really awful
Crashes / Fires:
1 / 0
Injuries / Deaths:
0 / 0
Average Mileage:
73,405 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 Escape exhaust system problems

exhaust system problem

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2002 Ford Escape Owner Comments

problem #6

Jul 182011

Escape 6-cyl

  • 137,000 miles


2002 Ford Escape. Catalytic converter problem. Problem began last week when dpfe tubes came off and dpfe sensor melted. The next day the valve next to the dpfe sensor blew a hole and all parts were replaced. The next day one of the dpfe tubes came off again. This was replaced again. The next day the car did not have good gas power. When going up a small incline the car would not go past 40 mph. Went to car repair shop and O2 sensor was removed to see if it was the catalytic converter. This car has 3 catalytic converters. This car is at another car repair shop now to see what the cause is for the catalytic converter(s) to go bad. One repair shop advised that this is a common problem with Ford Escapes. I contacted Ford Motor Company and was told that there have been no recalls for this problem. I went out to the Ford forum and there are entries from 2007 to present with many 2002 Escape owners that have experienced the same problems that I am experiencing. This problem can cause major engine problems that could cause an accident. No engine light has come since the dpfe tubes and sensor and valve was replaced.

- Columbus, IN, USA

problem #5

Nov 012009

Escape 4WD 6-cyl

  • 130,000 miles
2002 Ford Escape V6 four wheel drive, rear exhaust manifold cracks. Drive this car reasonably, not like a teenager, and the manifold cracked. Since this manifold has built-in catalysts, repair is extremely expensive. Ford has not recalled, but the exhaust fumes that build up in the vehicle are extreme (we get headaches). Also, mpg has fallen to 14 mpg, and still no cel-on condition.

- Sacramento, CA, USA

problem #4

Mar 092005


  • 84,000 miles
Catalytic converter cracked along welds at around 84000 miles. Research on open sources on the internet as found at the V-6 equipped Ford Escapes are prone to these failures over and over. There have been some reported cases of vehicles losing power while driving and vehicles completely dyeing while driving.

- Allen Park, MI, USA

problem #3

Jul 282008


  • 64,430 miles


I recently had $2,900 worth of repairs done to my 2002 Ford Escape XLT in July. My vehicle was bucking and almost stalled when I pulled into the nearest service center. The check engine light was on. The mechanic diagnosed the problem as clogged cat converters. The car has three sets of them. This is the effect of the cause which he believed was faulty oxygen sensors as well as bad spark plugs. At the end of Sept the car was not running well and I went to another mechanic who said the egr valve was blown and their was broken bolts where the mechanic was replacing the exhaust system. I was furious and proceeded to return to the merrick bellmore service center. He told me if the problem was on his end that he will take care of it and then diagnosed that the cats where clogged again. He didn't properly diagnose the cause of the cats getting clogged the first time. The mechanic has since replaced three sets of cat converters and he has a bill for $1600 and has had my car at his shop for two months now. The shop is "trying" to get Ford to pay for the exhaust parts. After numerous attempts to speak with the owners of this service station to no avail (the clerks tell me 5 different set of names as to who is the owner) all I want is my car back and let this service station "eat" this current bill due to the fact that on the bill that I paid in July the warranty on parts is one year or $12,000 miles. I am frustrated, angry and don't know where to turn.

- Farmingdale, NY, USA

problem #2

Mar 052004

Escape 6-cyl

  • 25,000 miles
While driving air bag light illuminated. Dealership was notified, but did not resolve the problem. The illumination of air bag light happened in an intermittent basis. Consumer was also involved in an accident where his air bags failed to deploy. In addition, consumer experienced noise in steering wheel and rattling noise in exhaust.

- Allentown, PA, USA

problem #1

May 292002


  • miles
I was driving in afternoon traffic yesterday when my car went from 40 mph to 20 mph. Oil light and emissions light came on, and then the car stalled and rolled to a stop. I turned the engine off, and it restarted after five minutes. I made it home. It was quite scary as I was sitting in traffic. I had heard from someone in a shopping center about this problem with their 2001 model. Upon research on your site today, I am alarmed at the number of occurrences and that this is a serious problem. I will be taking to the dealership today for repair. I am concerned that Ford has not done anything about this after reading how wide-spread this is. I am terrified to drive it now as I have a two year old daughter and am six months pregnant.

- Kennesaw, GA, USA

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