really awful
Crashes / Fires:
1 / 1
Injuries / Deaths:
2 / 0
Average Mileage:
45,794 miles

About These NHTSA Complaints:

The NHTSA is the US gov't agency tasked with vehicle safety. Complaints can be spread across multiple & redundant categories, & are not organized by problem. See the Back button — blue bar at the very top of the page — to explore more.

Get notified about new defects, investigations, recalls & lawsuits for the 2002 Ford Expedition:

Unsubscribe any time. We don't sell/share your email.

problem #8

Dec 232010


  • 133,334 miles
1. when it rains my 2002 Ford Expedition has water coming inside of it on the driver side. Consequently causing my GEM and fuse box to have to be replaced. I took it to the dealer and replaced the GEM and resealed my windshield. The next day after receiving my vehicle back from the dealer it rained again and had to take it back for the same symptom. They dried out the module and made sure the windshield was sealed good but until this day rain still comes in. I also replaced the door seal and took the luggage rack off and put sealant under it and it still gets water in my vehicle.

- Fort Mitchell, AL, USA

problem #7

Jun 012007

Expedition 8-cyl

  • Automatic transmission
  • 67,000 miles
Tire detreaded on our way to san antonio from edinburg ripping off the side fender around the tire. The bottom part of the truck caved in.

- Edinburg, TX, USA

problem #6

Oct 302006

Expedition 8-cyl

  • Automatic transmission
  • miles
We bought our 2002 Expedition Feb/2006. Since then, every time it rains, we experience water dripping from the visor hinges. We were concerned that our roof will rust so we took it to our mechanic but he could not find the problem. We continued to drive it but became more concerned about the potential problems so we took it back to our mechanic and told him to keep it until he finds the problem on Oct 30, 2006. We also noticed our dash lights flashing. We told him to also find out what is causing this problem also. We received a call from him later in the day and he advised us that he called the dealership who advised him that there's an overlayment of metal behind the windshield that Ford failed to seal correctly and the windshield wasn't sealed correctly so when it rains or snows, the water seeps through the windshield and fills the pillars with water. The overflow of water from the pillars is what drips through the visor hinges. Some of the water leaks into the wiring in the dashboard and other places. Ford advised there is no recall for this. We found someone else had a similar problem from a petrina compton @ my3cents.com which she advised of a "special message" sent directly from Ford to all Ford dealerships in April of 2002 which states 1997-2002 Expedition may exhibit electrical problems due to water leaking in through incorrectly sealed windshields. Special message #15773. If Ford is already aware of this problem and they admit they are aware of it in so many years of models, why has there not been a recall on this? I feel that this defect will be a potential safety hazard while operating vehicle when the electrical fails or causes a short in the electrical system and causes a fire. Please take the time to investigate this defect. I'm sure there are several other owners who have the same problem but don't know where to turn or have been told by their mechanics and dealerships that they cannot locate the problem.

- Fort Wayne, IN, USA

problem #5

Mar 202006

(reported on)

Expedition 8-cyl

  • miles
2003 Expedition leaked water inside vehicle. The outside molding of the windshield came off. The consumer stated while driving, the head lights, interior lighting and radio all went out due to the leaking water which was affecting the electrical system. The doors rattled.

- Yonkers, NY, USA

problem #4

Jan 242006

Expedition 4WD

  • Automatic transmission
  • 97,400 miles
My 2002 Ford Expedition's windshield wipers and audio system would not function in any position except park. I took the vehicle in on Jan. 24 and was told that since the vehicle audio and wiper system functioned properly. I got a call later in the day saying that the vehicle's wipers and audio system displayed the malfucntion that I had described. I was also told that there was severe corrsion around some of the eletrical parts. The service tech suspected a leak but could not tell where the leak was coming from. The dealership replaced the corroded part for the amount of $1065.70 and released the car to me. On Jan. 31, my husband noticed at 5:00 a.M as he was preparing for work that the audio system was blasing and the dash board was lit. He attempeted to start the car, but it wouldn't. he called the dealership at 8:00 a.M to report the problem. A towing company was contacted at this time. At approximately 12 noon, my husband attemted to start the car again. This time it started and my husband drove the vehicle to the dealership. The "service engine" light remained on, and the vehicle drove "rough". on arrival at the dealership, a small fire started under the hood of the vehicle. The starter had burned (according to the service tech). The starter was replaced on Feb. 6. the service manager then reported that a leak was detected, and he suspected that it was coming from the top of the windshield (we told them that we replaced the windshield in July because of a small whole from a rock in the road). We paid an additional $335 for the replacement of the starter. We carried the vehicle back to the glass delearship and had them run a "wet" test with my husband as a witness. Water did not enter the vehicle through the windshield. As an extra precaution we had extra sealant placed around the windshield. Upon further investigation, I learned that the wipers may have a malfunction that causes water to enter the dash after rain or snow. Both occurances started after rain.

- Savannah, GA, USA

problem #3

Sep 262005

Expedition 4WD 8-cyl

  • Automatic transmission
  • 37,000 miles
Windshield leaked on driver side during a rainstorm. Water then entered a relay control box causing electrical malfunctions with the climate control system. The system ran without the key in the on position while the vehicle was unattended.

- Muncie, IN, USA

problem #2

May 252004

Expedition 4WD

  • 31,614 miles
Ford Expedition failed suspension system repair request under warranty. The consumer's believed the suspension system is faulty. The consumer contacted the manufacturer but they refused any assistance. The transmission started with an occasional chunk and or ratcheting sound, rough, did not move and would bang when moved, the driver window occasionally rolled up out of the top rack and there was air leakage, the vehicle was extremely bouncy and was so severe that the consumers head would bounce against the roof top of the vehicle and the vehicle swayed severely when the vehicle made a turn around curves.

- Carson, CA, USA

problem #1

Apr 302002


  • Automatic transmission
  • miles
While driving at 40mph, the consumer had experienced a head-on collision with another vehicle, in which the airbags did not deploy. Estimated property damage was 20000 dollars. The accident caused the front-end to collapse all the way to the engine block.

- Montebello, CA, USA