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 owners, lightly cleaned up (personal details are redacted by NHTSA).
September 2, 2023 at about 6 pm I pulled over to grab a couple water bottles from the rear of my 2002 Ford Explorer Sport cause my engine was overheating. I got out walked to the rear of my vehicle pushed my unlatch button on the tailgate and I lifted the glass part of the rear hatch. Both air hinges were not working correctly to keep it up so I gently rested the glass on my hair that was put up in a bun and just a little bit of the glass was resting on the very top of my head where my hair was slicked back for my bun so my hands were free to grab the bottles of water. (My hair was the softest of resting place's). As I reached in the back to grab the water bottles I heard the loudest bang and hundreds of little pieces of glass fell everywhere around me. I was in so much distrot that I actually thought someone had shot at me with a fire arm but missed me and hit the rear glass instead. …
I was driving my Ford on the highway and the next thing I know my feet were really hot and black smoke started coming up. Then the black smoke started coming from the engine and I nearly crashed trying to get to the edge of the highway before the fire took over the whole front of the car. Luckily the fire department was right there for another accident. It was incredibly disturbing experience. Luckily my 3 small children were not in the car.
Vehicle leaks transmission fluid from what a appears tobe the trans bell housing and was told by experts after taking vehicle to investigate,main seal tranny damaged and trans needs tobe pulled,costing hundreds to fix.was in first accident in 30yrs because tranny would not engage,shift to proper torque for speed when needed.causing sluggish late shift to almost stop,and causing crash. Can you help?.................anyone? Thankyou!
Vehicle parked in stall when gear selecter was shifted from drive to park with foot on brake said vehicle experienced wide open throttle surged forward knocking down light pole only coming to stop ontop of fire hydrant or vehicle would of kept going as wheels were still spinning!
I was traveling in stop and go traffic. As soon as space opened between me and the vehicle in front of me, I accelerated. While gaining speed I looked in my right rear view mirror to see if I could change lanes. While looking in my mirror the vehicle in front of me stopped. I hit the back of his vehicle with the front of mine. The problem I have is that my airbag(s) fired but did no deploy. You could clearly smell that they fired and my airbag light is now on. My seat belt did not cinch up and restrain me either. This car had been well maintained and was never in an accident before this one. As I see it, it was a total failure of the SRS.
Tl* the contact owns a 2002 Ford Explorer. While driving at an unknown speed, the contact heard an abnormal rattling noise coming from the rear of the vehicle. The contact inspected the vehicle and noticed that the rear driver's side upper hinge was fractured. The vehicle was not repaired. Perry Ford of santa barbara (440 hitchcock way, santa barbara, ca 93105, [phone]) was contacted by phone and informed of the failure. The vehicle was not included in NHTSA campaign number: 04V442000 (structure). The manufacturer was notified. The approximate failure mileage was 204,000.
Tl* the contact owns a 2002 Ford Explorer. The contact stated that while opening the real lift gate, the rear lift gate glass window suddenly shattered. During the incident, the person sustained a facial laceration which required medical treatment. The cause of the failure was not determined. The local dealer (future Ford located at 650 automall dr, roseville, ca 95661) was notified of the failure. The manufacturer was not notified of the failure. The failure mileage was 184,000.
My 2002 Ford Explorer 4.6l is having major transmission problems at only 110K miles. It hesitates shifting gears and slips while driving. The vehicle also stalls when stopping at a red light or stop sign. It has the infamous crack down the back hatch. Both are problems thousands of customers have complained about yet Ford does nothing. The transmission problem is a very expensive cost to repair and it shouldn't be the customers responsibility when Ford knew there was a problem.
Back tailgate window is crooked, air pressure thing fell off on right side causing a lack of support on that side and hinges are starting to bend to the left also. Who knows when this window will fall off or how much longer it will be supported without the support on the right. It's just scary, we don't use this tailgate window at all so it May be fine? It is like this while stationary, in motion, on a city street or highway, turning etc.
Tl* the contact owns a 2002 Ford Explorer. The contact stated that there was a loud abnormal noise and noticed that the sun roof was detached. The vehicle was taken to an unknown independent mechanic who stated that the manufacturer discontinued the part. The dealer was not contacted. The manufacturer was notified of the failure and confirmed that the sun roofs were discontinued. The approximate failure mileage was 160,000.
Related recalls
Structure › Body › Hatchback/liftgate › Hinge and attachments
On certain sport utility vehicles, the liftgate glass strut May become disengaged or the hinge May fracture allowing the glass to fall and possibly break.
Remedy: Dealers will have the liftgate glass strut brackets and glass hinges replaced. For the vehicles built from August 1, 2000 through March 3, 2002, the dealers will replace the hinges and liftgate strut bracket.
Structure
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.
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…
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 years
Frequently asked questions
How common are body problems on the 2002 Ford Explorer?
NHTSA has 486 complaints about the body & structure of the 2002 Ford Explorer, 15% of the model year's 3,295 complaints. The component named most often is body › hatchback/liftgate › hinge and attachments (166 mentions).
Is there a recall for 2002 Ford Explorer body problems?
Yes — NHTSA recall 04V-442 (hinge and attachments, Sep 13, 2004); NHTSA recall 03V-094 (structure, Mar 7, 2003). Recall repairs are free at authorized dealers.
At what mileage do 2002 Ford Explorer body problems start?
Half of the complaints with a recorded mileage happened before about 66,000 miles, and 9% before 25,000 miles.
Is it dangerous?
Owners linked 4 crashes, 2 fires and 62 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.