Which parts fail
Components named in complaints (accessories, trailer hitches and other equipment).
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).
The consumer stated the home fire hazard created by faulty design of non ul approved personal snow plow use for SUV manufactured by western products. Snow plow electric motor was unfused and overheated not responding to the comman controller shorting out and causing a serious expensive fire.
I have a 2002 Ford Explorer limited that has had continuous rear axle leaking and operating issues. I have had the bearings replaced three times, the shaft axle seal replaced, the knuckle assembly replaced and the spindle replaced. I had this work done at cortese auto group in henrietta ny [phone]) in June of 2007 and April of 2008. I just noticed differential fluid leaking from the rear axle assembly area on March 16, 2009 and called the cortese group to see if they would honor their previous repair. They advised me that I was beyond the "original problem" 2007 repair date and the cost was on my own. To repair this leaky axle seal will cost me in the neighborhood of $400 and considering this has been an ongoing issue with this vehicle, I feel Ford motor company or cortese should fix this problem with no cost to me. …
Event/situation: hesitates and chokes at 40-45 miles per hour when trying to accelerate, along with a slight rubbing sensation felt through the steering wheel and gas peddle. They advised replacing the upper ball joints. They also stated a weak battery which was replaced. This did seem to fix various faulty false electrical issues: interior lights staying on and false light/dashboard readings. Faulty transmission, emissions or plugs/wiring have been possibilities. I've taken it to Goodyear who recommended changing out the plugs and wires, along with a flush. I've been told that flushes can ruin parts on older vehicles and cause other expensive problems. I found a few websites were there are many other customers having these same issues with the 2002 Ford Explorer. …
This is the second time in less then two years I have had to have the transmission rebuilt. It was bought on 8/14/04 as is no warranty from a dealer (demo) unit it had 38547 miles on it, 10/13/04 the transmission blew with 41675 miles on it. The dealer wouldn't give me no help as well as Ford customer service, I paid 2181.03 to have it rebuilt including the torque converter replaced, and the solenoid pak (which was replaced 2 more times shortly after being installed each time) it needed a ls kit, bas hing kit, 5 forward steels, filter and fluids. March 8th 2006 I find myself spending another 1412.56 to have it rebuilt yet again now only having 64460 miles on it, it needed an overhaul kit, filter and trans fluids, intermediate band, od servo piston, int servo piston and another solenoid pak as well as the transmission case repaired. …
I am very concerned at all of the transmissions complaints that the NHTSA has had on the Ford 2002 Explorer and nothing is being done about this. I have sent in 1 of many complaints because of course I am one of the unlucky citizens of the U.S. Who believed that the Ford Explorer was a very dependable vehicle. Hello is it going to take someone actually getting killed for this vehicle to be recalled for the transmission. I almost got rear ended and just in the past 4 months there has been complaints of people going in ditches, running off the side of the road, do you think that someone could really research this [redacted] issue and get this [redacted] vehicle recalled before someone does get hurt or at least make Ford replace the transmissions and reimburse anyone who has had their transmission replaced. …
O/d light flashes for a few days then at around 25 MPH the gear switches into neutral and runs very rough then the car is thrown forward. Had a rebuilt transmission (we were told we were getting a brand new transmission and paid extra for it!) at 83K miles on oct 15, 2010 then feb 5, 2011 the same exact thing happens. The dealer cannot take the truck for another 5 days and refused to give me a loner car because it is not under the warranty. Please note: below I put in the first incident date, feb 2011 is the second incident date. In May of 2009 I was told my engine failed at about 76,000 miles. We did buy the extended warranty and we were covered. The Ford dealership told us we were not covered. They had our truck for 3 weeks until the warranty people called the dealership and let them know it should be fixed. We also had a rental car or a loner car under the warranty. …
Within four months from date of purchase my 2002 Ford Explorer xlt 4wd start having problems. They are: 1. Vibration inside including physical movement inside when driving with rear window crack over 30 MPH. The faster you drive the grater the vibration. I took the Explorer to several dealers, they inform me that this is normal and it's refer to as helicopter effect. 2. The digital keypad stop working. 2. The keys don't open the door 3. The transmission slip, kick and delays when put in drive or reverse. 4.transmission delays going into overdrive. 5.the passenger side quarter panel glass shatter twice, at first I taught someone had broke it and my son reported it to the police. The insurance company replace it and few months later in my garage it shatter again and that's when it all came together. This time my son fix it for me. …
I was traveling to mt. Washington, ky. From lorain, ohio, ( approx. 330 miles). We stopped at the rest are at the halfway mark, between washington ch, oh. & jeffersonvlle, oh. When we came back out, started the car, & it wouldn't go into reverse. Pushed it out of the parking spot & it wouldn't go in drive either. About 30 miles before, it made some clunking noises & it felt like we had a flat tire. I took it out of cruise control & it drove normally until the rest area. I had to have it towed to washington courthouse & then back home on Monday, nov., 29th, (at my own expense). Approximate cost of repair to date was $2969. I had my daughter & 6 yr. Old great granddaughter with me & I feel this could have possibly ended with disastrous results. Ford has known about these faulty transmissions probably from day 1. I'm not trying to just blast Ford, happen to be an employee. …
I have had my transmission in my 2002 Ford Explorer rebuilt by a local Ford dealership at 53,000 miles and a Ford re-manufactured transmission installed at this dealership at 69,000. This local dealership has replaced the transfer case twice, drive axle, and universal joints between 69,000 and 74,000 to correct an ongoing reported shifting problem with the transmission. My transmission failed at 109,000, again, much to my dismay. The dealership responded that it was a manufacturer's issue and suggested that I contact Ford. Upon contacting Ford motor company, I was told that it was a dealership issue as the dealership had installed the transmission and May had done so incorrectly. I took my vehicle to an independent transmission specialist who replaced the transmission and indicated that the previous transmission was, in fact, defective.
It started around 78,000 miles. My transmission started to slip as I was driving up a hill. The tranny was slipping between 1st and 2nd gear. I took the vehicle into the dealership - had to replace the whole transmission ($3400). Transmission again at 137,000 miles slipping between 1st and 2nd gear again - warranty expired - Ford could only give me a warrant for 36,000 miles or 3 years - I'm under my 3 yrs but not mileage. Took to the dealership again, now its my transmission band ($2100) but with all the wear on the transmission and the cost. I will have to replace the transmission again. During this time that my transmission problems, I also had the right (I believe it was the right) rear axle went out twice my overdrive light came on. I think there is a correlation with the overdrive system and the tranny.
Equipment complaints in other Explorer years
Frequently asked questions
How common are equipment problems on the 2002 Ford Explorer?
NHTSA has 48 complaints about the equipment & accessories of the 2002 Ford Explorer, 1% of the model year's 3,295 complaints. The component named most often is mechanical › carrier/rack (3 mentions).
Is there a recall for 2002 Ford Explorer equipment problems?
No. NHTSA lists no equipment & accessories 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 equipment problems start?
Half of the complaints with a recorded mileage happened before about 71,000 miles, and 7% before 25,000 miles.
Is it dangerous?
Owners linked 2 crashes, 1 fire and 1 injury to equipment & accessories 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.