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. 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.


really awful
Typical Repair Cost:
No data
Average Mileage:
92,772 miles
Total Complaints:
2 complaints

Most Common Solutions:

  1. not sure (2 reports)
2002 Ford Explorer fuel system problems

fuel system problem

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2002 Ford Explorer Owner Comments

problem #2

Mar 022012

Explorer XLS V6

  • Automatic transmission
  • 105,543 miles


It is a pain in the ass to try to fill up!!! The pump clicks off every 2 sec. it takes forever to fill up. The service station workers have come out and asks me to move the nozzle in or out and it doesn't help. It is embarrassing!!!!

- , New Philadelphia, OH, USA

problem #1

Oct 202009

Explorer XL 4.0L V6

  • Automatic transmission
  • 80,000 miles

Recently I have been experiencing difficulty when fueling my 2002 Ford Explorer. I place the nozzle in the filler tube and begin fueling. I can get about 1 gallon in when the automatic nozzle shuts off. It sound like the gas is coming up the filler tube. I have to continue squeezing the fill nozzle at the pump about 50 times until I can get around 16 gallons into the tank. Takes about 15 minutes to completely fill the tank. I then stop, not sure if the tank is trully full. This happens all the time and is very annoying when trying to fill the gas tank. I have been told by a repairman that I will need a complete new gas tank to fix the problem. Approx. $450 dollars. I don't have that in pocket change right now.

- , Carmel, IN, USA

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