The 2002 Ford Expedition has 4 safety recalls and 340 owner complaints on file with NHTSA. The most-reported problem area is engine and engine cooling (95 complaints).
Recalls4safety recalls
Complaints340filed by owners
Crashes · fires19 · 69reported in complaints
Injuries · deaths27 · 2reported in complaints
2002 Ford Expedition in an NHTSA crash test
Safety recalls
Exterior lighting › Headlights
NHTSA recall 06E067000 · Aug 1, 2006 · 19,413 vehicles · opened after NHTSA action (OVSC)
Problem: CERTAIN MAXZONE HEADLIGHT ASSEMBLIES, DEPO BRAND, P/NOS. 331-1129L-ASN AND 331-1129R-ASN, SOLD FOR USE AS AFTERMARKET EQUIPMENT FOR THE ABOVE LISTED PASSENGER VEHICLES. THESE HEADLAMPS FAIL TO CONFORM TO THE PHOTOMETRIC REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 108, LAMPS, REFLECTIVE DEVICES, AND ASSOCIATED EQUIPMENT.
Risk: DECREASED LIGHTING VISIBILITY MAY RESULT IN A VEHICLE CRASH.
Fix: MAXZONE WILL NOTIFY OWNERS AND OFFER REIMBURSEMENT FOR ANY NONCOMPLIANT HEADLIGHTS. THE RECALL BEGAN ON JULY 28, 2006. OWNERS MAY CONTACT MAXZONE AT 909-822-3288.
Fuel system, gasoline
NHTSA recall 06E056000 · Jun 13, 2006 · 58,640 vehicles
Problem: CERTAIN AFTERMARKET FUEL FILTERS SOLD UNDER THE PUROLATOR BRAND NAME, P/N F65277, SHIPPED FROM JANUARY 16 THROUGH JUNE 2, 2006, FOR USE ON THE ABOVE LISTED PASSENGER VEHICLES. DUE TO INCORRECT DESIGN, THE QUICK CONNECTORS MAY NOT FULLY SEAT WITH THE TUBE INTERFACE, EVEN THOUGH THE PERSON MAKING THE CONNECTION MAY BELIEVE THAT THE QUICK CONNECTOR IS FULLY ATTACHED.
Risk: FAILURE OF THIS CONNECTION COULD LEAD TO FUEL SPILLAGE AND, IN THE PRESENCE OF AN IGNITION SOURCE, A FIRE COULD OCCUR.
Fix: UFI WILL NOTIFY OWNERS AND REPLACE THE FILTERS FREE OF CHARGE. THE RECALL BEGAN ON AUGUST 4, 2006. OWNERS MAY CONTACT UFI FILTERS USA AT 800-230-5876.
Vehicle speed control
NHTSA recall 05V388000 · Sep 7, 2005 · 4,500,000 vehicles · opened after NHTSA action (ODI)
Problem: ON CERTAIN PICKUP TRUCKS AND SPORT UTILITY VEHICLES EQUIPPED WITH SPEED CONTROL, THE SPEED CONTROL DEACTIVATION SWITCH MAY OVERHEAT, SMOKE, OR BURN.
Risk: A FIRE AT THE SWITCH COULD OCCUR.
Fix: BY LETTER DATED SEPTEMBER 12, 2005, OWNERS WERE INSTRUCTED TO RETURN THEIR VEHICLES TO THEIR DEALERS TO HAVE THE SPEED CONTROL DEACTIVATION SWITCH DISCONNECTED. OWNERS WHO HAVE HAD THEIR SPEED CONTROL DEACTIVATED ARE BEING NOTIFIED THAT PARTS WILL BE AVAILABLE AND ADVISED TO MAKE AN APPOINTMENT TO RECONNECT THE SPEED CONTROL BEGINNING IN FEBRUARY 2006. OWNERS WHO DID NOT HAVE THEIR SPEED CONTROL DEACTIVATED ARE BEING NOTIFIED TO HAVE THEIR SYSTEM REMEDIED BEGINNING IN FEBRUARY 2006. OWNERS ARE URGED TO AVAIL THEMSELVES OF THE FREE DISCONNECT SERVICE AS SOON AS POSSIBLE BECAUSE OF THE SIGNIFICANT RISK OF FIRE. OWNERS MAY CONTACT FORD AT 1-800-392-3673. (NOTE: ALSO SEE RECALLS 05V017 AND 06V286)
Structure
NHTSA recall 03V094000 · Mar 7, 2003 · 3,674 vehicles
Problem: CERTAIN PICKUP TRUCK, VAN, AND MINI VAN CONVERSIONS EQUIPPED WITH SOUTHERN COMFORT BUILT RUNNING BOARDS THAT CONTAIN CERTAIN COURTESY LIGHTS MANUFACTURED BY AMERICAN TECHNOLOGY COMPONENTS, INC. THESE UNITS CONTAIN A COURTESY LIGHT OR LIGHTS THAT MIGHT OVERHEAT WHEN THE WIRE HARNESS IS EXPOSED TO EXCESSIVE MOISTURE AND ROAD SALT.
Risk: THIS OVERHEATING CONDITION CAN CAUSE THE RUNNING BOARD TO MELT OR CAUSE A FIRE.
Fix: DEALERS WILL REPLACE THE WIRING HARNESS ON THESE RUNNING BOARDS. OWNER NOTIFICATION BEGAN MARCH 7, 2003. OWNERS WHO TAKE THEIR VEHICLES TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND DO NOT RECEIVE THE FREE REMEDY WITHIN A REASONABLE TIME SHOULD CONTACT SOUTHERN COMFORT AT 1-800-745-6096.
Recall repairs are free at any authorised dealer. A recall listed here may already have been fixed on a particular car: enter its 17-character VIN at nhtsa.gov/recalls to see open recalls.
Crash test ratings
2002 Ford Expedition 4-DR.
Overall
Not Rated
Frontal crash
Not Rated
Side crash
Not Rated
Rollover
★★★★★
NHTSA 5-Star Safety Ratings (New Car Assessment Program). Ratings are comparable only between vehicles of similar size and weight, and ratings from 2011 on use tougher tests than earlier years. Photos: NHTSA.
Fuel economy
Expedition 2WD
16mpg combined
City / highway
14 / 19 mpg
Fuel
Regular Gasoline
4.6 L · 8 cyl · Automatic 4-spd · Rear-Wheel Drive · about $4,200/year to fuel
Expedition 4WD
14mpg combined
City / highway
12 / 16 mpg
Fuel
Regular Gasoline
4.6 L · 8 cyl · Automatic 4-spd · 4-Wheel or All-Wheel Drive · about $4,800/year to fuel
Expedition 2WD
13mpg combined
City / highway
12 / 17 mpg
Fuel
Regular Gasoline
5.4 L · 8 cyl · Automatic 4-spd · Rear-Wheel Drive · about $5,150/year to fuel
Expedition 4WD
13mpg combined
City / highway
11 / 15 mpg
Fuel
Regular Gasoline
5.4 L · 8 cyl · Automatic 4-spd · 4-Wheel or All-Wheel Drive · about $5,150/year to fuel
EPA estimates from fueleconomy.gov for each engine and transmission sold. Annual cost is the EPA's estimate for 15,000 miles a year at its current fuel and electricity price assumptions. Your results will vary.
What owners report
Problem area
Complaints
Crashes
Fires
Injuries
Typical mileage*
Engine and engine cooling Engine; Engine › Gasoline
95
0
11
0
95,800 mi
Vehicle speed control Cruise control; Accelerator pedal
58
2
25
0
63,000 mi
Electrical system Wiring › Interior/under dash; Ignition
47
0
22
1
84,450 mi
Tires Tread/belt; Sidewall
27
2
0
3
34,800 mi
Engine
27
0
10
0
129,000 mi
Seat belts Front; Front › Buckle assembly
20
1
0
2
100,000 mi
Service brakes, hydraulic Antilock/traction control/electronic limited slip; Foundation components › Disc › Caliper
18
1
3
1
43,000 mi
Power train Automatic transmission; Driveline
18
1
2
1
54,943 mi
Air bags Frontal; Side/window
16
13
1
19
41,000 mi
Fuel system, gasoline Delivery; Storage › Tank assembly
16
0
2
0
60,945 mi
Suspension Rear; Rear › Springs › Air suspension system
15
3
0
3
89,002 mi
Structure Body › Roof and pillars; Body
14
1
3
2
59,000 mi
*Median odometer reading when the problem happened, where owners gave one. One complaint can name several problem areas.
Recent owner complaints
Jul 17, 2024 · fireVehicle speed control Cruise control deactivation switch. I was getting in my truck on my way to work in the early morning. as I walked by the hood I could smell what seemed like burning wire, so I opened the hood & right as I got it all the way up flames started shooting up. I put the fire out and had to wait to call my mechanic he came and told me it was definitely the deactivation switch that had caught fire.
May 12, 2022Fuel/propulsion system My spark plugs are going bad, I bought three tires. But now I'm having to take it to the shop because it's weird noises coming from the tire it may be the wheel baring or sway bar link and bushing the mechanic say.
May 31, 2022Service brakes re: IR 11467550. See attached photo.
Jun 2, 2022Service brakes 2002 expedition mfg date 12/2001 right front brake separated at swagged fitting to short tubing to caliper. had just parked, stopped fine. next day all fluid had drained through separated hose.
Dec 20, 2021 · 146,457 miles · fireFirerelated The contact owns a 2002 Ford Expedition. The contact stated that while the vehicle was parked, it caught fire. The fire started from under the hood of the vehicle. The contact was able to extinguish the fire with water. An independent mechanic came to the contact's residence and diagnosed that the failure was related to NHTSA Campaign Number: 05V017000 (Vehicle Speed Control) however, the contact did not receive notification of the recall. The mechanic informed the contact that the speed control deactivation switch caused the fire that damaged the hydraulic control unit and the pigtail. The vehicle was towed to the dealer. The dealer confirmed that the failure was related to the recall.…
Jan 15, 2021 · 256,547 milesEngine I HAVE REPLACE THE DRIVE BELT 2 TIMES THIS MONTH. THE BELT KEEP MESSING UP NOW I HAVE GET ANOTHER BELT BECAUSE IT IS TWISTED AROUND THE TENSIONER. I DON'T KNOW HIW IT HAPPEN I DRIVE ALL THAT DAY.
Nov 23, 2019Seat belts THE DRIVER'S SEAT BELT DISCONNECTS AT RANDOM TIMES.
Owner complaints are submitted to NHTSA by the public and are not verified. Shown as filed (NHTSA removes personal details); long reports are shortened.
NHTSA defect investigations
DP05005 · opened Sep 22, 2005 · closed Jan 4, 2006SPARK PLUG EJECTION FROM CYLINDER HEAD ON SEPTEMBER 6, 2005, ODI RECEIVED A PETITION REQUESTING THAT THE AGENCY INVESTIGATE ALLEGATIONS OF ENGINE SPARK PLUG EJECTION IN CERTAIN MODEL YEAR 1997 THROUGH 2004 FORD VEHICLES WITH TRITON V-8 AND V-10 ENGINES.ODI RECEIVED A TOTAL OF 474 NON-DUPLICATIVE COMPLAINTS ON THE SUBJECT VEHICLES WHERE THE COMPLAINANT, OR THE DEALER REPAIRING THE VEHICLE, REPORTED THAT A SPARK PLUG DETACHED FROM THE CYLINDER AND/OR EJECTED FROM THE ENGINE.AS OF DECEMBER 8, 2005, ODI IS NOT AWARE OF ANY ALLEGATIONS WHERE THE ALLEGED DEFECT RESULTED IN A LOSS OF VEHICLE CONTROL, A CRASH, AN INJURY, OR A FATALITY IN ANY OF THE 10,319,810 SUBJECT VEHICLES.IN ADDITION, ODI IS AWARE OF ONLY TWO INCIDENTS WHERE THE VEHICLE STALLED WITHOUT RESTART.INFORMATION CONTAINED IN THE ODI CONSUMER COMPLAINTS AND OBTAINED FROM 72 TELEPHONE INTERVIEWS WITH COMPLAINANTS SHOWED THE FOLLOWING:(1) 99% OF THE COMPLAINTS WERE ON MY…
EA05005 · opened Mar 22, 2005 · closed Aug 2, 2006 · led to recall 05V388000ENGINE COMPARTMENT FIRES EA05-005 IS CLOSED WITH FORD?S ACTIONS IN RECALLS 05V-017, 05V-388, AND 06V-286, RECALLING APPROXIMATELY 6.7 MILLION VEHICLES EQUIPPED WITH TEXAS INSTRUMENTS SPEED CONTROL DEACTIVATION SWITCHES (SCDS).THE BRAKE SYSTEMS IN THESE RECALLED VEHICLES GENERATE A VACUUM THAT CAN POTENTIALLY CAUSE THE SCDS TO FAIL AND, IN CERTAIN SWITCH INSTALLATION ORIENTATIONS, CATCH FIRE.FORD IS ALSO INCLUDING THE ENTIRE POPULATION OF 1998 EXPLORERS.FORD HAS INFORMED ODI THAT TESTING TO DETERMINE THE CAUSE OF FAILURES IN THE 1998 EXPLORERS WILL CONTINUE AFTER THIS INVESTIGATION IS CLOSED.ODI BELIEVES THAT THE VEHICLES EXHIBITING THE FACTORS CAUSING SCDS FAILURE DESCRIBED IN THIS REPORT CORRELATE WELL WITH THE OBSERVED FAILURE RATES ON THESE VEHICLES BY MODEL AND MODEL YEAR.THE CLOSING OF THIS INVESTIGATION DOES NOT CONSTITUTE A FINDING BY NHTSA THAT A SAFETY-RELATED DEFECT DOES NOT EXIST IN THE NON-RECALLED…
