definitely annoying
Crashes / Fires:
0 / 0
Injuries / Deaths:
0 / 0
Average Mileage:
37,000 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 Expedition exhaust system problems

exhaust system problem

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2002 Ford Expedition Owner Comments

problem #2

Jan 082010


  • 74,000 miles


I own a 2002 Ford Expedition. The spark plug popped out of the engine head on two occasions. The first time it happened was on thanksgiving, 11/26/2009. The engine was smoking and it smelled like gasoline. My mechanic said this is happening to Ford all over the country and that it is documented all over the internet if you do a "google " search on Ford spark plugs popping. The repair cost me $500. On January 8, 2010, another spark plug popped out from a different cylinder. The truck is in the shop now. My mechanic advised me not to put new Ford heads on the truck because the new heads will have the same defect. I expect this new repair to cost $500 as well. Ford needs to be ordered to issue a recall. This is a dangerous defect that can cause a fire or an explosion under the hood due to the gas vapors being pumped into the engine compartment while the popped out plug is still sparking. I was fortunate to shut down the engine when I started to smell the strong gas fumes.

- West Babylon, NY, USA

problem #1

Jul 042005


  • Automatic transmission
  • miles
The contact stated the inside of the vehicle occasionally had a strong smell of gasoline when driving at 75 mph. The vehicle was taken to a mechanic, but the mechanic could not duplicate the problem. The contact only used the vehicle for driving her children to school, which was about 5 or 6 blocks away. Due to her fears about the smell she tried to exchange the vehicle for another but the dealer denied her request.

- Fort Morgan, CO, USA

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