Which parts fail
Components named in complaints (struts, shocks, control arms, ball joints, springs).
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 rear toe arms came unhinged or disconnected from their placement and sank down to continuously rub a groove in the inner rim. The suspension was affected, the steering was effecting especially when turning, it made the brakes stick, and made loud crunching and rolling noises. It is quite frankly dangerous. It was through no fault of mine that this happened, just weak design. I took it to a shop and they charged me all my money, but nothing was fixed.
I got a knock on my door by the fire department telling me that my car set on fire I filed a claim with my insurance and they told me to file a claim with Ford because they have reason to believe it was the cruise control button that set the car on fire .
2002 Ford Explorer caught fire. Consumer stated that the vehicle caught fire while his mother was visiting his sister in a different state. No attempt was made to repair her vehicle and rental cost them $600.00 out of pocket. Prior to the fire, the consumer asked the mechanic to inspect the vehicle, because warning lights were coming on and going off intermittently. The consumer had a list of documentation relating to electrical issues. The vehicle had to get a jump several times, the vehicle would hesitate when first starting up. The brake lights were stuck, the dealer replaced the brake pedal switch. The cruise control was inoperable so the dealer replaced the brake light switch. The alternator and wheel bearings were replaced.
Tl* the contact owns a 2002 Ford Explorer. While the vehicle was at a local dealer for routine service, the front wheel bearings and hub assemblies were replaced. After the repairs, the contact heard an abnormal noise coming from the vehicle. The vehicle was taken back to the dealer where it was diagnosed that the front wheel bearings needed to be replaced. The vehicle was repaired; however, the failure persisted. While driving 60 MPH, the front driver side wheel detached from the vehicle. The vehicle was taken to an independent mechanic who diagnosed that the front wheel bearings needed to be replaced. The vehicle was repaired. The manufacturer was not notified of the failure. The failure mileage was 85,000.
My Ford Explorer started making a sound like there was something rolling around in back gate. First mechanic couldn't find problem. I worked on this for three months. Looks as if it is the bushings are worn and body is touching frame. I also understand that several others have had this problem.
Tl contact owns a 2002 Ford Explorer. While driving 40 MPH, the right wheel turned outwards and the vehicle rolled in a ditch. The contact stated that the stabilizer bar failed. He sustained injuries. The current and failure mileages were 160,000.
"Takata recall" I was driving about 10 miles took a right into the libiary parking lot and my front side drivers tire snapped the ball joint completely snapped and it broke the spring, upper control arm, sway bar and tyirod
ABS light came on at 19,518 miles, 22,071 miles, and 27,078 miles. More importantly, however, are my issues with the 2002 Explorer rear end. 10/1/03: 27,078 miles ABS light came on, the dealer replaced the assembly. Rear differential was leaking, dealer replaced the seals. 7/28/04: 40,541 miles rear end leaking again. Half shafts were worn. Rear locking diff was slipping. The dealer had to replace both halfshafts, seals, and clutch packs. 9/22/04: 43,203 miles rear axle chattering. Replaced whole rear axle assembly. 2/25/05: 54,960 miles rear diff making more noise. Left rear axle bearing was noisy. Replaced left rear axle hub and assembly. On test drive, the dealer found that the bearing they just installed was bad, so they had to replace it again. 8/11/05: 68,000 miles leaking fluid from rear end. …
In feb of 2006 with 65,995 miles on my car I heard a whirring/grinding noise from the passenger side while driving. I made an appointment with my mechanic for later in the week (~4 days) to have the noise looked into. 1 day prior to taking my car to the mechanic the noise got much worse and I took it in immediately. I was told that the right rear wheel bearing exploded and damaged the brake and emergency braking system. I had this repaired and chalked it up to bad michigan roads. In May of 2006 the left rear wheel bearing also eroded/wore out and needed to be replaced (only 68,368 miles at the time). The warehouse/retail outlet where my mechanics purchased the replacement wheel bearings told me the person working the counter commented on how many requests Ford has had for wheel bearings as of recent. …
In April of 2005 my 2002 Explorer with just over 40,000 miles started making grinding noise in the right rear. Took it to a mechanic and then to the Ford dealership, both said the right rear wheel bearing needed to be replaced, had it replaced on 5/11/05. Within 2 weeks, the left rear wheel bearing also started making a grinding noise, had it replaced on 5/25/05. Called Ford customer care who said they could do nothing. In October, 2006, at 80,000 miles (mostly e-way miles, no off-road driving, only one driver and I am the original owner), the right rear wheel bearing needed to be replaced again and one of the front bearings is going as well. Called Ford customer care again to report the failures, and they still aren't interested. Have been told by several mechanics that this is a know defect with 2002 explorers, wheel bearings should last well over 100K miles. …
Suspension complaints in other Explorer years
Frequently asked questions
How common are suspension problems on the 2002 Ford Explorer?
NHTSA has 422 complaints about the suspension of the 2002 Ford Explorer, 13% of the model year's 3,295 complaints. The component named most often is rear (192 mentions).
Is there a recall for 2002 Ford Explorer suspension problems?
No. NHTSA lists no suspension 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 suspension problems start?
Half of the complaints with a recorded mileage happened before about 80,000 miles, and 1% before 25,000 miles.
Is it dangerous?
Owners linked 3 crashes, 2 fires and 1 injury to suspension 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.