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 Focus owners, lightly cleaned up (personal details are redacted by NHTSA).
Tl* the contact owned a 2002 Ford Focus. While driving approximately 55 MPH the vehicle started to smoke from the back seat. Within a short time, the inside of the vehicle was completely filled with smoke. The engine shut off without warning. There were no flames and no injuries. The vehicle was placed in neutral and coasted to the side of the road. The vehicle was towed to the contact's residence and later towed to an independent mechanic who diagnosed that the oil pump burned up and the engine was completely destroyed. The vehicle was deemed destroyed. The vehicle was towed to a friend's residence. The manufacturer was made aware of the failure six months later and gave the contact a case number. The failure mileage was approximately 73,000. Updated 04/12/17 lj
Tl contact owns a 2002 Ford Focus. The contact stated that the wires on top of the fuel pump started to melt. As a result, the vehicle would intermittently surge forward and stall without warning. The vehicle was taken to an independent mechanic and the contact was informed that the melting wires were causing the failure. The failure mileage was 132,000 and the current mileage was 154,000.
Driving my 2002 zx5 Ford Focus around pittsburgh, with less than a 1/4 tank the engine started stuttering. Then the car stalled. I turned it back on and drove about a 1/4 mile when it started stuttering and shaking pretty bad again. When I tried to accelerate, there was no power and the engine stalled again. I waited a little before turning it back on. It did the same thing twice more; once it stalled when I was doing a left turn at a busy traffic intersection and the other while driving down a crowded avenue. Fortunately I was able to make the 2-hour trip back home without any incidents. I took it to the Ford dealership in my town and they told me they needed to replace the fuel pump, fuel filter and also perform a fuel flush. The total cost is roughly $600.00. I have been looking in the internet and there is a history of failures with the fuel delivery module on 2000-2001 Focus. …
Approximately 3 weeks ago, while driving on the interstate (~65 miles per hour), a cooling system light came on (2002 Ford Focus, manual transmission, 46,000 miles), and instantaneously, the car stalled. It almost threw me into the windshield. The car recovered and did not die, and I was able to get to where I was going. It happened again a few days later while making a right hand turn (~20 miles per hour). I brought it to pep boys, who could find nothing wrong. It stalled and died two blocks away from pep boys, so I brought it to the Ford dealership. I asked them to check on any recalls because I have noticed that many focuses have this problem. They called me to tell me that it was definitely the thermostat , thermostat housing assembly and o ring, and I needed an oil change (which was done at pep boys one week earlier). They wanted $1100.00 to fix it, so I took my car home. …
On a trip to florida from nc, my engine light came on. The following week, it turned off on it's own. A week later the light came on again. Before I had the diagnostics run, it went off again. Four days before the incident date, the light once again came on. During all of this, the car ran fine, no stalling, no surges or failures. I parked my car at work, and 12 hours later came out to go home, only to find my car would not start. After having it towed to a service station, I found out that my fuel pump was shot, and had to be replaced. This car is only 2 years old, and a fuel pump should last a lot longer than that. And the fact that I have to pay $500 out of pocket for Ford using a faulty part is not acceptable. I'll never understand why the investigation on this matter was closed. A recall needs to be enacted. …
I drive a 2002 Ford Focus wagon, mileage 85,578. Two days ago I had trouble starting it. I did get it started but everytime I took my foot off the accelerator the engine stall. There was no check engine light warning prior to this or during the event. I was able to drive my car home, but had to restart it each time I had to stop. The next morning it drove fine but I took it to a Ford dealer for diagnosis and repair. I was told it was a fuel pump failure and it cost me over a $1000 for repair. (parts lister were sender, gasket, kit, tube, gasket, filter). In researching recalls I found that model years 2000-2001 were having this exact same problems and a recall was determined for this. I do normal driving - 70% highway, 30% in town. My car is just over 5 years old, I don't believe that normal wear and tear should cause the fuel pump to fail. …
I own a 2002 Ford Focus and having troubles with hesitation and stalling when the fuel tank nears or below a quarter of a tank of fuel. Replaced the fuel filter trying to remove possible problem. Problem still excists. Researched and found that Ford has identified years 2000-2001 Focus's with the same defect in the fuel delivery module. Since this vehicle is driven by our college aged daughter, I am very concerned about the safety of this condition. I telephoned Ford customer relations and they have indicated an unwillingness to act in correcting this defect. I further identified that there was a current extended coverage program 03n01 for the 2000 and 2001 year models. Further in a odi resume, investigation #ea02-022 indicates that 2002 year vehicles are also being affected.
My 2002 Ford Focus with 80,000 miles stalls when going high speeds, and it has happened 5 times, to date. The last time I was going 55 MPH on an entrance ramp to the freeway, with over 1/4 tank of gas when the engine stalled, vehicle lost power, including power steering. I had to slam on the brakes and stop in "v" where road split, came very close to having an accident. Took it to Ford dealership at recommendation of Ford, determined it was the fuel pump. The first person we talked to at Ford said they would fix it once we took it in and pay for diagnostic, the second person we called at Ford after taking it in said it is our responsibility to replace the part. I am extremely concerned about this problem, it is a major safety hazard to lose steering and power at high speeds.
There is a line that went straight into the engine's intake that has been leaking fluid since 2,000 miles and was inspected by deler who told to me that it was nothing. But the engine case should not have a large leak of fluid that soon. Finally now, they have done something on this and replaced the hose, as it was seen once more and knows of all the times reported. I hope this is just not a easy fix or this now hasn't caused any damange to the inside of the engine itself, as the engine has been in the shop for riding rough. They told me last time that the part of the transmission that was fixed would fix this. I think it is due to the oil leak on the top of the engine case since it was new. A new car should never have a oil leak on a engine case.
2002 Ford Focus bought the end of March 2009, now sits in driveway, because Ford will not fix fuel delivery module failure, because of VIN# not on list as being one of the 671000 units affected. The car is doing the same thing as all the other 671000 that were affected, surging, loss of power, stalling, hesitation. We were going down the road, changed lanes and it started doing this, now I have had 3 mechanics work on this car, no help replaced fuel pump, battery, fuel filter etc, no luck. It starts when it wants will run then it starts losing power, stalls. We did expect problems with used car, but not one that should have been included in a recall and fixed. If accident happens because of this problem Ford will be at fault.
NHTSA investigations
Engine stalling
Clogging of the fuel delivery module (fdm) filters in the subject vehicles can lead to stalling and other related symptoms.these symptoms become increasingly obvious to the driver as the clogging gradually increases over extended periods of driving.stalling in these vehicles is most likely to occur when accelerating through a right hand turn such as merging into freeway traffic when the fuel level in the fuel tank…
Fuel System complaints in other Focus years
Frequently asked questions
How common are fuel system problems on the 2002 Ford Focus?
NHTSA has 67 complaints about the fuel & propulsion system of the 2002 Ford Focus, 7% of the model year's 939 complaints. The component named most often is delivery › fuel pump (27 mentions).
Is there a recall for 2002 Ford Focus fuel system problems?
No. NHTSA lists no fuel & propulsion system recall for the 2002 Ford Focus, though it has 1 recall 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 Focus fuel system problems start?
Half of the complaints with a recorded mileage happened before about 52,000 miles, and 19% before 25,000 miles.
Is it dangerous?
Owners linked 0 crashes, 2 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.