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2002 Ford F-250 Recalls, Problems & Maintenance

The 2002 Ford F-250 has no open NHTSA recalls. Owners report 8 recurring issue clusters, led by “Tire tread separation and blowout.” 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-250.

Reported to NHTSA

Tire tread separation and blowout

TIRES

17 NHTSA complaints · 2007-08 → 2015-11

“TL* THE CONTACT OWNS A 2002 FORD F-250 SD EQUIPPED WITH GOODRICH LONG TRAIL T/A TIRES, SIZE: P265/75/R15 (NA). WHILE TOWING ANOTHER VEHICLE, THERE WAS AN ABNORMAL VIBRATION POPPING NOISE FROM THE REAR PASSENGER SIDE TIRE”
— Owner report, NHTSA ODI #10749333
“TL* THE CONTACT OWNS A 2002 FORD F250 WITH DEFINITY DAKOTA A/T TIRES, SIZE LT 265/75R16, DOT NUMBER: UTW8PA91108. THE CONTACT WAS DRIVING 70 MPH WHEN THE TREAD SEPARATED FROM THE FRONT PASSENGER TIRE”
— Owner report, NHTSA ODI #10441772
“AT ABOUT 80MILES INTO A 1,000 MILE TRIP AFTER A SLIGHT VIBRATION THE LEFT REAR TIRE (FIRESTONE STEELE TEX A/T 265 75 R 16 LR-E TIRE VIOLENTLY LOST ITS TREAD CAUSING FENDER AND LIGHT DAMAGE TO VEHICLE AND WRAPPING THE LOOSE TREAD AROUND VEHICLE REAR AXLE HOUSING”
— Owner report, NHTSA ODI #10216292

Read all complaints on NHTSA →

Brake fluid leak and brake pedal to floor

SERVICE BRAKES

6 NHTSA complaints · 2008-08 → 2013-07

“2002 FORD F250 SUPER DUTY RUSTED STEEL BRAKE LINE WHICH CAUSED THE BRAKES TO FAIL AT 25MPH IN NEIGHBORHOOD. I HAVE 84,507 MILES ON THE VEHICLE AND DO NOT LIVE IN A HARSH ENVIRONMENT”
— Owner report, NHTSA ODI #10510904
“TL* THE CONTACT OWNS A 2002 FORD F250 SD. THE CONTACT STATED THAT WHILE DRIVING APPROXIMATELY 30 MPH, THE BRAKE PEDAL TRAVELED RAPIDLY TO FLOOR UPON ENGAGING. THE VEHICLE FAILED TO SLOW DOWN UNTIL AFTER REPEATED PRESSURE WAS APPLIED TO THE BRAKE PEDAL”
— Owner report, NHTSA ODI #10512342
“TL* THE CONTACT OWNS A 2002 FORD F-250 SD. THE CONTACT STATED THAT WHILE STOPPED, HE DEPRESSED THE BRAKE PEDAL AND THE PEDAL ABNORMALLY TRAVELED TO THE FLOORBOARD ACCOMPANIED BY A LOUD POP. THE CONTACT INSPECTED THE VEHICLE AND NOTICED BRAKE FLUID LEAKING”
— Owner report, NHTSA ODI #10523291

Read all complaints on NHTSA →

Exhaust manifold stud and bolt breakage

ENGINE AND ENGINE COOLING

6 NHTSA complaints · 2008-03 → 2010-05

“TL*THE CONTACT OWNS A 2002 FORD F-250 SUPER DUTY. THE CONTACT STATED THAT THE BOLTS ON THE EXHAUST MANIFOLD SNAPPED OFF ON THREE DIFFERENT OCCASIONS. THE FAILURE WAS BROUGHT TO HIS ATTENTION BY HIS MECHANIC DURING ROUTINE MAINTENANCE”
— Owner report, NHTSA ODI #10241698
“TWO MANIFOLD BOLTS SNAPPED OFF EACH SIDE OF MY 02 6.8 LITER ENGINE. THE REST ARE HORRIBLY RUSTED. THE TRUCK HAS ONLY 37000 MI ON IT. THERE HAS BEEN A TSB CONCERNING THIS, BUT IT IS A HUGE AND COMMON PROBLEM”
— Owner report, NHTSA ODI #10224399
“I HAVE 2002 FORD F250 WITH A 5.4L TRITON ENGINE. THE EXHAUST MANIFOLD STUDS ARE RUSTING AND BREAKING OFF. I HAVE CONTACTED MY DEALER AND HAVE BEEN TOLD IT IS COMMON PROBLEM. THIS IS AN $850 TO $1000 FIX”
— Owner report, NHTSA ODI #10326157

Read all complaints on NHTSA →

Spark plug ejection from cylinder head

ENGINE AND ENGINE COOLING

53 NHTSA complaints · 2007-10 → 2022-03

“WHILE DRIVING AT 35 MPH, A SPARK PLUG WAS EJECTED FROM MY 2002 FORD F-250 5.4L V8 PICKUP TRUCK, CAUSING THE ENGINE TO STALL AND RESULTING IN A LOSS OF POWER FOR STEERING AND BRAKING”
— Owner report, NHTSA ODI #10279556
“MY FORD F-250 PICKUP BLEW A SPARK PLUG OUT OF THE HEAD. THE DEALER CHARGED ME 5,200.00 TO REPLACE THE HEAD. AT THE TIME OF THIS, THE TRUCK HAD ONLY 47,000 MILES ON IT. IT'S A 2002 FORD F-250 SUPER DUTY, 5.4 LTR ENGINE. *TR”
— Owner report, NHTSA ODI #10229273
“I OWN A 2002 F-250 SD TRUCK WHICH HAS THE 5.4 TRITON ENGINE IN IT. ON SEPTEMBER 28,2007, I WAS DRIVING DOWN THE ROAD AND THE # 3 SPARK PLUG EJECTED OUT OF THE CYLINDER HEAD IN WHICH STRIPPED ALL THE THREADS IN THE CYLINDER HEAD AND THE SPARK PLUG. I HAVE THE SPARK PLUG”
— Owner report, NHTSA ODI #10205040

Read all complaints on NHTSA →

Front seat belt unlatching while driving

SEAT BELTS

9 NHTSA complaints · 2010-10 → 2023-09

“MY DRIVERS SIDE SEATBELT HAS STARTED TO RANDOMLY UNBUCKLE. THERE ISN'T ANYTHING TOUCHING IT, PRESSING IT OR OTHERWISE INTERFERING WITH THE OPERATION. I FIRMLY PRESS THE BUCKLE INTO THE RECEPTACLE, PULL ON IT TO ENSURE IT IS LATCHED AND RANDOMLY IT WILL COME UNDONE”
— Owner report, NHTSA ODI #10924148
“ON SEVERAL OCCASIONS, WITHOUT ANY REASON, MY DRIVER-SIDE SEAT BELT HAS UNBUCKLED ITSELF WHILE THE VEHICLE IS MOVING (SPEED DOES NOT SEEM TO BE A FACTOR)”
— Owner report, NHTSA ODI #10562287
“TL* THE CONTACT OWNS A 2002 FORD F-250. THE CONTACT STATED WHILE DRIVING ATA ANY SPEED, THE DRIVER SIDE SEAT BELT DETACHED INDEPENDENTLY. THE CONTACT STATED THAT IF THE SEAT BELT WERE TO DETACH DURING A CRASH, IT COULD CAUSE LIFE THREATENING INJURIES”
— Owner report, NHTSA ODI #10362657

Read all complaints on NHTSA →

Camshaft position sensor failure and engine stall

ENGINE AND ENGINE COOLING

12 NHTSA complaints · 2007-07 → 2019-10

“CAM POSITION SENSOR FAILURE ON 2002 FORD F250 POWERSTROKE DIESEL. 70 MPH ON INTERSTATE. LOSS OF POWER BRAKES AND POWER STEERING.*AK”
— Owner report, NHTSA ODI #10196054
“CAM POSITION SENSOR FAILED ON 2002 FORD F250 W. 7.3L DIESEL. WHEN THIS SENSOR FAILS YOU LOOSE ALL POWER ASSIST AND THE STEERING BECOMES VERY HARD AND BREAKS ARE AT BEST NO EXISTENT. I WAS ABLE TO GET THE TRUCK TO THE SIDE OF THE HIGHWAY AND NOT BECOME A HAZARD”
— Owner report, NHTSA ODI #10202759
“MY 2002 FORD F-250 SUPERCAB DIESEL 7.3 STARTED WITH A MISS AS I DROVE DOWN THE HIGHWAY AND HAS GOTTEN PROGRESSIVELY WORSE. NOW IT DIES OUT AT LOW SPEEDS IN TOWN DRIVING LEAVING ME WITH NO BRAKES OR STEERING”
— Owner report, NHTSA ODI #10197023

Read all complaints on NHTSA →

Speed control deactivation switch fire and recall repair

VEHICLE SPEED CONTROL

9 NHTSA complaints · 2007-08 → 2016-06

“TL*THE CONTACT OWNS A 2002 FORD F-250 SD. APPROXIMATELY ONE HOUR AFTER THE VEHICLE WAS PARKED, IT BURST INTO FLAMES. THE VEHICLE WAS TOTALLY DESTROYED”
— Owner report, NHTSA ODI #10227038
“OUR BARN AND CONTENTS BURNED DOWN ON JUNE 14, 2010. FIRE INVESTIGATORS BELIEVE THE FIRE STARTED WITH OUR 2002 FORD F-250 TRUCK THAT WAS PARKED INSIDE. FOUND OUT AFTERWARDS THAT THERE IS A RECALL ON THE TRUCK FOR A SENSOR THAT CAN CAUSE FIRE EVEN WHILE VEHICLE IS NOT RUNNING. *TR”
— Owner report, NHTSA ODI #10344878
“I RECEIVED A RECALL IN OCTOBER 2009 FOR MY FORD F-250 PICK UP (FORD RECALL 05S28) I TOOK THE VEHICLE IN FOR REPAIR AND WAS TOLD THAT THE DEFECTIVE PART (SPEED CONTROL DEACTIVATION SWITCH) CAUSED BRAKE FLUID TO LEAK INTO THE WIRING HARNESS AND FUSE PANEL DAMAGING BOTH TO THE”
— Owner report, NHTSA ODI #10298459

Read all complaints on NHTSA →

Steering gear box failure and loose steering

STEERING

7 NHTSA complaints · 2008-12 → 2023-06

“[XXX] THE STEERING BOX CONSTANTLY FAILS. BECOMES LOOSE INSIDE. VEHICLE WANDERS SEVERELY. THIS IS AN ONGOING PROBLEM SINCE VEHICLE WAS PURCHASED NEW. I'M PUTTING IN THE 3RD STEERING GEAR. FORD MECHANICS WOULD NOT CONSIDER THE BOX BEING BAD. IT WAS MY FAULT”
— Owner report, NHTSA ODI #10583233
“DRIVING DOWN INTERSTATE, HEARD A LOUD POP. LOST ALL STEERING ABILITY. STEERING BOX SHAFT SHEARED IN HALF. I WAS PULLING A 18' EMPTY TRAILER AT THE TIME. TRUCK BLOCKED BOTH WESTBOUND LANES ALMOST CAUSING LIFE THREATENING INJURIES”
— Owner report, NHTSA ODI #10954995
“TL*THE CONTACT OWNS A 2002 FORD F-250 SUPER DUTY. WHILE MAKING A LEFT TURN AT APPROXIMATELY 10-15 MPH, THE STEERING MADE AN UNFAMILIAR NOISE. THE CONTACT WAS UNABLE TO MOVE OUT OF THE INTERSECTION. WITHIN SECONDS, PINS BEGAN TO LOOSEN FROM THE GEAR BOX”
— Owner report, NHTSA ODI #10251392

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.

24

complaints mentioning a crash

27

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-250 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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