Which parts fail
Components named in complaints (battery, alternator, wiring, ignition, instrument cluster, infotainment).
Mileage when the problem started
Owner reports
Selected complaints filed with NHTSA by 2002 Ford F-250 SD owners, lightly cleaned up (personal details are redacted by NHTSA).
My 2002 Ford f-250 super duty truck caught fire due to the brake switch recall problem. The brake switch (under the hood) burned and the fuse block (under the dash) melted. The cab filled with smoke while my spouse was driving. The switch, fuse block, and cable end were replaced due to this incident.
Ford 2002, f250 crew cab pickup, diesel, started on fire in the driveway on December 1, 2003, 4-5 hours after it was parked. I burned down our garage and the second vehicle that was parked next to it. The garage is not attached to the house.
I have a Ford 2002 f-250 super duty that the spark plug blew out f the cylinder head. This caused a very significant power loss causing the truck to slow very quickly much like applying the brakes but not using them. This caused a very near accident on a highway traveling at 50 MPH and the slowing without brake lights nearly caused an accident. After approximately 1 min of researching the problem about the accident I realized that this problem is huge !!!! To say the least. There have been countless reports of spark plugs blowing and either people being stranded to near collisions. Also I am a firefighters paramedic and my nose is no hydrocarbon meter but the levels of gasoline vapors that accumulate in a very short time. …
On November 30, 2006, I was driving my 2002 f250 diesel super duty Ford truck on interstate 25 in denver at 6 am and in the middle lane, everything just shut down. No power brakes, steering, etc. I was able to pull over to the shoulder but not all the way off the interstate dodging rush hour traffic. I called aaa and had it towed to a Ford dealership. It was a bad cam sensor and this is the second time it has failed in less than 18 months. This was a very dangerous situation as I did not get off the highway and cars were buzzing by only a few feet from my door. Ford said this part goes out every 25,000 miles. What a safety hazard!! This know it fails frequently and they are not proactive in initiating a recall to improve this part. I sent them a message and they just gave me the standardized reply. …
The vsm (vehicle security module) failed. Symptoms include, but are not limited to: power door locks do not work, key fob does not work, auto headlights do not work, radio doesn't turn off when key is out of the ignition and door opens, no audible indicator for key in the ignition, no audible indicator for headlights on with door open, dome lights stay on. This problem is widespread with this model year and there are many reports on forums around the internet. Ford has also stopped making the original part and replaced its manufacture with a new part which supposedly does not exhibit the same random failure rate. Headlights not working is a major life safety issue. I drove without headlights on for some time (as the auto headlights did not come on) and did not notice it until I was on an unlit street. …
The vehicle is dependent upon a vehicle security module to open doors, show if doors are open or closed, automatically lock and unlock doors, turn on and off lights, etc. The unit installed in my vehicle has been replaced by another unit by Ford. Ford has not recalled this device. Many owners have reported and have had to replace these devices because of the problems with locks not working (open and close), headlights not working or turning off while driving, false safety indications being displayed, etc. I am now experiencing this problem and have to replace this module to stop these same issues in my vehicle. It is a thermal problem and only occurs whenever the vehicle is warmed during the day in the heat. It begins to work properly after the air conditioner cools the cab down or at night when the temperatures are cooler. …
While driving my 2002 Ford f250 7.3 diesel truck, my truck lost all power. I restarted the truck and had traveled about 1/2 mile when the failure occurred again. I restarted the truck again and had traveled about 1/2 a mile when the failure occurred again. At this point I was in my driveway. After further research on the internet, I discovered that this failure is very common in this vehicle and happens with no warning and at any speed. Several people on the internet went so far as to suggest carrying a spare part with you at all times as well as the tools needed to make the repair on the road. My local Ford dealer informed me that this a very common problem. I feel that this issue should be addressed before any fatalities occur as this has happened while driving at high rates of speed with no warning.
Tl* the contact owns a 2002 Ford f-250 super duty. The contact was driving at approximate speeds of 10 MPH with a boat hitched to the rear trailer. He proceeded to drive downhill and shifted into second gear and activated the vehicle overdrive. When the overdrive was activated, the instrument panel immediately went blank and the vehicle went idle. The vehicle was towed to a local dealer where the contact was informed that a fuse had blown in the vehicle and the dealer serviced the vehicle accordingly. The failure recurred on a separate occasion while towing a camper downhill under similar conditions as the first failure. The vehicle was taken to an authorized dealer to be serviced. The failure mileage was 64,000 and the current mileage was 64,100.
My 2002 Ford f250 v10 with an immaculate maintenance record and 70,000 miles on it, started to tic, tic, tic? I brought it to the dealer today to get checked out, he got in the truck and revved the engine and....boom! A spark plug shot out right before my eyes and gasoline/oxygen mist repeatedly shot out of the hole!!!. Simply put, tires wear out, ball joints wear out, wheel bearings wear out. Spark plugs don't shoot out of cylinder heads unless the cylinder head is defective!!!!!!!!!!!! The repair cost me $600.00! There are 1000's of complaints on the web of the same thing happening to many people. Ford needs to be held accountable......and I want my money back!
I own a 2002 Ford f250 7.3l power stroke diesel. On 10-20-06 the cps failed in a rainstorm. My wife (7 months pregnant) was driving and was nearly involved in a crash because when the failure occurred all electronics died as did the motor. This rendered the power steering and power brakes useless. This problem could have caused a fatality if not to my wife but other drivers as well. The truck stranded my wife on the side of a country road for 2 hrs. Waiting for a tow service. The vehicle had to be towed and the cps replaced before the truck would restart.
NHTSA investigations
Engine compartment fires
Ea05-005 is closed with Ford?s actions in recalls 05v-017, 05v-388, and 06v-286, recalling approximately 6.7 million vehicles equipped with texas instruments speed control deactivation switches (scds).the brake systems in these recalled vehicles generate a vacuum that can potentially cause the scds to fail and, in certain switch installation orientations, catch fire.Ford is also including the entire population of…
Electrical complaints in other F-250 SD years
Frequently asked questions
How common are electrical problems on the 2002 Ford F-250 SD?
NHTSA has 29 complaints about the electrical system of the 2002 Ford F-250 SD, 12% of the model year's 245 complaints. The component named most often is wiring (2 mentions).
Is there a recall for 2002 Ford F-250 SD electrical problems?
No. NHTSA lists no electrical system recall for the 2002 Ford F-250 SD, though it has 3 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 F-250 SD electrical problems start?
Half of the complaints with a recorded mileage happened before about 96,000 miles.
Is it dangerous?
Owners linked 0 crashes, 3 fires and 1 injury to electrical 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.