was not covered under the recall because it was built in a factory not affected by the recall. The nhtse should consider re-opening this case as it is the same exact problem as the recall on the same exact make and model. All incidents of this failure of the rear liftgate glass hinges should be covered by Ford. Thank you
NHTSA investigations
Rear liftgate glass assembly
Complaints report failure of the rear liftgate glass support while the operator is opening or closing the glass.the falling glass can strike the operator or bystander.the injuries reported are bruises to the head, neck or back, cuts to the face, arm or hand.on September 9, 2004, Ford notified the agency that it will recall approximately 955,732 my 2002 and 2003 Ford explorer and Mercury mountaineer vehicles to…
Body complaints in other Explorer Sport years
Frequently asked questions
How common are body problems on the 2002 Ford Explorer Sport?
NHTSA has 28 complaints about the body & structure of the 2002 Ford Explorer Sport, 21% of the model year's 133 complaints. The component named most often is body (10 mentions).
Is there a recall for 2002 Ford Explorer Sport body problems?
No. NHTSA lists no body & structure recall for the 2002 Ford Explorer Sport, though it has 3 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 Explorer Sport body problems start?
Half of the complaints with a recorded mileage happened before about 89,000 miles, and 4% before 25,000 miles.
Is it dangerous?
Owners linked 1 crash, 0 fires and 5 injuries and 1 death to body & structure 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.