Which parts fail
Components named in complaints (air conditioning, heater, defroster, HVAC controls).
Mileage when the problem started
Owner reports
Selected complaints filed with NHTSA by 2002 Ford Explorer owners, lightly cleaned up (personal details are redacted by NHTSA).
On my 2002 Ford Explorer SUV I have had to replace 3 of the 4 wheel bearings and hub assemblies(approx $250 each), with the 4th not far behind. I have also had to replace the 4-wheel drive module(approx $400-$500). I have had problems with the rear window motors going bad and having to replace these too. The air conditioning unit has stopped working. The passenger air bag dummy light has come on for no reason. The seat belt warning chime often comes on and will not go off, even though you have buckled your seat belt. You have to slam the buckle into place for it to go off and sometimes this does not work either. The transmission is now making a lovely clunking sound when shifting from park to drive and when you try to put it back into park, it does not want to. You have to put it up to park as far as it will go then go back to neutral and then into park from there. …
13jan03-rear windshield washer inoperative reinstall rear washer hoses. 5nov03-clicking noise from rear A/C; replace motor assembly temperature blend. 5nov03&13nov03-l/r power mirrors inop; fuse blows; replaced mirror rear view outside sail mount 13nov03-fuel guage inop read 1/2 tank but tank was full; 20nov03-instrument cluster fuel gauge inop; 24nov03-removed and replaced instrument cluster; 18mar04-fuel guage inop & l/r power mirrors inop, fuse blows; could not duplicate problem at this time about fuel guage; tested bce for short, traced to mirror switch, replaced switch and blown fuse; 20 July 04-l/r power mirrors inop; replaced fuse; 20 July 04 - rear winshield washer inop; access washer hose and reconnect; 20 July 04- air conditioner not cooling properly; replaced blower motor for poor operation; motor assembly-heater-A/C blower replaced. …
I brought truck on 02/27/2004. The salesman at bill heard Chevrolet made me sign some papers. In two weeks I had to go back to sign some more papers because they said they had made a mistake. They told me that I would finish paying for the car in three years the cost was supposedly $24,000. In two weeks after that I started having transmission problems. I told the dealership but they didn't want to fixed the problem so I had to pay out of my own money to fix the problem. After that they put an insurance on the truck which brought my payment to $518.00. My air conditioner didn't function since I brought it. My car has no direction at all. Also, when I run the truck more than 65 MPH it just starts shaking. In three months after I brought the car I read the papers and realize that the truck did not cost 24,000 like they had told me it actually cost 37,000.
Bought 2002 Explorer in 2003 with 12,000 miles. Servicng dealer replaced transmission and torque converter under warranty @ 32,000 miles after o/d light started flashing. Now needs another transmission @ 54,000 miles. Car has always been serviced, driven lightly, never towed, never abused. Dealer will not pay or help out one bit. Ford knows 2002 explorers have defective transmissions and rear ends, is ignoring problem, leaving consumer to absorb cost! Have also had to replace timing chain tensioner, rear windshield wiper assembly, air conditioning unit under warranty. Front and rear wheel bearings needed replacing- out of warranty. Rear end is making classic "humming" sound that Ford is also ignoring-pinion gears.
Horrible whining noise coming from rear differential of my 2002 Ford Explorer limited edition. Replaced twice already and now it's whining louder and louder everyday. I refuse to pay for the same repair a 3rd time. I have read many complaints on the web about this problem, along with many other similar complaints. Other popular defects for the new Ford Explorer are cracked rear coil over springs, along with transmission and A/C problems, etc, etc. How many more complaints is it going to take before Ford stands up to their design flaws...????
My Ford Explorer transmission it was at 36000 miles, my car was tuned and serviced as shudule, and it cost a total of $1700.00 to fix. Which the car is only 2 year old. The air condition stop working in December of 2003 and at the time my car was barely 1 year old thier has been many other concern with my Explorer that I am making $500.00 payment on. I belived I have purchase a defected car.
Tl contact owns a 2002 Ford Explorer. The contact stated that the blend door which regulates the heat and the defrost systems has failed. The dealer replaced the actuator motor that controls the blend door. The contact was responsible for paying $650 to repair the vehicle. There were no recalls or warranties related to the failure. The failure mileage was $64,000.
When stopping or slowing down, intermittently the vehicle stalled when turning left, there was a knocking sound coming from the front left wheel. The heat vents that blew directly on the consumer did not work. These problems have occurred at least three times in one month. The manufacturer and the dealer were not aware of the problem.
2002 Ford Explorer experiencing problems with the 4wd, the over drive light illuminates on the dashboard and the vehicle is giving off a rotten egg smell. There were front end problems. The 4wd module wasn't working. The driveshaft and both front wheel bearings were replaced. The rotors were out of round. The service engine light illuminated along with the over drive light. The transmission experienced the same problem on two occasions and possibly a third time. A large puddle of transmission was found under the vehicle. The torque converter was noisy. The acceleration pedal would pull back. When the vehicle was accelerated, it would whine. The left rear wheel bearing was gone and caused damage to the axle, brakes and the tire was barely holding on. The error code for the service engine soon light was due to the solenoid which had been changed before. The A/C was inoperative.
While driving down the road the air conditioner quit working. I heard the coolant and compressor still working, but no fan blower on levels 1,2 and 3 level 4 still worked luckily. I also have a howling sound coming from the rear end under light acceleration and hard shifting when accelerating and letting off of the gas during a shift. The air conditioner was caused by a faulty resistor, the rest has yet to be determined. I notice a number of complaints on this site for the same symptoms, a recall should be issued.
AC & Heater complaints in other Explorer years
Frequently asked questions
How common are ac & heater problems on the 2002 Ford Explorer?
NHTSA has 21 complaints about the a/c & heater of the 2002 Ford Explorer, 1% of the model year's 3,295 complaints. The component named most often is appliance › air conditioner (12 mentions).
Is there a recall for 2002 Ford Explorer ac & heater problems?
No. NHTSA lists no a/c & heater recall for the 2002 Ford Explorer, though it has 4 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 ac & heater problems start?
Half of the complaints with a recorded mileage happened before about 40,000 miles, and 30% before 25,000 miles.
Is it dangerous?
Owners linked 0 crashes, 0 fires and 1 injury to a/c & heater 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.