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 Nissan Frontier owners, lightly cleaned up (personal details are redacted by NHTSA).
The contact owns a 2002 Nissan Frontier. The contact stated while driving approximately 65 MPH, the vehicle lost motive power and stalled. There were no warning lights illuminated. The contact was able to restart the vehicle and drove home safely. The contact performed an inspection and noticed that the fuel pump was rusted. The vehicle was not repaired. The contact notified the manufacturer of the failure. The contact related the failure to NHTSA Campaign Number: 04V230000 (Fuel System, Gasoline) however, the VIN was not included. The approximate failure mileage was 200,000.
In just under 14 years of owning this vehicle, I now have had to replace the gas tank a third time due to leakage. I do not feel that this should be the responsibility of the owner, due to the frequency of this happening. I believe these tanks are a bad design and with poor material to rust out and leak in such short periods of time. I just can;t believe there have not been numerous injuries or any deaths due to these gas tanks. I have attached pictures of the second gas tank that was replaces about 6-7 years ago. And you can definitely see that it has been leaking. By the way. My truck has always been garage kept and I have yet to find someone that believes my truck is that old due to how nice that it still looks inside and out.
The frame on these vehicles are unsafe due to persistent corrosion which also carries throughout other parts under the vehicle like their steering. In my case, the rust is settling in and causing the frame to deteriorate despite it only have 69K miles. The concern is obviously having the vehicle crumble during use. Here are just a few other complaints listed on the internet by other owners. Http://www.nissanforums.com/pathfinder/117181-rusted-frame.html http://nissanproblem.com/2002-Nissan-Frontier-structure-frame-and-members-underbody-shields-problems-defects/ http://www.consumeraffairs.com/automotive/nissan_frontier.html
Tl* the contact owns a 2002 Nissan Frontier. The contact stated that while parked, there was a fuel odor coming from the vehicle. In addition, there was fuel leaking from the rear of the vehicle. The vehicle was diagnosed by an independent mechanic that the there was corrosion and the fuel sending unit needed to be replaced. The vehicle was not repaired. The VIN was not included in NHTSA campaign number: 04V230000 (fuel system). The manufacturer was not made aware of the failure. The failure mileage was approximately 115,000.
Tl* the contact owns a 2002 Nissan Frontier. While driving at an unknown speed, the engine warning light illuminated. The vehicle was taken to a dealer. The technician diagnosed that the fuel tank was completely corroded and needed to be replaced. The vehicle was repaired, but the failure recurred seven years later. The manufacturer was made aware of the failure and did not offer any assistance. The vehicle was not repaired. The failure mileage was 50,000.
Tl* the contact owns a 2002 Nissan Frontier. While driving at various speeds, the check engine warning indicator illuminated on the instrument panel. The contact stated that the vehicle was taken to an independent mechanic where it was diagnosed that the fuel tank was corroded and needed to be replaced. The vehicle was not repaired. The manufacturer was not made aware of the failure. The failure mileage was 133,000. The VIN was not available.
Was coming to a stop at a traffic light in s.c., when all of a sudden the motor started to race. I immediately turned the motor off. Turned it back on, and had no more problems. This was very frightening. [redacted]
NHTSA campaign #04V230000 applies to my 2002 Frontier but it is not covered because its VIN is a sc(supercharged) model it has the same gastank,sending unit, orings as trucks in the recall but my model is not included in recall
On June 30 my Nissan Frontier broke down. I had it towed to the webster Nissan office. I spoke with brian at Nissan on July 1st and he told me that my truck would either be fixed on July 7/3 or 7/8. The part that caused the issue is safety recall from 2003 that is an issue with fuel sensor in the gas tank. I contacted 1-800-nissan1 on 7/3 in search of a loaner car until they could get my truck fixed. Ginger at 1-800-nissan1 opened a ticket and told me some one would contact after the holiday weekend. I spoke catherine the region representative for Nissan on 7/7 and she said that Nissan will not provide a loaner car because my is off warranty. I explained to her the reason my truck broke down was because safety recall part that Nissan was responsible for. She said again Nissan will not provide me car. …
A very strong and very overpowering gas smell came inside the vehicle while I was driving it at night. I had my 5-year old strapped in his car seat in the back. I was stuck in traffic on I-95 and didn't have many options but to continue to drive home. The "service engine soon" light came on as well. The next day, I took the vehicle in for servicing at my Nissan dealership mechanic, and I have specific text from the work invoice that states the following word-for-word: "cannister coming apart. Right valve stuck inside - replaced - gas leaking down side. Replaced gas tank - rusted." the work invoice also details that the dealership mechanic replaced the following components: (1) canister assy e (2) valve assy - co (3) fuel tank (4) ring-o fuel gag. This vehicle has never been in any accidents and I fully maintain it according to the manufacturer's schedule. …
Related recalls
Fuel system, gasoline › Delivery › Fuel pump
On certain pickup trucks equipped with six cylinder engines and sport utility vehicles equipped with four or six cylinder engines, the fuel pump terminal on the fuel-sending unit can develop a crack in the plastic molding. This can cause the terminal strip to corrode under some environmental conditions.
Remedy: In the following states, dealers will replace the fuel-sending unit. These states are connecticut, delaware, illinois, indiana, iowa, kentucky, maine, maryland, massachusetts, michigan, minnesota, new hampshire, new…
Fuel System complaints in other Frontier years
Frequently asked questions
How common are fuel system problems on the 2002 Nissan Frontier?
NHTSA has 25 complaints about the fuel & propulsion system of the 2002 Nissan Frontier, 20% of the model year's 124 complaints. The component named most often is storage › tank assembly (1 mentions).
Is there a recall for 2002 Nissan Frontier fuel system problems?
Yes — NHTSA recall 04V-230 (fuel pump, May 24, 2004). Recall repairs are free at authorized dealers.
At what mileage do 2002 Nissan Frontier fuel system problems start?
Half of the complaints with a recorded mileage happened before about 110,000 miles, and 6% before 25,000 miles.
Is it dangerous?
Owners linked 0 crashes, 1 fire and 1 injury 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.