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 Explorer owners, lightly cleaned up (personal details are redacted by NHTSA).
1. Driving approximately 30 minutes on the evening (7:30 pm) of 12-4-04 to a holiday party with just myself and my wife. Upon arriving within seconds of the location an anonoymous dirver stopped our vehicle and made us aware that there was a fire coming from under our vehicle, a 2002 Ford Explorer xlt. As we jumped out of the vehicle and saw the fire a neighbor watching called the local fire department. Within minutes the fire department arrived and tried to extinguish the fire. Being unsuccesful it took the fire department approximately an hour to stop the fire at which time the vehicle was destroyed. There was nothing to be repaired as the vehicle was destroyed. And there had been no indication that there was anything wrong with the vehicle prior to this incident.
I had had this 2018 Jeep renegade not even 2.5 months and it needed an oil change and the tires were completely worn out they were every one slick as could get and dangerous. I called the dealer because the tires went bad and I hadn't had the first 50K miles on it yet and they did nothing. Called the tire company they did nothing. So I replaced them and another almost 3 months go by and the tires are completely worn out and slick again. This has repeatedly happened every 2-3 months to where they are so dangerous you either drive 30 MPH or get them changed. 3 times I've replaced the tires and and the oil goes so fast. And now I am stuck with this vehicle I don't feel safe in. I shouldn't have to pay these prices for a 30K vehicle that's not worth 10K.
I bought a used 2002 Ford Explorer in April of this year at a used car lot. It was a beautiful blue SUV in remarkable good condition. I had it four months, and it caught on fire while at a stop sight on my way home from a shopping strip twenty miles from my home. It started smoking and while I was fumbling for my purse to get my cell phone to call for help, it caught fire and bystanders on the thoroughfare pulled me forcefully from the car, and then called the fire department. It was a total loss when the entire hood caught fire and melted. My garage mechanic, who had just seen the car, told me that he could see no reason why it would have caught fire. Can you help me?
I do not know when the problem originated but I bought this vehicle in April 2016 and gas could not flow into the tank freely without stopping. It had to trickle in slowly. Also, the check fuel cap came on during this issue but when tested, passed as if nothing was wrong. Too many other owners report the same issue on Explorer forums for this to be an isolated occurrence. It seems this is faulty design or workmanship and owners should be informed and the vehicles recalled.
My truck began to shake when I stop at stop signs and lights. The service engine soon light came on and would not go out. I got a code reading, there were many fuel ejection issues. I got a diagnostic test today, and was told it could be the fuel pump. When I put gas in, the gas pump gets stuck inside sometimes. Does not come out smoothly. What is going on?
While driving approximately for two hours. The driver stopped at a toll booth. Suddenly white smoke started emitting from under the hood followed black smoke. The vehicle caught fire within seconds and was a total lost. The fire department says the gas line May have melted the manifold. Please describe any further information.
The service engine light came on and I was told there might be a transmission problem. After the service the light was off and I was going again. At 107,000 miles the light came back on and back to the service departmant and they said the #5 ring was having problems I could drive it and it would get worse. It was also mentioned this year Explorer had many transmission issues. Now they want a minimum of $3,500 to fix the SUV and the trade-in is only worth $3,500 dollars. I now have 117,500 miles on it and it shifts hard and goes in reveserves slowly. I have talked to Ford to no avail at all. The say sorry but we can't help with fixing it at all. There is no discounted rate for an issue that is well known on the blogs. This seems to be against the fact that Ford says they have the bext trucks on the road if they think 117,000 miles is enough to replace the transmission. …
At 74000 miles our transmission went out completely while we were on vacation! The dealership where we bought the vehicle, said that "we were the only one's who have had this problem" (yeah right!) it cost us $6000 out of our pocket to fix. At 86000 miles the rear window cracked right below the window. Ford and the dealership refuses to fix it. Again, stayton Ford told us that,"we were the only people who have had this particular issue." at around 85000, 95000 and 105000 miles, the rear seals leaked. We were promised each time that they would last "for at least 50000 miles." we were always a few miles away from getting them replaced for free since they're limited warranty is only good for 10000 miles. …
The middle panel under the glass in the back of the car has cracked. I suspect it was due to cold weather. I have since seen other explorers with this problem and notice that there are a lot of complaints online about this. In addition, this past summer my shifter snapped off the barrel. I had 4 kids in the car at the time. Ford responded by telling me that I had 75K miles and no warranty and I didn't typically get my car serviced there so they weren't going to be willing to "work with me" to get it resolved. When I told him I had my 'regular' mechanic look at it he said that the labor rate was probably cheaper with him than at Ford. Well - now tell me why I would service my car at a Ford dealership? Oh yeah...in case I get cracks or shifters fall off and maybe they'll 'work with me' on the price. Big incentive. Oh yeah, my fuel gauge doesn't work - another common problem. …
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. …
Fuel System complaints in other Explorer years
Frequently asked questions
How common are fuel system problems on the 2002 Ford Explorer?
NHTSA has 72 complaints about the fuel & propulsion system of the 2002 Ford Explorer, 2% of the model year's 3,295 complaints. The component named most often is storage › fuel gauge system (7 mentions).
Is there a recall for 2002 Ford Explorer fuel system problems?
No. NHTSA lists no fuel & propulsion system 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 fuel system problems start?
Half of the complaints with a recorded mileage happened before about 75,000 miles, and 22% before 25,000 miles.
Is it dangerous?
Owners linked 0 crashes, 4 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.