really awful
Crashes / Fires:
0 / 9
Injuries / Deaths:
0 / 0
Average Mileage:
99,460 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.

« Read the previous 20 complaints

problem #11

Apr 112008

Expedition 8-cyl

  • Automatic transmission
  • miles
My 2002 Ford Expedition exploded, last night on April 11th.

- San Antonio, TX, USA

problem #10

Mar 262008

Expedition 8-cyl

  • Automatic transmission
  • 115,000 miles
#1 spark plug ejected from cylinder head damaging coil and plug wiring this is 2nd incident costing over 4000 dollars to repair head replaced.

- San Diego, CA, USA

problem #9

Mar 152008

Expedition 8-cyl

  • Automatic transmission
  • 78,841 miles
2002 Ford Expedition with 5.4L trition engine suffered spark plug "blow out".

- Ledyard, CT, USA

problem #8

Mar 022008

Expedition 8-cyl

  • Automatic transmission
  • 131,000 miles
The #3 spark plug on my 2002 Ford Expedition ejected from the cylinder. I was told by a mechanic that this failure could have resulted in a fire in the engine compartment. I am now looking at a $2,200 repair bill!

- Elk Grove, CA, USA

problem #7

Jul 032007

Expedition 8-cyl

  • Automatic transmission
  • 84,500 miles
On 7/3/2007 I heard a loud banging sound and smelled gas coming from under my engine. When I had it towed to sioux falls Ford, they said a spark plug had blown out. When I asked if that was a factory defect, I was told that the plug may have been put in incorrectly. I have never had the spark plugs replaced, so I knew it was a factory plug, but the technician said that they had no way of knowing that. I spent $800 to have the it re-thread. 4 weeks later, a different spark plug did the same thing. At that time, they told me that they would check all of the spark plugs to ensure that they were tight. 4 weeks after that, the ignition coil needed to be replaced in that plug and the plug needed to be replaced. They claimed that their repairs had not caused this, but I feel like I have been getting the run-around on all of this simply because I am a woman.

- Sioux Falls, SD, USA

problem #6

Sep 212007

Expedition 8-cyl

  • Automatic transmission
  • 76,400 miles
The contact owns a 2002 Ford Expedition. The contact heard a clinking noise coming from under the hood when the vehicle was started. She inspected the vehicle and noticed that the spark plug blew off. The mechanic confirmed the failure, but was unable to determine the cause. The consumer stated dealer informed her this is a common problem with Expedition, the mechanic had not repaired the vehicle. The powertrain was unknown. The current is 82,362 and the failure mileages was 76,400. Eq-10203932-4200, date received 12/12/07. Updated 12/12/07

- Tomball, TX, USA

problem #5

Aug 202006

Expedition 4WD 8-cyl

  • Automatic transmission
  • miles
We were traveling at about 30-40 mph on a sharp curve on a freeway on-ramp. We experienced a loss of power and a very loud popping noise. We pulled over since driving at freeway speeds seemed impossible. We were stranded in a very dangerous spot about 100 feet in front of the freeway on-ramp. After aaa informed us it would be about an hour for a tow truck and an accelerating vehicle came within inches of our car, my family and I decided to abandon the vehicle and climb a very steep and dangerous embankment. I feared for my three kids and wife's the whole time waiting for the tow truck. We were towed to a Ford dealer where they told us( a week later) the number three spark plug had blown. The usual problem with these engines. The plug blows because there are only five threads for the spark plug in these aluminum heads. The new design from Ford now has 12 threads. We decided to have the whole engine replaced since this cost less than having two heads replaced. Its 5500 for the engine and 3500 per head. We wanted both heads since the other head would be prone to the same problem. I think Ford should own up to this problem because eventually there are going to be serious consequences to someone as a result of this. We were only inches away from this happening.

- Santa Cruz, CA, USA

problem #4

Apr 232006

Expedition 4WD 8-cyl

  • Automatic transmission
  • 120,000 miles
An original equipment never changed spark plug on my 2002 Ford Expedition suddenly and without warning blew off my engine, stripping the threads on the engine block. Prior to this failure, the engine was running well and without problems.

- Clarkston, MI, USA

problem #3

Apr 042006

Expedition 4WD 8-cyl

  • Automatic transmission
  • 36,046 miles
Blown spark plug on a 2002 Ford Expedition. Mileage:36046 cylinder number 3 I took the truck to Ford 4 days before the incident as I had been hearing a slight ticking nose coming from engine. Ford dealer told me to keep driving it until something bigger happened as my extended warranty might not cover all labor costs if they couldn't find the problem. Turns out it was small exhaust leak around the threads of the plug. Once the plug blew on the highway approximately 65 mph loud noise and loss of power. Now the vehicle needs a new head and will be with dealer for over a week.

- Surprise, AZ, USA

problem #2

Feb 082006

Expedition 4WD 8-cyl

  • Automatic transmission
  • 46,000 miles
My repair is as described in service bulletin # 041601 and NHTSA # 10018745. My coil was replaced.

- Milford, MA, USA

problem #1

Apr 062003

Expedition 8-cyl

  • Automatic transmission
  • 21,500 miles
On several separate occasions the engine has revved upon depression or release of the brakes. This causes the vehicle to lurch forward unexpectedly. The radio also becomes louder as if the speed sensitive volume is affected as well. I have notified the dealer but as they have been unable to duplicate the problem, they have not responded. Please help as I fear that this will eventually cause an accident.

- Santa Maria, CA, USA