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2002 Ford F-150 Recalls, Problems & Maintenance

The 2002 Ford F-150 has no open NHTSA recalls. Owners report 6 recurring issue clusters, led by “Fuel tank strap corrosion and tank drop.” 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 F-150.

Reported to NHTSA

Fuel tank strap corrosion and tank drop

FUEL/PROPULSION SYSTEM

12 NHTSA complaints · 2013-04 → 2024-07

“FUEL TANK STRAPS BROKE WHILE DRIVING STRAIGHT ON CITY STREETS PUTTING A HOLE IN THE TANK AND SPILLING OUT FUEL WHILE DRIVING. FORD HAD A RECALL ON THE SAME YEAR & MODEL OF VEHICLE, HOWEVER OURS WAS NOT RECALLED”
— Owner report, NHTSA ODI #10966223
“TL* THE CONTACT OWNS A 2002 FORD F-150. WHILE WALKING PAST THE VEHICLE, THE CONTACT NOTICED A STRONG ODOR OF FUEL. THE CONTACT DISCOVERED THAT THE FUEL TANK STRAPS WERE CORRODED AND CREATED A HOLE IN THE FUEL TANK, WHICH CAUSED FUEL TO LEAK FROM THE TANK”
— Owner report, NHTSA ODI #10855534
“THE VEHICLE WAS TRAVELING AT HIGHWAY SPEEDS WHEN THE GAS TANK FELL OUT. THE TANK STRAPS HAD RUSTED THROUGH DROPPING THE TANK. THE TANK CUT OPEN FROM SKIDDING ON AN INTERSTATE EXPRESSWAY RELEASING 23 GALLONS OF FUEL”
— Owner report, NHTSA ODI #10505634

Read all complaints on NHTSA →

Seat belt buckle unlatching while driving

SEAT BELTS

27 NHTSA complaints · 2013-03 → 2025-05

“WHILE DRIVING (IN MOTION), THE DRIVER'S SIDE SEAT BELT RANDOMLY DISCONNECTS. THERE IS NO WARNING OR SPECIFIC CONDITION THAT CAUSES THIS TO HAPPEN. OBVIOUSLY THIS CREATES A VERY DANGEROUS CONDITION”
— Owner report, NHTSA ODI #11097924
“DRIVERS SIDE SEAT BELT BUCKLE RELEASES RANDOMLY WITHOUT WARNING. AFTER BUCKLING / LATCHING SEATBELT DRIVER CAN PULL HARD ON BELT AND WON'T RELEASE, THEN AFTER DRIVING FOR A RANDOM AMOUNT OF TIME (30 SECONDS TO 3 HOURS) THE SEAT BELT WILL RELEASE WITHOUT WARNING”
— Owner report, NHTSA ODI #10903042
“I ALWAYS LATCH MY SEAT BELT. I HAVE BEEN DOING THIS SINCE 1983. I NEVER DRIVE WITHOUT MY SEAT BELT LATCHED. FOR A COUPLE OF YEARS MY DRIVERS SIDE SEAT BELT HAS BEEN MYSTERIOUSLY BECOMING UNLATCHED WHILE DRIVING DOWN THE ROAD”
— Owner report, NHTSA ODI #10649319

Read all complaints on NHTSA →

Spark plug ejection from cylinder head

ENGINE

52 NHTSA complaints · 2013-04 → 2024-05

“LOUD NOISE SPARK PLUG BLOW OUT AND CAUSED SPARKS WHEN OPENED THE HOOD. AFRAID IT WAS GOING TO CATCH FIRE SO HAD IT TOWED. ACCORDING TO MECHANIC IS A FORD ISSUE ONGOING BUT NO RECALL NOR WILL FORD PAY FOR IT. 91120 MILES ON TRUCK WELL MAINTAINED”
— Owner report, NHTSA ODI #10852913
“SPARK PLUG BLEW OUT OF #2 CYLINDER TAKING THREADS WITH IT REQUIRED SPECIAL INSERT FOR NEW PLUG COST $400 POSSIBLE FIRE HAZARD AS FUEL BLOWS INTO ENGINE COMPARTMENT AND SPARK PLUG IS STILL FIRING”
— Owner report, NHTSA ODI #10649448
“2002 F150 HARLEY DAVIDSON EDITION WITH ONLY 75,000 MILES BLEW A SPARK PLUG OUT OF THE HEAD. FORD ADMITS NO CULPABILITY EVEN THOUGH THEY HAVE TSB'S”
— Owner report, NHTSA ODI #10655218

Read all complaints on NHTSA →

Accelerator and cruise control failing to disengage

VEHICLE SPEED CONTROL

20 NHTSA complaints · 2013-08 → 2026-04

“The contact owns a 2002 Ford F-150. The contact stated that while driving approximately 45 MPH and attempting to pass a slower vehicle, the vehicle experienced unintended acceleration”
— Owner report, NHTSA ODI #11539704
“TL* THE CONTACT OWNS A 2002 FORD F-150. WHILE DRIVING 55 MPH, THE CRUISE CONTROL FAILED TO OPERATE AND THE CROSS CONTROL WENT INTO A LOCKED POSITION. THE CONTACT ATTEMPTED TO BRAKE, BUT THE VEHICLE WOULD NOT STOP”
— Owner report, NHTSA ODI #11229579
“WHILE DRIVING ON THE HIGHWAY, I PUSHED THE ON BUTTON FOR THE CRUISE CONTROL AND PUSHED THE SET/EXCEL BUTTON AT 70 MPH. AFTER A MINUTE OR SO I LOOKED DOWN AND WAS GOING 75 AND ACCELERATING. I TAPPED THE BREAK WHICH HAD NO EFFECT”
— Owner report, NHTSA ODI #10626514

Read all complaints on NHTSA →

Speed control deactivation switch fire

VEHICLE SPEED CONTROL

12 NHTSA complaints · 2013-04 → 2019-04

“THE RECALL IE AN INLINE FUSE ON SPEED CONTROL DEACTIVATION SWITCH DID NOT WORK IT JUST CAUGHT ON FIRE AND RUINED MY MASTER CYLINDER AND BRAKE SYSTEM.IT WONT HOLD BRAKE FLUID NOW BECAUSE THE SWITCH MELTED INTO IT.FORD SAYS OH WELL RECALLS BEEN DONE”
— Owner report, NHTSA ODI #11076795
“ON MARCH 22, 2014, THE TRUCK WAS PARKED IN A LOCAL PARKING LOT, THE IGNITION KEY WAS REMOVED AND THE TRUCK WAS LOCKED. THE DRIVER RETURNED TO THE TRUCK TO FIND THAT WHILE IT WAS PARKED, A FIRE HAD BEGUN IN THE ENGINE COMPARTMENT OF THE TRUCK”
— Owner report, NHTSA ODI #10626614
“TL* THE CONTACT OWNS A 2002 FORD F-150. THE CONTACT STATED THAT WHILE THE VEHICLE WAS UNOCCUPIED, IT IGNITED INTO FLAMES. THE FIRE DEPARTMENT EXTINGUISHED THE FIRE. THE VEHICLE WAS COMPLETELY DESTROYED. PRIOR TO THE FAILURE, THERE WAS A BRAKE FLUID LEAKAGE”
— Owner report, NHTSA ODI #10507127

Read all complaints on NHTSA →

Frame and bed rust-through

STRUCTURE

7 NHTSA complaints · 2013-05 → 2018-01

“FRAME HAS RUSTED TO THE EXTENT THAT THE BED HAS DROPPED AND IS ABOUT TO FALL OFF. WHEN I WAS REPLACING THE FUEL TANK, WHICH HAD RUSTED THROUGH, I DISCOVERED THAT THE ENTIRE FRAME HAS HOLES AND CRACKS FROM RUST”
— Owner report, NHTSA ODI #11065950
“MY TRUCK FRAME HAS RUSTED THROUGH JUST BEHIND THE RIGHT REAR WHEEL! THIS IS A 2002 FORD F150 SUPERCAB THAT HAS ONLY 75500 MILES ON IT. THE FRAME BROKE JUST AFTER I LEFT THE INTERSTATE AND DROVE TO MY SON'S HOUSE”
— Owner report, NHTSA ODI #11031617
“I HAVE A 2002 F 150 AND THE BED SUPPORT RAILS AND BED FLOOR ARE COMPLETELY RUSTED AWAY AS WELL AS THE FRAME RAILS. I AM AFRAID THE BED WILL COME OFF AT HIGHWAY SPEED AND CAUSE A WRECK”
— Owner report, NHTSA ODI #10545242

Read all complaints on NHTSA →

Issues on other model years

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)

1,790 crashes 1990–2024

How the 1,790 occupant deaths break down

1,376

driver deaths

407

passenger deaths

7

not recorded by seat

1,790

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.

58

complaints mentioning a crash

100

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 F-150 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.

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