Huge win for car owners! All TSBs to be made public. The Center for Auto Safety just made the NHTSA (US Government) make public the full text of all TSBs from now on. They are the same organization that has petitioned the NHTSA & filed lawsuits to protect car owners over exploding gas tanks & other major safety issues. Whenever you drive in your car, you are safer thanks in part to a lot of work over the years by this small but very effective consumer advocacy group.

Please take a moment & say thank you by donating $5 or whatever you can to the Center for Auto Safety.

CarComplaints.com Notes: The 2002 Ford Explorer is hands-down our worst vehicle on record. "Avoid like the plague" is putting it lightly.

The 2002-2005 Explorer has a very well-established record of expensive transmission failure at under 100k miles. The Explorer has an enclosed transmission which is typically replaced with a rebuilt transmission at a cost of almost $3,000.

Another common problem for the 2002-2003 Explorer is wheel bearing failure at around 90k miles, with a typical repair bill of $500 to $1000 depending on how many wheel bearings failed.

Adding insult to injury, the 2002-2005 Explorer also has a massive problem with the rear panel cracking. While it's a minor annoyance compared to transmission failure, ironically the crack usually goes right through the Ford logo.

7.3

pretty bad
Typical Repair Cost:
$287.00
Average Mileage:
96,116 miles
Total Complaints:
15 complaints

Most Common Solutions:

  1. not sure (7 reports)
  2. replaced rear a/c flapper (mixer) door (2 reports)
  3. replaced the rear ac mixer (flapper) door (2 reports)
  4. replaced the rear blower (2 reports)
  5. replaced the rear blend door actuator motor (1 reports)
  6. unplugged the rear a/c roof vent/low vent selector motor (1 reports)
2002 Ford Explorer AC / heater problems

AC / heater problem

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2002 Ford Explorer Owner Comments

problem #15

Dec 002000

Explorer XLT 4.0L V6

  • Automatic transmission
  • 0 miles

A D V E R T I S E M E N T S

I'm listing complaint under rear clicking noise but had identical problem with from Heat/AC unit. It's not as simple as merely replacing the door, you have to fix the electrical/vacuum issue that is causing the door to "click" as it constantly clicks as it tries to open/close. We had to replace the entire part. The cost for replacing both the front, then the rear was about $500 for each unit. We fixed the front and let our passengers in the rear have a free set of foam ear plugs. Seriously, we did not repair the rear unit as I'm ready to sell or scrap this piece of crap vehicle.

See other numerous complaints under cracked body panel under rear window.

This model is an albatross.

- , Knoxville, TN, USA

problem #14

Feb 052013

Explorer XLS 4.0L

  • Automatic transmission
  • 155,000 miles

Clicking when the rear heat was adjusted so I had to buy a new actuator motor and tear into the back rear panel.

- , Edmond, OK, USA

problem #13

Sep 062012

Explorer XLT 4.0L V6

  • Automatic transmission
  • 166,240 miles

Constant clicking noise when rear ac is on. I noticed the other day when i would move the temp to the middle setting the noise would stop.

Update from Sep 17, 2012: Problem seems to be getting worse..Clicks now even when A/C is off..

- , Pine Hill, NJ, USA

problem #12

May 182010

Explorer XLT 4.0L V6

  • Automatic transmission
  • 110,000 miles

A D V E R T I S E M E N T S

Bought an after-market at O'Reilly and installed it myself with help from the internet. Lasted a little over a year.

- , Dallas, TX, USA

problem #11

Mar 012011

Explorer XLT V6

  • Automatic transmission
  • 71,500 miles

The blower was clicking constantly regardless if the fan was on or not. The fix was necessary for comfort in the 3rd row

- , sugar grove, IL, USA

problem #10

Nov 242010

Explorer

  • Automatic transmission
  • 200,000 miles

Great car but A/C sucks. Rear unit starts a clicking sound when turned on.

- , Brandon, FL, USA

problem #9

Jun 012010

Explorer XLT 4.8L

  • Automatic transmission
  • 120,000 miles

A D V E R T I S E M E N T S

THE HEATER CORE WENT OUT NOW IT COST 1500 TO TAKE THE WHOLE DASH OUT OF THE VEHICLE AND INSPECT THE VEHICLE.

- , Vallejo, CA, USA

problem #8

Jul 052008

Explorer Limited 4.0L

  • Automatic transmission
  • 99,000 miles

I was a Realtor at the time, and I needed rear air conditioning for my clients. One day there began an awful clicking sound, so loud and constant you could not expect people to ride in my car. I had to fix it for the comfort of my clients. $400 later, wow....THANKS FORD!

- , Summerville, SC, USA

problem #7

Nov 042008

Explorer XLT 4.0L V8

  • Automatic transmission
  • 12,000 miles

i bought a piece of sh*t car. from the heater in the rear to the transmission, to the hubbs and bearings, the recall on fire problems, to axle defect i heard about from my mechanic, what else oh ya my shifter was going from drive to neutral on its own that was the only thing they fix because i cought that just before the warranty ran out

- , Stroudsburg, PA, USA

problem #6

Mar 292009

Explorer V6

  • Automatic transmission
  • 100,000 miles

I will always support the American auto industry. HOWEVER I believe issues that do not result from poor driving habits or lack of maintenance were covered under warranty longer. There is no reason this many people should be experiencing the clicking noise, half the car blowing hot, and the other half of the car blowing cold...then turning to no heat or airconditioning - this is not a consumer caused issue it is a quality issue. My mother worked for Ford's for over 36 years as a single mom supporting two kids on her own. I know she worked hard, and I know she did an honest days work. Unfortunately not everyone is as honest and dedicated because someone is definitely not being honest about the problem affecting your customers!

- , Roseville, MI, USA

problem #5

Jul 102008

Explorer Eddie Bauer 4.0L V6

  • Automatic transmission
  • 120,000 miles

A D V E R T I S E M E N T S

Anytime the rear AC is turned on, the clicking sound appears. Makes the rear AC basically useless.

- , Wichita, KS, USA

problem #4

May 152005

Explorer XLT 4.0L V6

  • Automatic transmission
  • 35,000 miles

Problem occurred again at 75,000 miles, replaced the rear ac mixer (flapper) door again.

- , Chandler, AZ, USA

problem #3

May 152007

Explorer XLT 4.0L V6

  • Automatic transmission
  • 75,000 miles

Rear ac mixer (flapper) door failed at 35,000 miles and again at 75,000 miles

- , Chandler, AZ, USA

problem #2

Aug 162008

Explorer Eddie Bauer

  • Automatic transmission
  • 100,000 miles

This is the second time I've had the rear blend door motor go out. The first time I took to the dealer and had replaced under warranty. This time the warranty is up and from info on the web I'm going to attempt the repair myself. Shouldn't be too tough; $50 part and a couple hours of labor. Still a pain for a recurrent problem.

- , Friendswood, TX, USA

problem #1

May 012008

Explorer Eddie Bauer 4.0L V6

  • Automatic transmission
  • 78,000 miles

Extremely loud clicking sound coming from the left rear of the truck everytime I turned on the rear A/C. Ford said my warranty was up and it wasn't covered. I took off the back left panel and unplugged the selector switch motor for the rear air. I still have rear air, but only from the headliner and center counsel. Just not from the left and right air ducts beside the second row seats.

- , San Antonio, TX, USA

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