really awful
Crashes / Fires:
0 / 4
Injuries / Deaths:
3 / 0
Average Mileage:
113,369 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 F-150 fuel system problems

fuel system problem

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2002 Ford F-150 Owner Comments (Page 3 of 3)

« Read the previous 20 complaints

problem #15

Mar 112011

F-150 6-cyl

  • 37,400 miles


Spark plug blow out. # 2 plug passenger side.this happened yesterday March 11,2011. My truck has 37,000 miles on it. This is a Ford F-150, 7700 series with a 5.4 engine.where is the recall on this truck.after reading all the problems, with the same thing. What a slap in the face by Ford. And yet no recall mandated by the feds. What a country we live in?

- Fairland, OK, USA

problem #14

Mar 092011


  • 148,000 miles
The fuel tank dropped down from my truck as I drove. I stopped in the middle of the street, put my hazard lights on and got out to see what had happened. I didn't know what it was, it looked like maybe the end of the exhaust system, there was no liquid and no smell. I called for help and slowly pulled my car over at the nearest side street. When I got out, gasoline was pouring out and I could then tell that it was indeed the fuel tank that was hanging from the underbody of the truck. The fire department had to be called and I have to pay for the clean up of the fuel. The truck was towed to a repair shop and they said the straps that hold the tank up rusted out and failed. Total repair cost will be around $1500.

- Champaign, IL, USA

problem #13

Sep 132010


  • 102,000 miles
Fuel tank straps rusted and broken causing tank to almost fall out

- South Lyon, MI, USA

problem #12

Dec 212010


  • 143,000 miles


The contact owns a 2002 Ford F-150. While driving approximately 50 mph, the fuel tank fell off of the vehicle and started sparking. The manufacturer was contacted who stated the failure could have been the bands that hold the gas tank were rusted and the problem had been reported before. The vehicle was not repaired. The approximate failure mileage was 143,000.

- Indianapolis, IN, USA

problem #11

Sep 232010


  • 89,800 miles
The rear fuel tank strap on my 2002 Ford F 150 rusted through causing the tank to come loose. The rust was so bad that there was also a small hole in the fuel tank. I have taken the truck in for repairs and after the tank was removed it was discovered that the brake lines above the tank were also rusted with one starting to leak.

- Columbus, OH, USA

problem #10

Jul 012010

F-150 4WD

  • 170,000 miles
Gas tank leak at strap holding tank in place. 2002 Ford F-150 4X4 4.6 liter. At this time I can not fill the vehicles tank to full. The problem will only get worse with time. At this time the vehicle is only filled to 1/2 full.

- Fenton, MI, USA

problem #9

Aug 302010

F-150 4WD 8-cyl

  • 173,000 miles


I was driving in the urban street and I suddenly hear a noise coming from the engine compartment, like something is leaking from the engine. So I had it towed to my house which is around 2 kms away. We discovered that one of the spark plug just pull out of the engine and it was the one that was making the noice and no power. I brought it to my friend whjo is a mechanic and he discovered that the tread is damaged and he cannot insert the plug anymore. I bought it used on March 2008.

- Coquitlam, 00, USA

problem #8

Apr 142007

F-150 4WD 8-cyl

  • 136,500 miles
On April 17, I noticed a whistling sound coming from the engine, but could not find the source of the sound, and thought it was a vacuum line leak. I started the truck on the morning of April 14 and I heard a loud popping sound followed by a small black cloud, upon examining under the hood, I found the #3 spark plug on the passenger side had blown out of the hole and the coil had been blown off with it, breaking the plastic that had a steel insert that was screwed down to the block. I tried to replace the spark plug, but could not get it started in to the threads on the head. I found out that O'reily's sells a cylinder head repair kit # 42025 specifically for this problem, it had a insert that you screwed into the head and it was threaded on the inside to accept a extended length spark plug that was included in the kit, I tried this kit @ $64 dollars plus the new coil @ $43, upon completing the work with the kit and the new coil installed, I started the truck and still had the same whistling problem and was losing compression, I contacted a local mechanic, and found out from him that this is a very common problem and he see this same problem once every two weeks or so, I took the truck to him and he worked on it for approx. 6 hours and has the problem fixed, however, he said he couldn't promise that this is not going to happen again, to the same plug or others. If Ford knows there is a problem why won't anybody make them fix it and make it right for the little guy (consumers?)

- Mansfield, TX, USA

problem #7

Feb 262010

(reported on)

F-150 8-cyl

  • miles
2002 Ford F-150.the consumer received notice in the mail about risk of fire in some vehicles. The consumer stated her vehicle caught on fire a few years ago.

- Mineola, TX, USA

problem #6

Sep 072009


  • 69,044 miles
Truck stopped and idling at stop sign followed by loud bang and thumping noise. Shut off truck, and looked under hood to find spark plug had blown out of cylinder head along with coil. The smell of fuel was evident from the open hole in the cylinder head. Lucky there was no fire when the plug was discharged. Ford will not do anything to remedy the problem even though this is very common in these vehicles even with the original spark plugs. I was told that this was my mistake for overtightening the plugs. I have never changed the plugs nor does Ford recommend this until 100,000 miles. I believe that the issue is widespread enough to warrant a recall, but this has not happened yet. Average people cannot afford the $1,000 - $3,500 repair that is necessary to fix this problem nor should they be required to when it is a problem that Ford has known about and refused to fix. Ford is providing an inferior product and will not take responsibility for it.

- Sheridan, WY, USA

problem #5

Jul 142009

F-150 8-cyl

  • 130,000 miles


I own a 2002 Ford F150 with the Triton 5.4L V-8. I have had spark plugs eject from 3 different cylinders now and Ford claims it is not a recall issue. This problem has been noted on many of the Ford vehicles with the Triton 5.4 V-8. when the spark plug is ejected fuel vapor can leak into the engine compartment and possibly cause a fire. I have not had that problem but I am frustrated with Ford's unwillingness to cover a known problem with their design.

- St. Paul Park, MN, USA

problem #4

Feb 032009


  • 81,300 miles
While driving at 45 mph on level surface the #5 spark plug was ejected from it's hole damaging the coil over plug causing arcing from the coil to the engine. The vehicle immediately slowed dramatically and the smell of gasoline was apparent. Luckily there was very light traffic and I was able to pull to the side of the road and shutdown the engine. I identified the problem and having some mechanical training knew enough to disconnect the fuel injector wire for the #5 cylinder. This was the only way I could safely move the vehicle. Had I not known what to do, an engine compartment explosion would have easily resulted.

- Colfax, WI, USA

problem #3

Nov 012008


  • 125,000 miles
On 11/1/08 I was driving and heard loud pop from my engine. Upon further investigation I saw that the spark plug in the seventh cylinder of my 2002 F150 5.4 Triton had blown out of the head and broke the coil. This was preceded by a ticking noise that almost sounded like a exhaust manifold leak. I personally changed my plugs at 100,000 miles and the truck currently has about 125,000 miles on it. While on the internet researching the problem I realized that I'm not alone and this is a nation wide problem with the F150. At this point my truck is sitting in the driveway because the dealership is charging at least $2000 dollars to replace the head. I am researching a cost effective alternative to replacing the parts at this time.

- Lafayette , LA, USA

problem #2

Aug 012005

F-150 8-cyl

  • Automatic transmission
  • miles
The consumer has noticed a discrepancy in the mpg the manufacturer said the vehicle would get and the actual mpg the 2002 Ford F150 get. The consumer claimed that he never gets more than 11 mpg while driving in the city, on long distance trips, while pulling a trailer or while driving empty.

- Silverdale, WA, USA

problem #1

Nov 152003


  • Manual transmission
  • 77,249 miles
Excessive exhaust smoke. Poor performance.

- Mesa, AZ, USA

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