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 Mercury Mountaineer owners, lightly cleaned up (personal details are redacted by NHTSA).
I purchased a 2002 Mercury Mountaineer on 4/11/2011. As I was driving it home from the dealership, the same day, I noticed some black smoke coming out the back of the car. There were no messages that came up in the message center window so I had no clue what was happening. As I looked back up from the rear view mirror, I noticed a first responders truck next to the drivers window who was yelling " get out of the vehicle, its on fire!" immediately I pulled over and my mother and I had to jump from the vehicle because the entire engine area was engulfed with flames. I was injured while I was fleeing from the vehicle. The fire department and state troopers were enroute and my vehicle was hosed down and towed. I almost died in this vehicle because of the rear differential going out on it. This vehicle type has had many problems with this part and their customers should be compensated! …
Driving at normal speed of approximately 40 MPH on a city street, the spark plug and coil shot out from the #2 cylinder. A large percussion banging sound emitted from under the hood which was the detectable evidence something had just gone desperately wrong with the engine.
Just left the highway and ended up at a red light traffic signal and one the light turned green, I went to drive off and a loud boom I could hear coming from under my hood, as I looked in my rear view mirror a semi truck started honking its horn and slammed to miss hitting from behind. I went to pull to the side the road but truck was jumping all over and I had to pull in front of cars turning which I smelt a smell like something burning. The spark plug had ripped from its socket, it had happened the first time 1 year ago now 2nd one, repairman says he sees this all the time with my vehicle, " Ford is helping putting my kids through college with these problems from your year" wow, I thought Ford got, paid, repairmen got paid, and I'm the only one taken for a ride of a lifetime. Not right is it.
Tl* the contact owns a 2002 Mercury Mountaineer. While driving approximately 3 MPH, the high temperature and low oil warning indicators illuminated. The oil pressure gauge dropped to zero and a loud noise was heard. The contact merged the vehicle to the emergency lane and shut the vehicle off. The contact checked the oil level and observed that the oil was full. The contact restarted the vehicle and the noise was still present. The vehicle was towed to an independent mechanic. The technician noticed that there were metal shavings in the engine oil and the engine needed to be replaced or repaired. The manufacturer was notified. The approximate failure mileage was 150,000.
Tl* the contact owns a 2002 Mercury Mountaineer. The contact stated while driving approximately 20 MPH and suddenly all of the instrumental panel lights including the "door ajar" light illuminated on and off then suddenly the vehicle stalled . Immediately after the failure occurred the contacts dome lights did not disengage. The contact took her vehicle to an independent mechanic for diagnostic testing. The mechanic stated that the failure was caused by an unknown electrical failure. Both the dealer and manufacturer were not made aware of the failure. The vehicle was not repaired. The failure mileage was 150,000.
Driving from dallas, tx, to west lafayette, in, in jan 2010, the 2002 Mercury Mountaineer with 4.6l v8 engine blew a spark plug out of the cylinder head causing us to stop in a small town to have the engine repaired. This was a factory installed (not replaced) spark plug. I have seen many complaints about this in the Ford v8 engine. The vehicle had around 86,000 miles on it at the time and was not due for a spark plug replacement until 100,000 miles. This was a safety hazard as gasoline is spewing out of the cylinder head with an attached and still arcing spark plug.
2002 Mountaineer stalls, transmission control assembly, main control valve, and gasket had to be replaced. The lift gate was sticking, and while closing it, the glass shattered, the glass was recalled, and was suppose to have been fixed. The oil light illuminated. The trim on the front door fell off while driving. There was a grinding noise coming from the rear wheels, it was determined that there was severe rust on the brake componets, the park brake shoes fell apart due to corrosion, the rear wheel bearing and knuckle assembly had excessive rust.
Rear panel under window has recently cracked, there are now 2 vertical cracks running down the back of the vehicle. Also, hitch to rear door doesn't stay up. This vehicle has also had a new engine put it and injectors have popped out on more than one occasion. This is the most expensive vehicle I have ever purchased and it has given me more problems than I could ever expect in a vehicle. Ford needs to compensate for this vehicle. We have owned several Ford's and have never seen anything like this. It is a true lemon>>>>
Just left the highway and ended up at a red light traffic signal and one the light turned green, I went to drive off and a loud boom I could hear coming from under my hood, as I looked in my rear view mirror a semi truck started honking its horn and slammed to miss hitting from behind. I went to pull to the side the road but truck was jumping all over and I had to pull in front of cars turning which I smelt a smell like something burning.
The exhaust pipe had some way bent which caused the pipe to get close to the rear fender. The rear fender was made of some sort of plastic which melted from the exhaust pipe. The owner was told "the only way that the pipe could have been disfigured if you ran over a speed bump". The owner does not recall doing that or over loading the truck. Ts reconditioned bumper, absorber, reflector had to be replaced.
NHTSA investigations
Spark plug ejection from cylinder head
On September 6, 2005, odi received a petition requesting that the agency investigate allegations of engine spark plug ejection in certain model year 1997 through 2004 Ford vehicles with triton v-8 and v-10 engines.odi received a total of 474 non-duplicative complaints on the subject vehicles where the complainant, or the dealer repairing the vehicle, reported that a spark plug detached from the cylinder and/or…
Engine complaints in other Mountaineer years
Frequently asked questions
How common are engine problems on the 2002 Mercury Mountaineer?
NHTSA has 35 complaints about the engine & cooling of the 2002 Mercury Mountaineer, 9% of the model year's 372 complaints. The component named most often is engine (7 mentions).
Is there a recall for 2002 Mercury Mountaineer engine problems?
No. NHTSA lists no engine & cooling recall for the 2002 Mercury Mountaineer, though it has 2 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 Mercury Mountaineer engine problems start?
Half of the complaints with a recorded mileage happened before about 92,000 miles, and 17% before 25,000 miles.
Is it dangerous?
Owners linked 0 crashes, 1 fire and 2 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.