2002 Ford Expedition Recalls, Problems & Maintenance

The 2002 Ford Expedition has no open NHTSA recalls. Owners report 8 recurring issue clusters, led by “Seat belt unlatching while driving.” Ford uses the Intelligent Oil-Life Monitor (IOLM) to determine when oil changes are due based on actual driving load — not just mileage. Ford's published cap is 10,000 miles or 1 year, whichever comes first. The schedule below reflects Ford's Normal service intervals; F-Series trucks and Super Duty have additional towing-specific items.

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No open recalls on file. NHTSA lists no unrepaired safety recalls for this year, make and model. A recall can be issued at any time, and a specific car can still have one open — check yours by VIN at nhtsa.gov/recalls.

Known issues & problems for this vehicle

What drivers and federal regulators have officially reported about the 2002 Ford Expedition.

Reported to NHTSA

Seat belt unlatching while driving

SEAT BELTS

13 NHTSA complaints · 2008-01 → 2019-11

“WHILE DRIVING, THE DRIVER AND PASSENGER SEATBELTS IN THE FRONT WILL RANDOMLY UNLOCK. THIS CAR HAS NOT BEEN IN ANY ACCIDENTS. THE EQUIPMENT IS FACTORY ORIGINALS. THIS HAS BECOME A REAL SAFETY ISSUE AS WE NEVER KNOW WHEN THEY ARE GOING TO UNLOCK. *TR”
— Owner report, NHTSA ODI #10668626
“DRIVER'S SEAT BELT RANDOMLY UNLATCHES WHILE DRIVING DESPITE HAVING BEEN PROPERLY LATCHED TO START. *TR”
— Owner report, NHTSA ODI #10594532
“THE SEAT BELTS FRONT, PASSENGER SIDE UNLOCK BY THEMSELVES WHILE IN MOTION. IT CAN HAPPEN DURING CITY OR HIGHWAY DRIVING. THIS HAS NOT BEEN REPAIRED BY ANYONE AND IS FACTORY ORIGINAL. SEEMS LIKE A DANGER TO PASSENGERS”
— Owner report, NHTSA ODI #10958288

Read all complaints on NHTSA →

Gear selector will not leave park with blown fuse

ELECTRICAL SYSTEM

6 NHTSA complaints · 2010-06 → 2015-03

“TL*THE CONTACT OWNS A 2002 FORD EXPEDITION. THE CONTACT STATED THAT THE GEAR LEVER FAILED TO SHIFT OUT OF THE PARK POSITION. IN ADDITION, THE FOUR POWER WINDOWS AND DOOR LOCKS BECAME INOPERABLE”
— Owner report, NHTSA ODI #10690006
“MY CAR STARTED JUST FINE BUT IT WOULD NOT SHIFT OUT OF PARK AND NONE OF THE WINDOWS WORKED. I CHECKED THE FUSES AND ONE WAS BLOWN. I REPLACED THE FUSE AND MY CAR APPEARED TO BE WORKING NORMALLY”
— Owner report, NHTSA ODI #10340430
“MY 2002 FORD EXPEDITION HAS SUFFERED NUMEROUS ELECTRICAL PROBLEMS”
— Owner report, NHTSA ODI #10421064

Read all complaints on NHTSA →

Rear control arm and differential link corrosion

SUSPENSION

4 NHTSA complaints · 2012-12 → 2017-04

“TAKATA RECALL DURING AN INSPECTION OF MY SUSPENSION FOR WORN BUSHINGS, I NOTED SEVERE CORROSION ON MY REAR TRAILING ARMS FOR THE REAR AXLE. THE LOWER ARM ON THE PASSENGER SIDE ACTUALLY HAD A QUARTER SIZE HOLE IN THE INBOARD SIDE OF THE WEB”
— Owner report, NHTSA ODI #10981416
“HAD ROUTINE SERVICE ON MY 2002 EXPEDITION AT DEALERSHIP,WAS TOLD I NEEDED TO REPLAC UPPER AND LOWER TRAILING ARM ALSO TRACK ARM BECAUSE OF SEVERE CORROSION”
— Owner report, NHTSA ODI #10522113
“REAR DIFFERENTIAL CONTROL LINKS RUSTED THRU AND BROKE. THIS ALLOWED THE DIFFERENTIAL TO MOVE TOWARD THE REAR. WHEN IT MOVED FAR ENOUGH THE REAR DRIVE SHAFT FELL OUT OF THE TRANSFER CASE AND BROKE OFF AT THE REAR YOKE”
— Owner report, NHTSA ODI #10487262

Read all complaints on NHTSA →

Transmission slip and overdrive light flashing

POWER TRAIN

4 NHTSA complaints · 2007-11 → 2011-01

“MY 2002 FORD EXPEDITION OD LIGHT FLASHES ON AND OFF. I WAS DRIVING DOWN I75 AND MY TRANSMISSION KEPT SHIFTING IN AND OUT OF GEAR.. MY WHOLE TRIP. IT SLAMMED INTO GEAR ALMOST CAUSING ME TO LOOSE CONTROL OF MY VEHICLE. THIS TRANSMISSION IS DEFINITELY A SAFETY HAZARD”
— Owner report, NHTSA ODI #10318257
“TRANSMISSION SLIP. O/D LIGHT STARTED TO BLINK AND TRANSMISSION CLUNKS INTO GEAR. THIS PROBLEM SEEMS TO BE VERY PREVALENT AS A FEW OF MY FRIENDS WHO OWN 2000 TO 2002 MODEL FORDS HAVE HAD THIS PROBLEM. THEY HAVE HAD THEIR TRANSMISSIONS REPLACED OR REBUILT”
— Owner report, NHTSA ODI #10310688
“MY 2002 FORD EXPEDITION HAS ALWAYS HAD TRANSMISSION SHIFTING PROBLEMS. OVER THE YEARS, IT WILL SOMETIMES NOT GO OUT OF 4X4 WITHOUT SOME GENTLE COAXING. JUST THE OTHER DAY, IT SHIFTED OUT OF GEAR ON THE HIGHWAY AND THE OVERDRIVE LIGHT STARTED FLASHING”
— Owner report, NHTSA ODI #10377116

Read all complaints on NHTSA →

Spark plug ejection from cylinder head

ENGINE AND ENGINE COOLING

78 NHTSA complaints · 2007-10 → 2017-05

“2002 FORD EXPEDITION, ORIGINAL FACTORY SPARK PLUG WAS VIOLENTLY EJECTED FROM THE ENGINE DURING NORMAL OPERATION. SPARK PLUG SMASHED THROUGH FUEL INJECTOR AND DENTED THE HOOD. HAD SOMEONE BEEN SERVICING THE ENGINE THE INJURIES COULD HAVE BEEN SEVERE”
— Owner report, NHTSA ODI #10330988
“I HAVE HAD SIX OCCURRENCES OF A SPARK PLUG BLOWING OUT OF THE CYLINDER HEAD. EACH TIME, IT BLEW THE COIL OFF ALSO. THE DANGEROUS POPPING AND VAPORS THAT BLOW FROM THE NOW OPEN HEAD ARE A SERIOUS IGNITION HAZARD IN THE ENGINE BAY. IT IS NOT ALWAYS THE SAME PLUG THAT HAS BLOWN OUT”
— Owner report, NHTSA ODI #10456322
“JUST WANT TO ADD MY CAR TO THE LIST OF FORD EXPEDITION 5.6L ENGINES THAT HAVE EXPERIENCED THE SPARK PLUG EJECTION ISSUE. THANKFULLY, THIS OCCURED WHEN STARTING THE VEHICLE, SO IT DID NOT CAUSE ANY ACCIDENT OR INJURY”
— Owner report, NHTSA ODI #10918916

Read all complaints on NHTSA →

Speed control deactivation switch and parked-vehicle fire

VEHICLE SPEED CONTROL

22 NHTSA complaints · 2007-11 → 2024-07

“VEHICLE HAD NO MECHANICAL ISSUES UP TO THE DATE OF THE INCIDENT. THE VEHICLE WAS DRIVEN ON A DAILY BASIS TO AND FROM WORK. THE VEHICLE CAUGHT FIRE WHILE PARKED IN THE DRIVEWAY”
— Owner report, NHTSA ODI #10255435
“SMALL FIRE EXTINGUISHED PRIOR TO FIRE DEPARTMENT ARRIVAL. FIRE OCCURRED ON A SENSOR ATTACHED TO THE BRAKE FLUID RESERVOIR. FIRE APPEARS TO BE CONSISTENT WITH SPEED CONTROL DEACTIVATION SWITCH AS PREVIOUSLY RECALLED. *TR NO DAMAGE OUTSIDE OF VEHICLE”
— Owner report, NHTSA ODI #10454836
“I RECEIVED A LETTER FROM FORD STATING THAT THERE IS A SAFETY DEFECT WITH SPEED CONTROL DEACTIVATION SWITCH FOR MY VEHICLE. IN THIS LETTER I'VE BEEN INSTRUCTED TO CONTACT MY LOCAL FORD DEALER TO SET UP A TIME/ DATE FOR REPAIRS”
— Owner report, NHTSA ODI #10221220

Read all complaints on NHTSA →

Engine compartment fire while parked

ENGINE

12 NHTSA complaints · 2009-12 → 2016-06

“TL* THE CONTACT OWNS A 2002 FORD EXPEDITION. WHILE THE VEHICLE WAS PARKED IN A RESIDENTIAL DRIVEWAY, THE ENGINE COMPARTMENT ERUPTED INTO FLAMES WITHOUT WARNING AND A LOUD EXPLOSION SOUND EMITTED FROM THE VEHICLE”
— Owner report, NHTSA ODI #10874409
“TL* THE CONTACT OWNS A 2002 FORD EXPEDITION. WHILE PARKED, THE VEHICLE UNEXPECTEDLY BECAME ENGULFED IN FLAMES. THE FIRE DEPARTMENT EXTINGUISHED THE FLAMES AND DETERMINED THAT THE FIRE ORIGINATED FROM A DEFECTIVE WIRING HARNESS. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE”
— Owner report, NHTSA ODI #10475862
“VEHICLE WAS PARKED. OVERNIGHT, VEHICLE ENGINE COMPARTMENT CAUGHT FIRE AND ENTIRE VEHICLE BECAME ENGULFED IN FLAMES. TOTAL LOSS OF VEHICLE. *TR”
— Owner report, NHTSA ODI #10452912

Read all complaints on NHTSA →

Sudden acceleration while parking or idling

VEHICLE SPEED CONTROL

5 NHTSA complaints · 2008-05 → 2016-05

“2002 FORD EXPEDITION, STICKING THROTTLE OR ACCELERATOR CAUSES SUDDEN ACCELERATION AND IS QUITE DANGEROUS, HAS HAPPENED SEVERAL TIMES AND ALMOST DROVE INTO A BUILDING”
— Owner report, NHTSA ODI #10318036
“IDLING AT A METERED RAMP I EXPERIENCED UNINTENDED ACCELERATION WHILE IN LINE WAITING FOR MY TURN AT THE METERED LIGHT.THE CAR IN FRONT OF ME ROLLED FORWARD AND I FOLLOWING SUIT. I DID NOT TOUCH THE ACCELERATOR BUT MERELY RELEASED MY FOOT FROM THE BRAKE PEDAL”
— Owner report, NHTSA ODI #10870278
“IN MARCH 2012 MOTHER WAS PULLING INTO A PARKING LOT IN WACO. CAR SUDDENLY ACCELERATED AND RAN THROUGH THE PARKING LOT EVENTUALLY HITTING A PARKED CAR. CAR WAS FIXED AND MOTHER TOLD THEM TO CHECK THIS ISSUE OUT”
— Owner report, NHTSA ODI #10475317

Read all complaints on NHTSA →

Source: NHTSA Office of Defects Investigation (ODI). Complaint data refreshed Sep 20, 2026. Investigation data refreshed Sep 20, 2026.

We display NHTSA's record with attribution; we don't editorialize on what these complaints mean for any specific vehicle.

Raw data + downloads for this vehicle →

Essential maintenance

Critical for safety and preventing major damage

Engine Oil & Filter

Every 7,500 mi

Replace synthetic-blend or full-synthetic Motorcraft oil per the IOLM, or every 7,500-10,000 miles. EcoBoost engines require full synthetic; Coyote 5.0L V8 specifies SAE 5W-30.

Estimated cost — typical U.S. ranges

Dealer

~$120–$160

Shop

~$85–$115

DIY

~$25–$55

Full synthetic costs more than conventional. 5-quart 0W-20 + filter is the typical bill.

Tire Rotation

Every 10,000 mi

Rotate tires every 10,000 miles, or with every other oil change. F-150 4x4 owners should rotate every 5,000-7,500 miles to even out drivetrain bias wear.

Estimated cost — typical U.S. ranges

Dealer

~$85

Shop

~$60

DIY

Free

Often free at the shop where you bought the tires — worth asking before paying.

Brake Inspection

Every 10,000 mi

Inspect brake pads, rotors, and brake fluid level every 10,000 miles. Front pads on F-150 and Explorer typically last 40,000-60,000 miles.

Estimated cost — typical U.S. ranges

Dealer

~$85

Shop

~$60

DIY

Free

Most shops do this free as a courtesy with any service. Don't pay separately if you can avoid it.

Brake Fluid

Every 45,000 mi

Ford specifies brake fluid replacement on an inspection basis, but moisture testing every 3 years is recommended. Replace if reading exceeds 3% water content.

Estimated cost — typical U.S. ranges

Dealer

~$180–$200

Shop

~$125–$140

DIY

~$10–$25

DOT 3 or 4 — match the cap. Vacuum bleeders make this a one-person DIY.

Important maintenance

Keeps your vehicle running smoothly and efficiently

Engine Air Filter

Every 30,000 mi

Replace the engine air filter every 30,000 miles. EcoBoost turbocharged engines are sensitive to airflow restriction — don't extend.

Estimated cost — typical U.S. ranges

Dealer

~$60–$95

Shop

~$45–$70

DIY

~$15–$40

5-minute job on most cars; the airbox lid usually has clips, no tools needed.

Automatic Transmission Fluid

Every 150,000 mi

Ford 6R80, 10R80, and 8F transmissions use Mercon LV fluid rated 150,000 miles under normal service. Severe service (towing, plowing) drops this to 60,000 miles.

Estimated cost — typical U.S. ranges

Dealer

~$330–$500

Shop

~$235–$355

DIY

~$60–$180

Some sealed transmissions have no dipstick — fill is precise and best left to a shop. Many drivers can still DIY drain-and-fill.

Transfer Case Fluid (4WD models)

Every 60,000 mi

On 4x4 models, replace transfer case fluid every 60,000 miles. Use Motorcraft XL-12 — do not substitute generic transfer case fluid.

Estimated cost — typical U.S. ranges

Dealer

~$105–$140

Shop

~$75–$100

DIY

~$15–$40

AWD/4WD vehicles only. Easy drain-and-fill on most platforms.

Rear Differential Fluid

Every 100,000 mi

F-Series and Expedition: replace rear axle fluid every 100,000 miles, or 50,000 miles if towing. Limited-slip rear ends require friction-modifier additive.

Estimated cost — typical U.S. ranges

Dealer

~$150–$195

Shop

~$105–$135

DIY

~$20–$50

Drain plug + fill plug — straightforward DIY. AWD vehicles have two; budget for both.

Spark Plugs

Every 100,000 mi

Iridium spark plugs on Coyote 5.0L, EcoBoost 2.7L/3.5L, and 2.3L are rated 100,000 miles. EcoBoost engines: never exceed the interval — gap erosion causes coil failure.

Estimated cost — typical U.S. ranges

Dealer

~$285–$390

Shop

~$200–$275

DIY

~$25–$100

Iridium plugs cost more but last 100k+ miles. V6/V8 access varies wildly — some are tough.

Engine Coolant

Every 50,000 mi

Motorcraft Orange (Dex-Cool compatible) coolant: first change at 100,000 miles, then every 50,000. Older trucks with Yellow Motorcraft coolant: 50,000 miles throughout.

Estimated cost — typical U.S. ranges

Dealer

~$285–$330

Shop

~$200–$235

DIY

~$25–$60

Use the manufacturer-specified coolant — wrong color/chemistry can damage the cooling system.

Recommended maintenance

Extends the life of your vehicle and improves comfort

Cabin Air Filter

Every 20,000 mi

Replace the cabin air filter every 20,000 miles. On F-150, located behind the glove box; on Escape and Explorer, accessed from the passenger footwell.

Estimated cost — typical U.S. ranges

Dealer

~$60–$95

Shop

~$45–$70

DIY

~$15–$40

Usually behind the glovebox. Shops charge labor for a 10-minute job — easy DIY win.

Fatal crash history & reported problems

Occupant deaths in fatal crashes (FARS)

236 crashes 1990–2024

How the 236 occupant deaths break down

143

driver deaths

89

passenger deaths

4

not recorded by seat

236

occupant deaths

Crash years covered: 1990–2024 This model year first appears in 2002 crashes. Older models have had more years on the road to appear in these crashes, so a higher count here does not by itself mean a vehicle is less safe.

FARS counts every occupant death in a fatal crash, whatever the cause — it does not mean the vehicle was at fault or defective. Counts are not adjusted for how many of each vehicle are on the road. How to read this number

FARS 2024 data is an annual report file. NHTSA revises these records when the final file is published, so this count can change.

Why we show driver deaths too

Every vehicle has exactly one driver seat, so driver deaths line up fairly when you compare one model to another. Occupant deaths include passengers, so a three row SUV can show a higher number than a two seat car simply because it carries more people.

Both figures are plain counts, not rates. A rate would need to know how many of each vehicle are on the road, and that registration data is not public, so we do not publish rates or scores of any kind.

IIHS publishes driver death rates using this same driver only idea, paired with a registered vehicle years denominator we do not have. Their rates and these counts answer different questions, so do not read either number here as a safety rating.

Owner-reported problem signals

Separate from the federal fatality data above: complaints owners filed with NHTSA about this year and model. These are reports of problems, unverified, and are counted here only as signals.

21

complaints mentioning a crash

73

complaints mentioning a fire

Reviewed known issues for this vehicle

Typical U.S. ranges. Actual quotes vary by shop, parts choice, and vehicle condition.

How we estimate: Dealer = OEM parts × 1.4 + labor × $165/hr. Shop = parts + labor × $115/hr. DIY = parts only.

This maintenance schedule for the 2002 Ford Expedition reflects Ford's published service intervals and the Intelligent Oil-Life Monitor system. Your actual service needs may vary based on driving conditions, climate, and vehicle usage. Always consult your owner's manual for model-specific recommendations.