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.

3.3

definitely annoying
Crashes / Fires:
0 / 0
Injuries / Deaths:
0 / 0
Average Mileage:
41,000 miles

About These NHTSA Complaints:

This data is from the NHTSA — the US gov't agency tasked with vehicle safety. Complaints are spread across multiple & redundant categories, & are not organized by problem.

So how do you find out what problems are occurring? For this NHTSA complaint data, the only way is to read through the comments below. Any duplicates or errors? It's not us.

2002 Ford Explorer exhaust system problems

exhaust system problem

Find something helpful? Spread the word.
Get notified about new defects, investigations, recalls & lawsuits for the 2002 Ford Explorer:

Unsubscribe any time. We don't sell/share your email.

2002 Ford Explorer Owner Comments

problem #10

Jan 022011

Explorer

  • 107,000 miles

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

The contact owns a 2002 Ford Explorer XLT(na). The contact stated that while driving approximately 65 mph, the vehicle stalled. The vehicle was towed to a local shop where the contact was informed that the catalytic converters failed. The manufacturer was contacted who stated that they were not able to help because the vehicle was out of warranty. The vehicle was repaired. The failure and current mileages were 107,000.

- West Covina, CA, USA

problem #9

Nov 162008

Explorer

  • 94,000 miles
Was hearing a banging noise in the hood, my husband found out that the spark plug blew out and stripped the head.

- Cochranville, PA, USA

problem #8

Nov 062008

Explorer

  • 125,000 miles
Intake manifold is made of burned two holes in itself due to plastic construction not able two withstand heat witch caused a cascading affect and catalytic converters also had to be replaced. This is the first time it happened. I had to replace the converters and the manifold to correct problem.

- Richmond, CA, USA

problem #7

Mar 152008

Explorer

  • 84,000 miles

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

Engine ticking at idle.

- Findlay, OH, USA

problem #6

Sep 302006

Explorer 4WD 6-cyl

  • Automatic transmission
  • miles
: the contact stated while driving 55 mph, a burning odor was smelled coming from the A/C vents in the rear of the vehicle. When the vehicle was stopped, the rear vent was hot to the touch and a burning odor was evident. The service dealer and manufacturer had not been notified. Updated 10/30/2006 -

- Lido Beach, NY, USA

problem #5

Dec 202001

Explorer 4WD

  • miles
The truck has a very strong rotten egg smell that come in the vehicle. Myself and other passengers have experienced nausea and headaches from the smell. It has been serviced several times to no prevail. The dealship says that the smell should go away after the truck has been driven for 10,000 miles. They have no solution.

- Fort Wayne, IN, USA

problem #4

May 072002

Explorer

  • Automatic transmission
  • miles

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

There is a strong sulphur smell coming from exhaust. It is very noticeable inside vehicle. Dealer has inspected vehicle, and said there was nothing they could do.

- Beverly Hills, FL, USA

problem #3

Oct 152001

Explorer

  • miles
After vehicle has warmed up after about 20 minutes of normal operation there is an odor that smells as if oil is burning. The best way to describe this odor is it as if oil was spilled on a hot manifold. The odor can be smelled in the cabin of the vehicle through the heating/ac vents in the vehicle when operating. When the engine is turned off the odor is very predominent. Vehicle has been taken to dealer twice they state they cannot find any problem. My concern is that there may be a vehicle fire from this unknown source of what appears to be burning oil somewhere in the vehicle. Something was mentioned that on other Ford trucks the catalytic converters were being replaced, but not on this model.

- Sterling Heights, MI, USA

problem #2

Jan 242002

(reported on)

Explorer

  • miles
While driving short or long distances consumer has noticed a very strong chemical odor in passenger compartment. Odor has caused occupants of vehicle to become ill. Consumer has contacted dealer and manufacturer. Cause of problem has yet to be determined.

- Northville, MI, USA

problem #1

Apr 262001

Explorer

  • miles
When stopped at a light, there is a strong sulfur odor in the car causing occupants to have trouble breathing. Owner has developed breathing problem since purchasing the vehicle. Vehicle will hesitate without notice when pulling out into traffic.

- Winterville, NC, USA

Not what you are looking for?