really awful
Crashes / Fires:
0 / 10
Injuries / Deaths:
0 / 0
Average Mileage:
118,046 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 #26

Apr 252017


  • miles
Two spark plugs blew out of the head. Pain in the butt to fix. Ford needs to stand behind its name and fix the known problem.

- Buena Park, CA, USA

problem #25

Jun 022009


  • 170,000 miles
I went to get an oil change I was told by worker at shop that everything under hood was rusty and chances are that this truck was in the new orleans flood (katrina) it was down hill from then. Everything started to malfunction.

- Atlanta, GA, USA

problem #24

Dec 272016


  • 129,000 miles
This is about a blown out spark plug. The blown out spark plug (#4 on passenger side)) happened when my family & I were traveling in highway near stockton ca at around 5 pm. There was no shop open and I had to call aaa to tow the 2002 Ford Expedition to our friend's house about 30 miles away. It was also a very cold night and we waited for about 1 hr for the tow truck to arrive. It was incredibly inconvenient for this incident to happen on the freeway/highway. I heard that this is a common problem for the older Expedition with Triton engine. I love Ford trucks/SUVS and I hope they can fix this problem with the engine before somebody gets in serious trouble. I would rather want to see a recall than a class action suit in the future.

- San Diego, CA, USA

problem #23

Oct 232016


  • 147,000 miles
Just want to add my car to the list of Ford Expedition 5.6L engines that have experienced the spark plug ejection issue. Thankfully, this occured when starting the vehicle, so it did not cause any accident or injury. This is our son's car and we intended it to be the vehicle our 15 year old used as well. However, now that we know about the spark plug problem, we no longer feel it's safe and hope to trade it in. It's extremely disappointing and disheartening to know that Ford has not taken responsibility for this issue. Our vehicle had all original factory-installed spark plugs.

- Newbury Park, CA, USA

problem #22

Jun 142016


  • 180,000 miles
The contact owns a 2002 Ford Expedition. While the vehicle was parked in a residential driveway, the engine compartment erupted into flames without warning and a loud explosion sound emitted from the vehicle. The contact mentioned that the vehicle was completely burned and part of the garage was damaged. The police and fire departments filed reports. There were no injuries. The vehicle was not taken to the dealer. The manufacturer was not made aware of the failure. The vehicle was not repaired. The VIN was not available. The failure mileage was 180,000.

- Pea Ridge, AR, USA

problem #21

May 232016


  • 219,000 miles
Idling at a metered ramp I experienced unintended acceleration while in line waiting for my turn at the metered light.the car in front of me rolled forward and I following suit. I did not touch the accelerator but merely released my foot from the brake pedal. The truck surged forward unexpectedly. I was able to apply the brakes before impacting the car in front of me. As I sternly applied the brakes the engine settled down and all systems worked as expected for the remainder of my commute. 5/23/2016 approx. 7:25 am cdt. Sunny and clear weather approx 63 degrees F. "normal" humidity. My daughter is the primary driver of this vehicle and when asked if this has happened to her the answer to my surprise was yes.

- Edina, MN, USA

problem #20

Apr 182016


  • miles
The vehicle was driven earlier that day for about 2 to 3 miles and then it was parked inside a private mobile home park. After 30 to 45 minutes had passed, an explosion was heard outside the mobile home park; the vehicle exploded and was on fire. The explosion occurred in the hood and now it is a total loss. This occurred on April 18th, 2016. We contacted the National Highway Traffic Safety Administration and they informed us that a recall back in 2005 was issued. The Ford Motor Company has not helped us out in this accident.

- Torrance, CA, USA

problem #19

Jun 252015


  • 89,000 miles
The contact owns a 2002 Ford Expedition. While starting the vehicle, an abnormal noise was heard from the engine. In addition, the vehicle stuttered without warning. The vehicle was taken to a dealer where it was diagnosed that the plug and ignition coil were replaced. The vehicle was repaired; however, the failure persisted eight months later. The vehicle was taken back to the dealer where it was diagnosed with the same failure. The vehicle was repaired, but the failure persisted. The manufacturer was notified of the failure. The approximate failure mileage was 89,000.

- Cleveland, OH, USA

problem #18

Mar 092016


  • 161,000 miles
I was driving my truck, when it started to make a crazy noise coming from the engine. I had to pull over and pop the hood and I noticed that my plug on right side head, had blew out. I was on the side of the road and ended up having it towed because I didn't want to drive it in the condition that it was in. I understand most will say this is not a safety issue, however, when this happens in the middle of traffic or going down the interstate, it could very well be a big safety issue. This is a very common issue that I feel Ford should be held responsible for.

- Sugar Hill, GA, USA

problem #17

Jan 122016


  • 112,500 miles
Spark plug shot from engine. Has 112500 miles on SUV. Was ice and snow on back road 30 miles from home at 14 degrees. Sounded like engine blowing up. Then load ping sound in motor and lack of power. Engine shut off on idle. Was stuck. Have not serviced yet. Ford needs to fix this issue immediately. This 5.4 L Triton should run for longer than 110,000 miles. My old Dodge would not and did not have any issue and it had 130,000 miles when it was wrecked.

- Myersville, MD, USA

problem #16

Jul 072015


  • 145,000 miles
On the evening of July 7th, 2015 at approximately 10:45 P.M. we heard a commotion outside our apartment complex and discovered my '02 Expedition fully on fire and being doused by the local fire department. It had just come back from repairs that afternoon - to the pigtail switch and re-wiring in the steering column due to loss of turn signals and radio. Not only was my car destroyed, but the cars on either side were damaged, as well as damage to the apartment complex. We retained an attorney and our initial report from the fire department stated the cause as "faulty wiring." The private fire investigator we retained has advised our attorney that the fire is due to the flawed cruise control system that has been the cause of hundreds of other fires in Ford vehicles.we intend to pursue this matter legally and would sincerely appreciate any assistance or advise your office can provide.

- Saraland, AL, USA

problem #15

Mar 022015

Expedition 8-cyl

  • 134,200 miles
Car started without any problems in the morning but it did not shift any gear, car was towed to the mechanic and taken to the mechanic. While the mechanic was checking the vehicle the car caught on fire, the engine and the whole front of vehicle caught on fire.

- Lutz, FL, USA

problem #14

Dec 272014

Expedition 8-cyl

  • 155,000 miles
Spark plug popped out my iginition coil and the threading section is stripped. When I started my car an exploration sound occurred. Also, my driver side head light won't stay lite even with replacement light unit. Also car stalls when car is facing down a hill, even with a full tank of gas.

- Lawrenceville, GA, USA

problem #13

Nov 132014

Expedition 8-cyl

  • 122,200 miles
1:00 am, started engine to go home from work. Loud bang, fumes, sound like something is caught in the fan. Investigation revealed spark plug blown out of engine, hanging by the lead. Made it home driving at 30 mph. It appears Ford has known about this for some time. To say I am disappointed in them is the understatement of the year. Vehicle has been meticulously maintained.

- Dunwoody, GA, USA

problem #12

Jan 212014

Expedition 8-cyl

  • 129,500 miles
#3 coil damaged, spark plug blew out. Had to have a new coil, new spark plug, and rethread #3 hole. Very upsetting that Ford knows of this issues and refuses to do a recall and pay for the repairs!

- Boise, ID, USA

problem #11

Jun 152014


  • 100,000 miles
The contact owns a 2002 Ford Expedition. The contact stated that smoke emitted from the driver's side of the vehicle. The vehicle was taken to an independent mechanic who replaced the engine and the timing belt. The contact also stated that the vehicle failed to respond to deceleration attempts and that it caught on fire while it was parked and unoccupied. The vehicle was destroyed. A police report was filed. The manufacturer was notified of the failure. The approximate failure mileage was 100,000.

- Centreville, VA, USA

problem #10

Nov 102011

Expedition 8-cyl

  • 120,000 miles
While driving 35 mph I heard a loud pop and then what sounded like a belt smacking around the engine. I opened the hood and saw the belt was ok. Went to dealer and had to get loaner to get home. Spark plug had popped out.

- Tinley Park, IL, USA

problem #9

Oct 302012


  • 150,000 miles
After starting the vehicle a loud popping sound could be heard from the engine on the passenger side and then all the sudden a fire erupted in the back of the car at the location of the sound. The ignition coil was ripped from its bolt and the spark plug was ejected. The fire department was called to extinguish the flames. Thank goodness I was not driving it with my three kids or we could have been seriously injured. All across the U.S this is happening, does someone have to die before measures are taken?

- Winfield, KS, USA

problem #8

Jul 292012


  • 100,000 miles
The contact owns a 2002 Ford Expedition XLT. The contact stated that while the vehicle was parked a fire started under the hood. The police and fire department were contacted. The vehicle was destroyed. The vehicle was not towed to the dealer. The manufacturer was made aware of the failure. The failure and current mileage was 100.000.

- Beaumont, TX, USA

problem #7

Aug 252012


  • 110,000 miles
The contact owns a 2002 Ford Expedition. The contact stated that while the vehicle caught on fire while parked. The contact called the fire department to extinguish the flames. The fire department advised that the fire started under the hood on the driver's side. The contact called the manufacturer regarding the fire and the manufacturer advised that they would send someone to further inspect the failure however, the manufacturer failed to send a representative. The vehicle was destroyed due to the fire. The failure mileage was 110,000.

- Hartwell, GA, USA

Read the next 6 complaints »