2002 Ford Explorer Recalls, Problems & Maintenance

The 2002 Ford Explorer has no open NHTSA recalls. Owners report 7 recurring issue clusters, led by “Rear liftgate window glass shattering and hinge failure.” 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 Explorer.

Reported to NHTSA

Rear liftgate window glass shattering and hinge failure

STRUCTURE

31 NHTSA complaints · 2015-02 → 2025-07

“WHILE PARKED IN MY DRIVEWAY THE BACK WINDOW (LIFT GATE WINDOW) WAS RAISED TO REMOVE THINGS FROM THE BACK OF THE VEHICLE AS SOON AS THE WINDOW WAS BEING CLOSED ABOUT HALFWAY DOWN IT EXPLODED AND SENT GLASS FLYING ALL AROUND OUTSIDE AND INSIDE THE VEHICLE. THE BOTTOM PIECE OF THE”
— Owner report, NHTSA ODI #10903796
“THE REAR LIFTGATE MOUNT BROKE OFF AND WINDOW FELL ON MY DAUGHTERS HEAD AND BENT THE OTHER MOUNT AND BROKE LEFT STRUT OFF. CAN'T LINE IT UP TO GET IT TO CLOSE AND LATCH SHUT. CAN'T DRIVE THE CAR OR LIFTGATE WILL FALL OFF. GOING TO GET SOME ROPE AND TRY TO TIE IT ON. IT WAS IN”
— Owner report, NHTSA ODI #10954043
“TL* THE CONTACT OWNS A 2002 FORD EXPLORER. THE CONTACT STATED THAT WHILE OPENING THE REAL LIFT GATE, THE REAR LIFT GATE GLASS WINDOW SUDDENLY SHATTERED. DURING THE INCIDENT, THE PERSON SUSTAINED A FACIAL LACERATION WHICH REQUIRED MEDICAL TREATMENT. THE CAUSE OF THE FAILURE WAS”
— Owner report, NHTSA ODI #11353727

Read all complaints on NHTSA →

Wheel bearing, hub, and suspension component failure

SUSPENSION

12 NHTSA complaints · 2015-04 → 2026-09

“I OWN A 2002 FORD EXPLORER, IT'S OUR DAILY DRIVER EVERYTHING WORKS EXCEPT THE HUBS, THIS TRUCK HAS NEVER BEEN WRECKED, AND WE FIND OURSELVES@ ABOUT EVERY 15,000 TO 20,000 MILES HAVING TO REPLACE THE WHEEL BEARINGS AND HUB ASSEMBLY'S , LAST NIGHT ON THE WAY HOME THE DRIVER SIDE”
— Owner report, NHTSA ODI #10885215
“TL* THE CONTACT OWNS A 2002 FORD EXPLORER. WHILE THE VEHICLE WAS AT A LOCAL DEALER FOR ROUTINE SERVICE, THE FRONT WHEEL BEARINGS AND HUB ASSEMBLIES WERE REPLACED. AFTER THE REPAIRS, THE CONTACT HEARD AN ABNORMAL NOISE COMING FROM THE VEHICLE. THE VEHICLE WAS TAKEN BACK TO THE”
— Owner report, NHTSA ODI #10875201
“BOTH REAR COIL SPRINGS BROKE. REPLACED FRONT AND REAR WHEEL BEARINGS REPLACED BALL JOINTS REPLACED TRANSMISSION HAS NOW FAILED AND IS NOW UNDEPENDABLE. MAY FAIL WITH OUT WARNING NO ACCIDENTS, ANY OF THE ABOVE COULD HAVE RESULTED IN AN ACCIDENT FORD IS AWARE OF ALL OF THE”
— Owner report, NHTSA ODI #10816783

Read all complaints on NHTSA →

Automatic transmission failure and hard shifting

POWER TRAIN

43 NHTSA complaints · 2014-12 → 2022-06

“TL* THE CONTACT OWNS A 2002 FORD EXPLORER. THE CONTACT STATED WHILE DRIVING AT VARIOUS SPEEDS, THE TRANSMISSION EXPERIENCED HARD SHIFTING WITH A CLUNKING NOISE PRESENT COMING FROM THE TRANSMISSION. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC WHO DIAGNOSED THAT THE”
— Owner report, NHTSA ODI #11397933
“TRANSMISSION, JERKED, STALLED AND HAD DIFFICULTY SHIFTING WHILE DRIVING ON FREEWAY/ HIGHWAY. ADDITIONALLY, THE O/D (OVERDRIVE) LIGHT CAME ON AND CONTINUALLY FLASHED PRIOR TO THE TRANSMISSION STARTING TO NOISILY GRIND WITH A BURNING SMELL. I'VE HAD 5 PROFESSIONAL DIAGNOSIS ALL”
— Owner report, NHTSA ODI #10907332
“THE TRANSMISSION OF OUR 2002 EXPLORER STARTED SLIPPING, JUMPING, JERKING' SURGING, REFUSING TO SHIFT, SHIFTING SLOWLY AND OTHER ASSOCIATED THINGS APPROXIMATELY 4 YEARS AGO. THERE IS NO CONSISTENCY, IT DOES IT WHENEVER IT WANTS, REGARDLESS OF THE SPEED, OUTSIDE TEMPERATURE,”
— Owner report, NHTSA ODI #10763399

Read all complaints on NHTSA →

Gear shift lever fracture at steering column

STEERING

14 NHTSA complaints · 2015-01 → 2018-07

“THE SHIFT LEVER LITERALLY SNAPPED OFF AT THE STEERING COLUMN WHILE PUTTING THE CAR INTO DRIVE. CAR COULDN'T BE SHIFTED INTO PARK, STILL RUNNING. KEYS COULDN'T EVEN BE REMOVED TO TURN THE CAR OFF. VERY DANGEROUS. SEEMS LIKE A FAIRLY COMMON PROBLEM AMONG 2002 FORD EXPLORER OWNERS”
— Owner report, NHTSA ODI #11046319
“THE GEAR SHIFT JUST BROKE OFF WHILE I WAS PUTTING THE CAR IN REVERSE THIS IS EXTREMELY DANGEROUS THE CAR HAD TO BE TOWED BUT WE HAD TO FIGURE OUT HOW TO SHUT OFF THE CAR, SINCE IT WOULD NOT SHUT OFF WHILE IN REVERSE. I GOT ANOTHER WHOLE STEERING COLUMN PUT IN AND WITHIN LESS”
— Owner report, NHTSA ODI #10908824
“I WAS PULLING OUT OF A PARKING SPACE AND I NO MORE THAN PULLED THE GEAR SHIFT LEVER BACK AND IT BROKE OFF. I COULD NOT SHIFT AT ALL. THE KEYS GOT STUCK IN THE IGNITION, TOO. I HAD TO LEAVE MY CAR THERE OVER NIGHT UNTIL THE FOLLOWING MORNING WHEN THE TOW COMPANY CAME. I ALSO”
— Owner report, NHTSA ODI #10810804

Read all complaints on NHTSA →

Airbags deploying without impact

AIR BAGS

9 NHTSA complaints · 2015-06 → 2026-07

“TL* THE CONTACT OWNS A 2002 FORD EXPLORER. THE CONTACT STATED THAT WHILE THE DRIVER WAS DRIVING AT 40 MPH, BOTH DRIVER AND PASSENGER SIDE AIR BAGS DEPLOYED WITHOUT IMPACT. AS A RESULT, THE VEHICLE FAILED TO START. THE DRIVER SUSTAINED LEFT ARM INJURIES AND THE PASSENGER”
— Owner report, NHTSA ODI #10916807
“AROUND 1015AM ON SATURDAY JULY 25, 2015, I WAS IN THE PROCESS OF ATTACHING MY BOAT TRAILER TO THE HITCH. AFTER OPENING MY DRIVERS DOOR SEVERAL TIMES, CHECKING ON THE HITCH POSITION, I PUT MY VEHICLE IN PARK, GOT OUT, SHUT THE DOOR, AND THEN HEARD A LOUD SOUND THAT SOUNDED LIKE A”
— Owner report, NHTSA ODI #10743483
“ON MAY 6, 2016 I WAS DRIVING ON INTERSTATE 5 BETWEEN 55-60 MPH IN THE MIDDLE LANE OF HEAVY TRAFFIC WHEN SUDDENLY THERE WAS AN EXPLOSION INSIDE MY CAR. THE RIGHT/LEFT SIDE AIRBAGS DEPLOYED WITHOUT ANY WARNING. I WAS ABLE TO GET TO THE SHOULDER AND CALL AAA. I WAS TOWED TO THE”
— Owner report, NHTSA ODI #10871375

Read all complaints on NHTSA →

Airbags failing to deploy in a crash

AIR BAGS

9 NHTSA complaints · 2015-02 → 2019-08

“TL* THE CONTACT COMPLAINED ABOUT A FATAL CRASH WHICH INVOLVED A 2002 FORD EXPLORER AND STATED THAT THE AIR BAGS FAILED TO DEPLOY. THE CONTACT STATED THAT THE VICTIM'S VEHICLE WAS FOUND THREE HOURS AFTER THE CRASH AND THE VEHICLE HAD FLIPPED UPSIDE DOWN. THE VICTIM WAS FOUND,”
— Owner report, NHTSA ODI #11221054
“TL* THE CONTACT OWNS A 2002 FORD EXPLORER. WHILE DRIVING 24 MPH, A VEHICLE ON THE OPPOSITE SIDE OF THE ROAD CRASHED INTO THE DRIVER'S DOOR OF THE CONTACT'S VEHICLE. THE AIR BAGS DID NOT DEPLOY. THE CONTACT SUSTAINED LOWER AND UPPER BACK INJURIES, WHICH REQUIRED MEDICAL”
— Owner report, NHTSA ODI #11169996
“REAR ENDED SEMI THAT SUDDENLY STOPPED IN FRONT OF ME. DRIVER'S AIR BAG DID NOT DEPLOY BUT PASSENGER AIR BAG DID . NO PASSENGER IN CAR. BASICALLY DRIVER AIR BAG DID NOT DEPLOY WHEN IT SHOULD. FORD SHOULD PAY! IS THERE ANY CLASS ACTION LAW SUIT FOR THIS? FIRST ACCIDENT WITH THE”
— Owner report, NHTSA ODI #10692763

Read all complaints on NHTSA →

Unintended acceleration and cruise control malfunction

VEHICLE SPEED CONTROL

14 NHTSA complaints · 2015-01 → 2023-07

“VEHICLE ACCELERATED TO MAXIMUM RPM'S ON A CITY STREET AND WOULD NOT STOP, EVEN AFTER BRAKE APPLIED. TRIED DOWNSHIFTING, WOULD NOT WORK. RAN THROUGH A RED LIGHT, FORTUNATELY NO ONE WAS IN FRONT OF US OR GOING THE OTHER DIRECTION. HAD TO PUT IT INTO NEUTRAL AND TURN THE KEY OFF TO”
— Owner report, NHTSA ODI #11098661
“TL* THE CONTACT OWNS A 2002 FORD EXPLORER. WHILE DRIVING APPROXIMATELY 50 MPH WITH THE CRUISE CONTROL ACTIVATED, THE VEHICLE WOULD NOT DISENGAGE FROM THE CRUISE CONTROL WHILE DEPRESSING THE BRAKE PEDAL. THE VEHICLE SPONTANEOUSLY ACCELERATED TO 70 MPH, THE EMERGENCY BRAKE DID NOT”
— Owner report, NHTSA ODI #10874221
“TL* THE CONTACT OWNS A 2002 FORD EXPLORER. WHILE PULLING INTO A PARKING SPACE AT A VERY LOW RATE OF SPEED, THE VEHICLE SUDDENLY EXPERIENCED UNINTENDED ACCELERATION AND SURGED FORWARD BEFORE CRASHING INTO A BUILDING. THE DRIVER SUSTAINED INJURIES TO THE LEFT ARM, HIP, HEAD, AND”
— Owner report, NHTSA ODI #10808369

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)

1,195 crashes 1990–2024

How the 1,195 occupant deaths break down

760

driver deaths

432

passenger deaths

3

not recorded by seat

1,195

occupant deaths

Crash years covered: 1990–2024 This model year first appears in 2001 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.

163

complaints mentioning a crash

71

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 Explorer 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.