Which parts fail
Components named in complaints (engine, cooling system, oil leaks, timing chain, exhaust).
Mileage when the problem started
Owner reports
Selected complaints filed with NHTSA by 2002 Ford Ranger owners, lightly cleaned up (personal details are redacted by NHTSA).
My wife and I were driving on hwy 79from palistine tx to jacksonville tx Thursday 7/11/2016 when we noticed smoke coming out from under the truck we pulled over and noticed fire under the hood I tried to poor water on it all it did was just get worse and our truck all my work tools my lively hood blew up.
Purchased a new 2002 Ford Ranger 4x4 4dr xcab with the 4.0 engine. Vehicle identification # [redacted], on September 14, 2002. After coming to stop, engine has surged. First time RPM went to 1500 and could keep the truck in place with brake pressure. Took to dealer for 3000 service in December and reported problem. Dealer performed normal 3000 service and found no problems, however they asked to be informed if it happens again. This time engine surged to over 3000 RPM and could not keep truck stopped pushing into another truck in front of me. We hit bumpers and the only way to stop my truck was to slam the transmission into park. Are there any other reported problems of engine surge like this. Using regular gasoline in the tank. Taking truck back to dealer for inspection.
Engine ejected spark plug from cylinder number three. Mechanic said it is a common problem with Ford vehicles manufactured with an aluminum head. I am fortunate that this occurred while accelerating from a stop sign at only 20mph. At higher speeds, the mechanic said the spark plug May have ejected itself straight through the hood after which, the engine often catches fire because of the gasoline spurting out of the cylinder. Repair included a helicoil tap kit and new spark plugs. This is a very dangerous defect and should be addressed by Ford and all government safety agencies. This truck has very low mileage for it's age and has been taken very good care of. There is no reason why this should have happened other than faulty design and use of an aluminum head.
Tl contact owns a 2002 Ford Ranger. While driving 35 MPH the vehicle began to over heat and smoke came out of the engine. The contact was able to stop the vehicle and shut the engine off; however, as soon as he shut the engine off, the vehicle caught fire. The contact attempted to extinguish the fire and was unsuccessful. The entire vehicle was engulfed in flames and was completely destroyed. The cause of the fire has not been determined. The VIN was not available. The failure mileage was 146,000.
I owned a 2002 Ford Ranger with 45,000 miles on it. My daughter was driving it and came to a stop at an intersection after exiting an expressway. Black smoke started coming out of the engine compartment. Within 10 minutes, the trucks engine compartment and cockpit were completely engulfed in flames and the truck was destroyed.
Engine error code p303 displayed and engine missing on that cylinder. Ford TSB 05-26-3 states head replacement necessary to correct. This appears to be a generic issue with the 3.0 liter vulcan engines,. Car will not pass emissions inspection until this is repaired.
I am having multiple problems with my 6 month old truck. A strange oil loss that was loosing 1-2 quarts of oil a week, now fixed for the moment. The clutch disengages if any pressure is applied to the clutch pedal and will not engage until the pedal is fully released, dealer claims its normal. Various electrical problems with this heap, including failing sensors, interior light coming on when it wants to, and the check engine light comes on occasionally. This truck has starting problems sometimes, you have to crank the engine for a long time(up to 30 seconds sometimes) before it will start. Had to have a tire replaced with 1066 miles on the vehicle because some of the tread was beginning to come off, vehicle was realigned at the same time to cure a pull to the right which did nothing still pulls to the right. …
Exhaust odor after engine reaches normal operating temp. The odor is like rotten eggs, sulphur, phosphorus. Problem began when vehicle was approx. 9 months old with less than 10,000 miles. Vehicle was bought new and is a 2002 Ford Ranger with 4.0, auto, 4x4. Vehicle now has 17,405 miles and has been back to the dealer 4 or 5 times without resolve and is about to go back again. The dealer said they have done everything Ford has advised them to do and they do not know what to try next. The dealer said Ford will not authorize replacing the catalytic convertor because the problem would start over again when the new convertor "burns" in. The dealer told me the first time it would go away in approx. 5,000 miles. The smell remains and, if anything, is getting worse. The frustration began when I took the truck in the first time for the exhaust odor and a severe jerk when putting the trans. …
This vehicle is unsafe at high speeds. Recently I bought a used 2002 Ford Ranger xlt, w/ 4.0 liter engine, and I noted the 125 MPH speedometer. Last evening an 18 wheeler cut into my lane and I quickly accelerated hitting about 90 MPH on the interstate to avoid being crushed. However just as I was clearing the front end of the semi the engine began to faulter and the vehicle began to slow. Pressing on the accelerator didn't increase vehicle speed or engine RPM. I was scared out of my wits. I called the dealership that night and they agreed to look at the vehicle. Which they later deferred on (basically they knew of the defect). After talking to several service department reps at the dealership I was told the fuel ejectors are designed to cut out at high speeds. …
Since about 10,000 miles my engine has made a crackling noise under acceleration. 've talked to many other Ranger owners who are having the same problem. Some of them said they took their trucks to a dealership and the service department said the noise was from the timing in the engine and the problem could not be fixed. It was to my understanding that if a automotive company makes a mistake and it is not easily repairable and is frequent there should be a recall so the problem could be fixed. I'm going to sell my truck in the spring because of this problem. I have no idea if this timing problem will have any long term effect on the engine itself but I do not want to wait around and see since Ford only offers a 3 year 36,000 mile warranty and I have 45,000 miles on my truck.
Engine complaints in other Ranger years
Frequently asked questions
How common are engine problems on the 2002 Ford Ranger?
NHTSA has 45 complaints about the engine & cooling of the 2002 Ford Ranger, 13% of the model year's 346 complaints. The component named most often is engine › gasoline (12 mentions).
Is there a recall for 2002 Ford Ranger engine problems?
No. NHTSA lists no engine & cooling recall for the 2002 Ford Ranger, 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 Ranger engine problems start?
Half of the complaints with a recorded mileage happened before about 45,000 miles, and 46% before 25,000 miles.
Is it dangerous?
Owners linked 1 crash, 4 fires and 0 injuries to engine & cooling 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.