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hardly worth mentioning
Crashes / Fires:
0 / 0
Injuries / Deaths:
0 / 0
Average Mileage:
135,590 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-250 engine problems

engine problem

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2002 Ford F-250 Owner Comments

problem #16

Nov 262017


  • 98,000 miles


On November 26th 2017, my truck started having a significant mis-fire in cylinder #4. travelling at about 30 mph on city streets; this particular incident was not a safety issue although difficult to limp the vehicle home as it did not accelerate well. Upon removing the spark plug; it was determined that the cylinder head threads in the spark plug port have been damaged. This would have resulted in an ejected spark plug had the vehicle been continued to be operated. Since this is the 3rd different cylinder this has occurred on with numerous reports from multiple owners of the same engine design by Ford; I have decided to file this report. This is the 2nd report I have filed with the NHTSA. The first report I filed was because the 2nd time this occurred; a spark plug ejected from the #3 cylinder at highway speeds with a significant reduction in speed in traffic on the highway. That occurrence also caused a significant vibration and had to be pulled over immediately. Even though there have been significant reports to Ford and documented occurrences dating back to 1997; Ford continues to say that because no "safety issues" have risen or been proven to be caused by this issue that it is not there problem. I will also be filing reports with BBB, Consumer Affairs and consumer reports.

- Auburn, WA, USA

problem #15

Mar 312017


  • 117,000 miles
The contact owns a 2002 Ford F-250. While driving 40 mph, the vehicle stalled without warning. The vehicle was able to restart on the second attempt; however, the failure recurred. The vehicle was not diagnosed or repaired. The VIN was not included in NHTSA campaign number: 07V553000 (engine). The manufacturer was made aware of the failure. The failure mileage was 117,000.

- Grandbury, TX, USA

problem #14

Sep 152016


  • 86,000 miles
The contact owns a 2002 Ford F-250. While driving at any speed and as soon as the engine became hot, a burning oil odor was present inside the vehicle. There were no warning indicators illuminated. The dealer diagnosed that there was a defective head gasket that needed to be replaced. The manufacturer was not made aware of the failure. The vehicle was repaired. The failure mileage was approximately 86,000.

- Barboursville, VA, USA

problem #13

Jun 062016


  • 165,000 miles


My 2002 Ford F250 Super Duty 5.4 gasoline engine had a spark plug blow out at around 165,000 miles. I had pulled over to take a call turned off the engine, when I started it back up it was making a loud popping sound, my machanic shop was next door to where I was so I was lucky that I did not have to drive it anywhere.

- Hye, TX, USA

problem #12

Dec 302014

F-250 4WD 8-cyl

  • 119,000 miles
Driving on the freeway a spark plug came out of the engine causing the vehicle to shake and loose power. The dealer and a shop I took the vehicle to stated that this is a frequent problem with this engine.

- Kaysville, UT, USA

problem #11

Jun 172013

F-250 4WD 10-cyl

  • 70,500 miles
#4 sparkplug ejected

- Jeddo, MI, USA

problem #10

Mar 122014

F-250 8-cyl

  • 150,000 miles


Spark plug failure as accelerating from a stop light, and engine problem resulting from 7 cylinder operation. Got it to a mechanic and he was able to sleeve the spark plug thread and install a new plug. Now the same is starting again. I am taking the vehicle to the mechanic to make permanent repairs for all the spark plug. This may end up with the engine heads being removed in order to make complete repairs, and the cost for that will be thousands of dollars. This is a Ford engine design problem that Ford has been aware of, yet they continue to deny any responsibility.

- Seattle, WA, USA

problem #9

Mar 242014

F-250 8-cyl

  • 206,000 miles
Was driving down the road at 35 mph and heard a pop then the engine started to run rough. Took to the mechanic said that I had a blown spark plug.

- Pierre, SD, USA

problem #8

Feb 032014

F-250 4WD 8-cyl Diesel

  • 185,500 miles
Oil pan rusted out.

- New Baltimore, MI, USA

problem #7

Jan 042014

F-250 8-cyl

  • 180,000 miles
A spark plug ejected from the right side head of the engine head while running down the hwy at 60 mph. The head might be damaged. I haven't had a chance to get it fixed. Been a Ford truck guy all my life & I can't believe Ford hasn't accepted any responsibility of any portion or kind for this. My estimated expense to repair this is $1,000 to $3,000 depending on any damage to the head etc.. I paid $4200 for the truck in April of is in very good condition & to good to junk in my opinion. Besides I can't afford to buy another truck so I have to try to fix it. This is beyond disappointing, it is a major blow to the budget etc. Etc. Etc......

- Wisconsin Dells , WI, USA

problem #6

Sep 262013

F-250 8-cyl

  • 66,000 miles


Spark plug ejected while driving on high way. This is the second time a plug has ejected. The first time the truck had 39000 miles, original factory torqued spark plugs.

- North Andover , MA, USA

problem #5

Aug 152013

F-250 8-cyl

  • 192,000 miles
Spark plug blew out of engine. This is the second time in a year on two different plugs. These are the original plugs.

- Wisconsin Rapids, WI, USA

problem #4

Jul 032013

F-250 8-cyl

  • 66,000 miles
Oil leaking passenger side rear on to the starter and exhaust system.

- Las Vegas, NV, USA

problem #3

Oct 022012


  • 156,000 miles
The #3 spark plug blew out of the engine head. This is the second time this has happened on the same side of the engine. By blowing out, it is a fire hazard, as the engine still pumps gas through this piston. This is an expensive problem to fix and Ford needs to take responsibility for its bad head problem.

- Oxford , MI, USA

problem #2

Jun 042012

F-250 8-cyl

  • 200,500 miles
A spark plug worked loose from the head and blew out causing damage to the head and the ignition coil. All 8 plugs had to be replaced, two damaged spark plug holes repaired and two ignition coils replaced.

- Hortonville, WI, USA

problem #1

May 282012

F-250 8-cyl

  • 111,943 miles
Driving on highway 30 mph and #3 spark plug blew out.

- Mineral Wells, TX, USA

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