NHTSA lists 10 safety recalls and 3,613 owner complaints for the 2002 Ford Explorer. Most complaints involve power train (1,576) and structure (532). The EPA rates it 14–39 mpg combined.
FORD IS RECALLING MODEL YEARS 1995-2003 WINDSTAR, 2000-2003 EXCURSION DIESEL, 1993-1997 AND 1999-2003 F-250 SD THROUGH F-550 SD DIESEL, 1992-2003 E-150 THROUGH E-550, 1995-2002 EXPLORER, 1997 AND 2002 MERCURY MOUNTAINEER, 1995-1997 AND 2001-2003 RANGER, AND 1994 F53 VEHICLES EQUIPPED WITH THE TEXAS INSTRUMENTS SPEED CONTROL DEACTIVATION SWITCH (SCDS). THE SCDS MAY LEAK INTERNALLY AND THEN OVERHEAT, SMOKE, OR BURN.
DOPE, INC. IS RECALLING 42,540 COMBINATION CORNER AND BUMPER LAMP ASSEMBLIES OF VARIOUS PART NUMBERS SOLD FOR USE AS AFTERMARKET EQUIPMENT FOR VARIOUS PASSENGER VEHICLES. THESE HEADLAMPS FAIL TO CONFORM TO THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 108, "LAMPS, REFLECTIVE DEVICES, AND ASSOCIATED EQUIPMENT." THESE LAMPS DO NOT CONTAIN THE REQUIRED AMBER SIDE REFLECTORS.
SABERSPORT IS RECALLING 16,270 COMBINATION CORNER AND BUMPER LAMP ASSEMBLIES OF VARIOUS PART NUMBERS SOLD FOR USE AS AFTERMARKET EQUIPMENT FOR VARIOUS PASSENGER VEHICLES. THESE HEADLAMPS FAIL TO CONFORM TO THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 108, "LAMPS, REFLECTIVE DEVICES, AND ASSOCIATED EQUIPMENT." THESE LAMPS DO NOT CONTAIN THE REQUIRED AMBER SIDE REFLECTORS.
Complaints are unverified owner reports to NHTSA and are not normalized for sales volume. One complaint can cite several components.
Complaints for each Explorer model year we’ve synced.
| Model year | NHTSA complaints |
|---|---|
| 1996 | 1,468 |
| 1997 | 1,789 |
| 1998 | 2,099 |
| 1999 | 1,465 |
| 2000 | 1,078 |
| 2001 | 730 |
| 2002 | 3,613 |
| 2003 | 1,313 |
| 2004 | 1,408 |
| 2005 | 568 |
| 2006 | 635 |
| 2007 | 208 |
| 2008 | 148 |
| 2009 | 33 |
| 2010 | 115 |
| 2011 | 1,197 |
| 2012 | 830 |
| 2013 | 2,237 |
| 2014 | 1,684 |
| 2015 | 1,814 |
| 2016 | 2,464 |
| 2017 | 1,713 |
| 2018 | 733 |
| 2019 | 302 |
| 2020 | 1,247 |
| 2021 | 452 |
| 2022 | 271 |
| 2023 | 113 |
| 2024 | 21 |
| 2025 | 107 |
| 2026 | 44 |
“Overdrive light flashes after driving a little bit hard shifting doesn't shift into overdrive 4x4 lights indicate that it's working when the buttons are pushed but doesn't go into 4x4”
“September 2, 2023 at about 6 pm I pulled over to grab a couple water bottles from the rear of my 2002 Ford Explorer Sport cause my engine was overheating. I got out walked to the rear of my vehicle pushed my unlatch button on the tailgate and I lifted the glass part of the rear hatch. Both air hinges were not working correctly to keep it up so I gently rested the glass on my hair that was put up in a bun and just a little bit of the glass was resting on the very top of my head where my hair was slicked back for my bun so my hands were free to grab the bottles of water. (My hair was the softest of resting place's). As I reached in the back to grab the water bottles I heard the loudest bang and hundreds of little pieces of glass fell everywhere around me. I was in so much distrot that I actually thought someone had shot at me with a fire arm but missed me and hit the rear glass instead. The top of my head was stinging and it felt like I had just been smacked with a tree branch and the glass had went all over me causing a few minor cuts and scrapes as I fell to my knees in shock my heart racing faster than I had even imagined a heart could beat while histaraclly…”
“The rear toe arms came unhinged or disconnected from their placement and sank down to continuously rub a groove in the inner rim. The suspension was affected, the steering was effecting especially when turning, it made the brakes stick, and made loud crunching and rolling noises. It is quite frankly dangerous. It was through no fault of mine that this happened, just weak design. I took it to a shop and they charged me all my money, but nothing was fixed.”
Towing, payload and dimensions aren’t in the EPA or NHTSA data, so we don’t list them.
| Version | City | Hwy | Comb. | Fuel / yr | CO₂ g/mi |
|---|---|---|---|---|---|
| Explorer USPS Electric · 2-Wheel Drive | 45 | 33 | 39 | $1,950 | — |
| Explorer 2WD Man 5-spd, 6 cyl, 4.0 L · Rear-Wheel Drive | 15 | 20 | 17 | $3,650 | 523 |
| Explorer 2WD Auto 5-spd, 6 cyl, 4.0 L · Rear-Wheel Drive | 14 | 19 | 16 | $3,900 | 555 |
| Explorer 2WD FFV Auto 5-spd, 6 cyl, 4.0 L · Rear-Wheel Drive | 14 | 19 | 16 | $3,900 | 555 |
| Explorer 4WD Man 5-spd, 6 cyl, 4.0 L · 4-Wheel or All-Wheel Drive | 14 | 18 | 16 | $3,900 | 555 |
| Explorer 4WD FFV Auto 5-spd, 6 cyl, 4.0 L · 4-Wheel or All-Wheel Drive | 14 | 19 | 16 | $3,900 | 555 |
| Explorer 2WD Auto 5-spd, 8 cyl, 4.6 L · Rear-Wheel Drive | 13 | 18 | 15 | $4,150 | 592 |
| Explorer 4WD Auto 5-spd, 6 cyl, 4.0 L · 4-Wheel or All-Wheel Drive | 13 | 18 | 15 | $4,150 | 592 |
| Explorer 4WD Auto 5-spd, 8 cyl, 4.6 L · 4-Wheel or All-Wheel Drive | 13 | 17 | 14 | $4,450 | 635 |
| Item | Miles | Time | Note |
|---|---|---|---|
| Engine oil & filter | 5,000–10,000 mi | 6–12 months | Follow the oil-life monitor if fitted |
| Tire rotation | 5,000–7,500 mi | Every oil change | Check pressure monthly |
| Engine air filter | 15,000–30,000 mi | 1–2 years | Sooner in dusty areas |
| Cabin air filter | 15,000–25,000 mi | 1–2 years | |
| Brake fluid | — | 2–3 years | Absorbs moisture over time |
| Coolant | 60,000–100,000 mi | 5–10 years | Long-life coolants last longer |
| Spark plugs | 60,000–100,000 mi | — | Iridium/platinum plugs at the long end |
| 12V battery | — | 3–5 years | Heat shortens battery life |
10 safety recalls as of Nov 7, 2026, according to NHTSA. Recall repairs are free at a dealer. Check your VIN to see whether your car is included and whether the repair was done.
Owners filed 3,613 complaints with NHTSA. The most-cited components are power train (1,576), structure (532), suspension (444). Complaints are unverified owner reports and aren't adjusted for how many cars were sold.
The EPA rates the 2002 Ford Explorer at 14–39 mpg combined, depending on engine and drivetrain (9 versions rated).