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.

10.0

really awful
Crashes / Fires:
1 / 0
Injuries / Deaths:
0 / 0
Average Mileage:
76,982 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 suspension problems

suspension problem

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2002 Ford Explorer Owner Comments (Page 3 of 10)

« Read the previous 20 complaints

problem #152

Nov 142009

Explorer

  • 93,346 miles

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

2002 Ford Explorer rear springs broke, punctured the tire.

- Strongsville, OH, USA

problem #151

Nov 112009

Explorer

  • 63,164 miles
Both rear coil springs rusted through and broke on 2002 Explorer. This was noticed during inspection while having the oil changed. It appears to be bad steel as there have been many reports of this on the internet. Ford should recall and pay for anyone who has already had to have these replaced. My take on this is it needs immediate attn.(in the form of a recall from Ford) to save lives.

- Huntley, IL, USA

problem #150

Nov 112009

Explorer

  • 86,000 miles
2002 Ford Explorer XLT rear coil springs. I have been in contact with many Explorer owners and they report that their rear coil springs are breaking and cracking prematurely! as of now, no recall has been issued for this problem and as I checked under the rear end of my Explorer today, both rear coils are broken and will need replacement. As I understand, this problem does not only exist in 2002 models, but others also.

- Riverside, RI, USA

problem #149

Oct 292009

Explorer

  • miles

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

Upon inspecting our 2002 Ford Explorer for state inspection, I discovered the right rear coil spring to be broken. This is one of two broken on this vehicle to date, the first was the left rear discovered by the local Ford dealer when in for a routine check, they replaced that spring, I replaced the right side & still have the pieces (3 to be exact) in my possession. We have also had all four axle bearings replaced. One of which became so hot, the left side rear hub cap melted & fell off the wheel. All four bearings were replaced by the dealer. None of the bearings or hub cap were under warranty so we were stuck with those & the rr spring expense. Knowing the type of part failures on our Explorer it brings up a more crucial question of, could any of them have resulted in serious consequences. Rollover, swerving off of the road to possibly hit something or someone, etc. What could have happened if both rear coil springs broke around the same time? I've always enjoyed Ford products, repaired many, hope they will take this and apply it to tougher test standards. Vehicles' current mileage is over 120,000 I understand other Ford models have had other coil spring concerns also, such as a notice we received when we owned our '95 Windstar.

- Mill Hall, PA, USA

problem #148

Jul 012007

Explorer 8-cyl

  • 60,000 miles
2002 Explorer first rear end went and was replace only to find its gone again after 20,000 miles, then 4.6 V8 engine has a knock in it, Ford is aware of it but wont replace or fix it, now both rear springs are broke which Ford also knows and wont replace.

- Attleboro, MA, USA

problem #147

Oct 022009

Explorer

  • 118,524 miles
2002 Ford Explorer XLT. This SUV has a third seat, that's seldom used. Has a towing package that's been rarely used. Rear coil springs that tell me none of these extra options can be used. Without endangering everybody in the car, as well as everybody on the road. This car was driven daily, to and from work, and seldom used on the weekends. Parked on pavement, not gravel, or grass, and never off road. Why are they breaking" does the general public have to be warned to avoid driving past one of these SUV's because they may randomly veer off the road with a tire blowout" this is typical of Ford to send out recalls on the hatch, but not the much more serious (life safety) problem with it's rear coil springs.

- Linwood, MA, USA

problem #146

Sep 092009

Explorer

  • 28,000 miles

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

I own a 2002 Ford Explorer. While having my tires rotated the mechanic told me that my rear drivers side coil spring was broken. I am waiting for the dealer to order new springs as it appears both need to be changed. I was made aware of this on 9-9-09. So I don't know when it broke. I did not hear any noise or notice any difference in handling.

- Broad Channel, NY, USA

problem #145

Aug 142009

Explorer

  • 85,000 miles
I took my car in for a simple oil change and inspection and they noticed 2 rear coil springs broken and bad rear right wheel bearing. I feel this is a major repair/recall Ford Motor Company should take care of before someone seriously gets injured or dies. I drive this vehicle to and from work locally with 2 small children under the age of 6. I'm glad we didn't get into a major accident with this happening.

- Easton, PA, USA

problem #144

Aug 122009

Explorer

  • 60,000 miles
In May 2005, the car would not go into reverse. The O/D light had been going on and off for a number of days. Transmission has to be replaced at a cost of $4500. Car had approximately 60000 miles. In January of 2008, the engine had to be replaced due to because the timing belt went at a cost of $3000. Car had 75000 miles. In August 2009, both rear spring were discovered to be broken when the car was taken in for a whining in the rear, which was the rear axle bearing. The car had 94000 miles, cost of repair was $1200.

- Bethel, CT, USA

problem #143

Aug 042009

Explorer

  • 79,000 miles
After hearing several different noises coming from the Explorer, I took it in to have it checked out. I was told that the front struts were broken and needed replaced. I paid to have those replaced. After leaving, I continued to hear a second noise. I took the vehicle back to have it checked out again. I was told that they couldn't find any problem. After another week I didn't hear the noise anymore. I then started having problems with a chugging occurring in the engine. While having this serviced, I was told that the rear springs were broken and the struts also need replaced. The first estimate for the rear springs and struts was $780! so far on the 2002 Explorer I have had to have the transmission rebuilt (50K miles), od sensor replaced (45K miles), ABS sensor replaced (45K miles), rear control arm replaced (75K miles), front struts (78K miles), and rear latch replaced (recall). The emergency brake (75K miles) also needed replaced. When the control arm was replaced, the emergency brake crumbled apart. I was told by the dealership that I am luckily the broken spring did not pierce the tire and cause a blowout. The springs/struts and the transmission are common problems and should be recalled. Between paying out of pocket and the issues covered by an after market warranty, over $5000 have been spent on a vehicle 7 years old with only 79000 miles. This vehicle has never towed anything or been driven off road.

- Cincinnati, OH, USA

problem #142

Jul 262009

Explorer

  • 65,000 miles

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

I was changing the rear brakes on my mothers 2002 Ford Explorer and found that the left rear coil spring was broken in 2 places and cracked quite some distance through the center of the spring. I looked online to see if this is a common problem and it turns out it is a huge problem. The first link I clicked on lead me to a forum with 92 threads were people have had broken springs on their 2002 Explorer. This is clearly a widespread issue. I do have the old spring, but am missing one part because it must have fallen out while driving.

- East Greenbush, NY, USA

problem #141

Jul 212009

Explorer

  • 51,109 miles
I took my car to have the tires replaced. When the mechanic put the car on the lift he informed me that both of my rear springs were crumbling. One of the springs was broken in 3 places, the other was broken in two places. The mechanic claims in his 30 years of experience he has never seen a broken spring at 51,000 miles, when the vehicle is only used as a family car and had not been a result of an accident. He said how lucky I was that the spring did not come apart killing myself and my family on the highway. We contacted Ford, hoping that they had recalled this fault after we saw hundreds of complaints about the same problem on the internet. Ford said there was no recall and we were responsible for repairs. This repair is going to cost over $500. I guess it is a small price when my family could have been killed. I am hoping the government can contact all Ford Explorer customer to warn them of this problem and hopefully prevent a certain death.

- Pittsburgh, PA, USA

problem #140

Jul 102009

Explorer

  • 70,707 miles
When in a Ford dealership for lube, oil & filter change, the mechanic noticed that both rear coil springs were broken.

- South Windsor, CT, USA

problem #139

May 102002

Explorer

  • 41,000 miles
Rear coil springs failed on 2002 Ford Explorer. Vehicle only has 4,100 miles on it. This was found while oil was being changed at the dealer. It appears this is a very common problem with this vehicle. Ford need to be held accountable with this many vehicles having the same problem. Now I'm facing a $500 repair bill.

- Eagleville, PA, USA

problem #138

Jul 012009

Explorer

  • 62,932 miles
While rotating the tires on my 2002 Ford Explorer I found that both rear springs are broken. I believe this is caused due to sub standard materials as my car has never been used for off road or towing. My car has only 62,000 miles. Both springs and struts will have to be replaced.

- Crittenden, KY, USA

problem #137

Feb 252009

Explorer

  • 85,000 miles
Broken rear coil springs on 2002 Ford Explorer XLT, 85000 miles. Also need front and rear wheel bearings, seat belt tensioner, emergency brake repair.

- Apo, AE, USA

problem #136

Jun 162009

Explorer

  • 114,500 miles
Broken rear coil springs were discovered during routine brake replacement. Truck had been handling poorly, was brought to dealership for brakes & shocks. Service advisor advised of discovery of cracked springs, had to keep vehicle overnight for repair/replacement.

- Morganville, NJ, USA

problem #135

Jun 152009

Explorer

  • 59,000 miles
Driving from parking lot, heard a loud thump from the rear. Upon inspecting, the rear coil spring is broken in two places.

- Natick, MA, USA

problem #134

Jun 092009

Explorer

  • 103,000 miles
Passenger side rear coil spring broken in half near top portion. Apparently it is a common problem with this year of Explorer, but nothing has been fixed yet.

- Front Royal, VA, USA

problem #133

Jun 102009

Explorer

  • 86,000 miles
I drive a 2002 Ford Explorer with 86,000 miles. The driver side rear coil spring broke.

- Naperville , IL, USA

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