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 1 of 10)

problem #192

Aug 112011

Explorer 8-cyl

  • 47,000 miles

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

I have a 2002 Ford explore with 47,000 miles. Was told both rear springs were broke during vehicle inspection. Don't know when they broke. Daily driver only, no towing. Should not happen at 47,000 miles should have a recall with all the complaints with springs.

- Roselle, IL, USA

problem #191

May 042010

Explorer 6-cyl

  • 114,000 miles
Both rear coil springs (strut assembiles) broken on 2002 Ford Explorer XLT. Breaks in steel coil springs discovered during dealer inspection in 2010. Vehicle is used for standard daily driving on paved roads. Resulted in sagging rear of vehicle and degraded vehicle control in bumpy terrain. Parts likely broken for some time before detection. Replacement parts have been installed to correct problem. Photos of broken parts available.

- Mayfield Heights, OH, USA

problem #190

Jun 302011

Explorer 6-cyl

  • 80,000 miles
Rear cracked/crumbling strut springs both sides.

- Prospect Park, PA, USA

problem #189

Jun 092011

Explorer 4WD 6-cyl

  • 26,116 miles

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

Upon taking my 2002 Ford Explorer for a routine oil change. I was informed by the Ford dealer that my left rear spring was broken. My Explorer only has 26,116 miles, how could the springs break" I never carry anything heavy, usually only one person is in the vehicle. Iv'E been reading on the internet and there are hundreds of other people with the same problem. Why hasn't NHTSA looked in this issue since it is a safety problem" Ford Motor Co. Knows this is a defect since they changed their design after it was discovered. Can NHTSA re-examine this issue and order a recall before someone jets injured.

- Waterbury, CT, USA

problem #188

Jan 012005

Explorer 4WD 8-cyl

  • 50,000 miles
Rear springs are cracked and my mechanic and friends said its a common problem among 2002 Explorer. Also saw many complaints and photo's of the same problem online.

- Stamford, CT, USA

problem #187

Feb 102011

Explorer 4WD 6-cyl

  • 107,000 miles
Our 2002 Ford Explorer XLT with 109,000 miles has serious transmission slippage between 2nd and 3rd gears. The local dealer and an independent repair shop state that the transmission needs replaced at a cost between $2,500 and $3,500. It is dangerous to drive in its current condition because there are times when it will not accelerate. The rear differential and ball bearings also need replaced according to 2 separate mechanics. There is a random thumping coming from the back of the vehicle daily. The cost to repair is between $2,000 and $5,000. They cannot tell us exactly until they actually get in there to do the repair.

- Evansville, IN, USA

problem #186

Mar 072011

Explorer 4WD 6-cyl

  • 46,000 miles

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

Both rear coil springs on my 02 Ford Explorer broke. There wasn't any indications prior for us to know it would happen.when it did it fell onto rubber stops but tracted crooked and spring almost hit tire.I went to dealer they said no recall call Ford. I called Ford rep said nothing they could do not enough complaints to justify a recall or fix my Explorer. I went to local parts store and bought monroe quik strut.. installed myself.saved old parts just in case because Ford said get rid and save my receipt for parts in case of future recall.vehicle mileage at time was about 46,000 miles.

- Bethel Park, PA, USA

problem #185

Mar 022011

Explorer 4WD 6-cyl

  • 58,000 miles
Rear coil spring. After having tire rotated was informed that driver rear spring was broken. Had both rear coil springs replaced since this seems to be an eventual problem down the road.

- Hillsborough, NJ, USA

problem #184

Oct 102010

Explorer 4WD 6-cyl

  • 83,000 miles
O/D light flashes for a few days then at around 25 mph the gear switches into neutral and runs very rough then the car is thrown forward. Had a rebuilt transmission (we were told we were getting a brand new transmission and paid extra for it!) at 83K miles on Oct 15, 2010 then Feb 5, 2011 the same exact thing happens. The dealer cannot take the truck for another 5 days and refused to give me a loner car because it is not under the warranty. Please note: Below I put in the first incident date, Feb 2011 is the second incident date. In may of 2009 I was told my engine failed at about 76,000 miles. We did buy the extended warranty and we were covered. The Ford dealership told us we were not covered. They had our truck for 3 weeks until the warranty people called the dealership and let them know it should be fixed. We also had a rental car or a loner car under the warranty. They refused to pay for a rental car and said they did not have a loaner car available. It took 4 more weeks (in total 7 weeks) to get the truck back and never paid for the rental.

- Brookfield, CT, USA

problem #183

Aug 182008

Explorer

  • 140,816 miles
The contact owns a 2002 Ford Explorer. There was a loud noise coming from the rear of the vehicle which caused the back wheel to fail. The vehicle was taken to a mechanic who stated that the rear differential system, rear wheel and back hub needed to be replaced at a cost of $3,600. The dealer and the manufacturer were contacted but stated that there were no recalls and offered no assistance. The vehicle was not repaired. The failure mileage was 140,816.

- Bossier, LA, USA

problem #182

Nov 152010

Explorer

  • 76,000 miles

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

The contact owns a 2002 Ford Explorer. The contact stated that the vehicle was taken to an independent mechanic to replace rear brakes where a technician noticed that both rear coil springs fractured. Repaired brakes and rear springs. Was informed by shop that this is a very common issue with 2002 Ford Explorer. The failure mileage was approximately 76,000. Added note, this vehicle has never been used to tow or carry heavy loads, only used as personal Transport.

- Northville, MI, USA

problem #181

Dec 312010

Explorer 4WD 6-cyl

  • 162,000 miles
Left side coil spring snapped suddenly while car was parked in driveway.

- Babylon, NY, USA

problem #180

Apr 042010

Explorer

  • 75,000 miles
The contact owns a 2002 Ford Explorer. The contact stated that the vehicle was taken to an independent mechanic where a technician noticed that both rear coil springs fractured. The vehicle was not repaired. The failure mileage was approximately 75,000.

- Akron, OH, USA

problem #179

Aug 252010

Explorer 4WD 6-cyl

  • 90,000 miles
During the 90,000 mile servicing of this vehicle, it was discovered that the rear coil springs on our 2002 Ford Explorer XLT had rusted completely through and needed to be replaced. We do not reside in a coastal area resulting in exposure to the salty ocean spray nor do we drive this vehicle in off road situations that would cause water to accumulate under the vehicle. For these reasons there is no apparent cause for the coil springs to prematurely rust through. I don't want to think what would have happened to my wife or I if these springs would have fallen completely off while the vehicle was being operated.

- Clinton, MD, USA

problem #178

Oct 152010

Explorer

  • 90,000 miles
2002 Ford Explorer ltmd...90K miles front wear bearings completely blew out, rear struts leaking massive oil and rear springs fractured....had front bearings replaced when it disables brake usage from tires being crooked in next couple of days need to have rear end done with struts, springs and bushings....all new parts no choice and $2600 later in all the springs are the biggest issue, they should not break.

- Fishkill, NY, USA

problem #177

Oct 022010

Explorer 4WD 6-cyl

  • 77,000 miles
Broken rear springs. My Ford service manager said that there is a known problem with broken rear springs on Explorer's as well as other Ford's. this is very dangerous as the driver has lost the functionality of the truck. Mine broke while sitting at a stop light and my daughter and I heard a loud bang. I thought a tire blew. $800 to fix, for just the 2 rear springs, but service manager said he would recommend replacing the fronts as well. Until I can get truck in for service I am afraid to drive the truck as the bottom of the spring landed on the rear suspension and may cause further damage as it rubs. I drove truck slowly home as the truck now leans to the right (side that failed) and I have definitely lost the handling characteristics to this truck.

- Park Ridge, IL, USA

problem #176

Sep 062010

Explorer

  • 107,000 miles
2002 Ford Explorer. Rear springs/coils rusted, broken, on both sides didn't know until I had estimate done for noise in front end which turned out to be uv joint. I understand to repair back springs it will cost about $325 each side and the other things I need uv joint, wheel hub, strut, etc...another $400 this is sad!!!

- Ashtabula, OH, USA

problem #175

Aug 282010

Explorer 4WD 6-cyl

  • 172,000 miles
Noticed fluid on rear passenger side lower control arm. Upon closed inspection, noticed fluid coming from rear shock and both rear coil springs were broken. Repair estimates to replace both rear coil spring assembly range from $655 to $800.

- Newark, DE, USA

problem #174

Sep 062010

Explorer 4WD

  • 140,000 miles
2002 Ford Explorer XLT 4WD rear coil spring broke under normal driving condition. Created bad situation with car swaying left to right. Had to replace spring and strut. Also all 4 wheel bearings had to replaced in 5 years.

- Brunswick, OH, USA

problem #173

Aug 272010

Explorer

  • 94,000 miles
Rear springs both cracked-front & rear wheel bearings bad needed to be replaced Ford should recall these vehicles before someone seriously if not already has been hurt or killed in an accident.

- Easton, PA, USA

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