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.

2.4

hardly worth mentioning
Crashes / Fires:
0 / 0
Injuries / Deaths:
0 / 0
Average Mileage:
63,760 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 2 of 2)

« Read the previous 20 complaints

problem #18

Jul 162007

Explorer 4WD 6-cyl

  • Automatic transmission
  • 74,680 miles

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

Rear coil spring on drivers side is cracked through. Talked with my mechanic and he said that this is not the first time he has seen this. Probably every third Explorer he has seen has this problem. He questioned local Ford dealer on this and was told there is no recall on this problem.

- Duanesburg, NY, USA

problem #17

Jul 102007

Explorer 6-cyl

  • Automatic transmission
  • 54,200 miles
Broken rear coil spring.

- Blairstown, NJ, USA

problem #16

Jun 112007

Explorer 4WD 6-cyl

  • 81,900 miles
Rear spring failure.

- Salisbury, MA, USA

problem #15

Feb 172007

Explorer 6-cyl

  • Automatic transmission
  • miles

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

Passenger side rear coil spring broke.

- Calgary, 00, USA

problem #14

Dec 012005

Explorer 4WD 6-cyl

  • Automatic transmission
  • 50,000 miles
The rear coil springs on the 2002 Ford Explorer fell apart! pieces of the coil are breaking apart with razor sharp edges. I've never seen springs fall apart like this, the metal has to be defective. I have found parts of the coils in my driveway, so I'm sure there has to be some coming off on the road. I have pictures if you would like a better understanding of what I'm talking about.

- Toledo, OH, USA

problem #13

Mar 162007

Explorer 4WD 6-cyl

  • Automatic transmission
  • miles
The contact owns a 2002 Ford Explorer XLS. The mechanic was rotating both rear tires and changing brake pads. The mechanic stated that the rear coil springs sheared off. The current mileage was 51,600. The consumer has provided both the invoice and pictures of the broken coil springs. Update 4/23/07

- Hinckley, OH, USA

problem #12

Mar 072007

Explorer 4WD 6-cyl

  • Automatic transmission
  • miles

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

Rear coil spring on Ford 2002 Explorer broke. Took car in for annual inspection and mechanic discovered the problem. While it was replaced with a dealer part, I was informed that all it would have taken for the spring to pierce a tire or brake line was to hit a bump in the road. Who knows how long I was driving around with this problem and in danger of a possible fatal incident.

- Tonawanda, NY, USA

problem #11

Jan 152007

Explorer 4WD 8-cyl

  • Automatic transmission
  • 85,916 miles
Broken rear coil springs. Vehicle never used off road or anything other than normal roadway driving. Went for new tires and mechanic found both rear coil springs broken. The drivers side spring was broken into multiple pieces.

- North Easham, MA, USA

problem #10

May 172006

Explorer 6-cyl

  • Automatic transmission
  • 46,425 miles
While driving my 2002 Ford Explorer within the city, I was stopped at a stop sign when I heard a popping sound and the car's right rear tire deflated. I moved out of traffic, called a tow truck and it was discovered that the right coil spring had broken off and punctured the rear tire (which by the way was brand new). It was very fortunate that I was not traveling at a high rate of speed when this occurred. The Ford dealer replaced the right spring, but saw no need to replace the left. Sounds like defective heat treating to me.

- Racine, WI, USA

problem #9

Jun 202006

Explorer 6-cyl

  • Automatic transmission
  • 60,000 miles
Apparent manufacturing defect causes a simultaneous breakage of one or both rear suspension coil springs. In my case, both rear springs were discovered broken on a routine service visit.

- Portland, ME, USA

problem #8

Jun 212006

Explorer 6-cyl

  • Automatic transmission
  • 60,000 miles

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

: the contact stated the vehicle rode lower than normal. The vehicle was taken to a service dealer, who determined that the rear coil springs were both fractured. The springs were replaced, but the dealer was unable to determine the cause of the fractures. The manufacturer was also notified. Updated 12/12/2006 -

- Portland, ME, USA

problem #7

May 172006

Explorer 4WD 6-cyl

  • Automatic transmission
  • 99,000 miles
Horrible whining noise coming from rear differential of my 2002 Ford Explorer limited edition. Replaced twice already and now it's whining louder and louder everyday. I refuse to pay for the same repair a 3rd time. I have read many complaints on the web about this problem, along with many other similar complaints. Other popular defects for the new Ford Explorer are cracked rear coil over springs, along with transmission and A/C problems, etc, etc. How many more complaints is it going to take before Ford stands up to their design flaws..."??"

- East Aurora, NY, USA

problem #6

Sep 012005

Explorer 6-cyl

  • Automatic transmission
  • 126,000 miles
: the contact stated after having rear axle pinion seal repaired at a local independent repair shop the mechanic noticed the rear suspension coil springs were broken and needed to be replaced. The manufacturer was consulted.

- East Aurora, NY, USA

problem #5

Apr 042006

(reported on)

Explorer 4WD 6-cyl

  • miles
2002 Ford Explorer rear coil spring was defective, consumer wants to be reimbursed.

- South Hamilton, MA, USA

problem #4

Jun 192005

Explorer 4WD 6-cyl

  • Automatic transmission
  • 58,000 miles
On routine inspection, it was discovered that the left rear spring on my 2002 Ford Explorer was broken. This vehicle has 55,000 miles on the odometer. Fortunately, it was probably not broken long since I inspect my vehicles regularly. When I went to the local Ford dealer, they initially wanted me to pay the full repair bill for replacement of the spring; however, after negotiation, they offered replacement if I paid half of the bill, or $78. I agreed to this offer, and had the spring replaced. I feel, and expressed this opinion to the Ford Agency, that this spring should not break after only 55,000 miles. In addition, I am now concerned about the other rear spring, and what would happen if I was traveling at highway speeds and it broke.

- Stroudsburg, PA, USA

problem #3

Aug 062005

Explorer 4WD 8-cyl

  • Automatic transmission
  • 47,000 miles
Broken rear springs

- Novi, MI, USA

problem #2

Jul 102005

Explorer 4WD 6-cyl

  • Automatic transmission
  • 50,500 miles
1. inspection of vehicle 2. rear coils springs broken 3. repalcement

- Harpursville, NY, USA

problem #1

May 202005

Explorer 4WD 6-cyl

  • Automatic transmission
  • miles
Contact took vehicle to a service dealer, and they informed him that the rear coil spring broke.

- Findlay, OH, USA

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