really awful
Crashes / Fires:
0 / 6
Injuries / Deaths:
0 / 0
Average Mileage:
99,168 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 F-150:

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

problem #100

Jun 212012

F-150 8-cyl

  • 135,000 miles
While driving the truck one of the spark plugs blew out of the aluminum head on top of the motor. This vehicle malfunction destroyed a coil pack, spark plug and wiring.

- Chester, VA, USA

problem #99

Nov 252011


  • 180,000 miles
On three separate occasions my truck has blown 3 separate spark plugs from 3 different ports in the head. I have read numerous complaints about these motors doing this, and Ford should be held responsible.

- Brownsville, KY, USA

problem #98

Mar 042012

F-150 4WD 6-cyl

  • 140,000 miles
The contact owns a 2002 Ford F-150. The contact stated that while driving 65 mph, he heard a loud bang from the engine and started to smell an abnormal fuel odor. The vehicle taken to an authorized dealer where the contact was informed that one of the spark plugs was fractured. The vehicle was not repaired. The manufacturer was not made aware of the failure. The failure mileage was 140,000. Updated 05/07/12

- Courtland, NY, USA

problem #97

May 312011


  • 128,000 miles
Driving to work and had to stop at a stop light a few blocks from work. When light turned green I accelerated to go and the car sound like the exhaust manifolds blew off. Parked car and had it towed to a local repair shop. Was notified by the technician that the back passenger side spark plug blew out of the cylinder. Technician repaired by using an insert. I have been doing alot of reading and I am finding out that this a common problem with these motors. Why has their not been an investigation into this matter?

- Fairview Park, OH, USA

problem #96

Mar 052012


  • 169,000 miles
Spark plug ejected at ignition while parked.

- Coffeyville, KS, USA

problem #95

Feb 282012


  • 121,000 miles
Spark plug blew out and stripped threads in head. This is the 2nd time a spark plug has blown out of the head. Repaired once about a year ago.

- Alamosa, CO, USA

problem #94

Feb 152012

F-150 8-cyl

  • 101,108 miles
A neighbor called 911 to report my vehicle on fire, parked in my driveway while I was at work. The engine was not on and there were no keys in the ignition. The last time the vehicle was driven was 2/14/2012. A neighbor was able to spray water on the fire, and the fire department was able to get the fire out and prevent the fire's spread to the cab, or to my house. There is quite a bit of fire damage to the engine. There are several components of the engine melted on the driver side of the engine, above the left front tire.

- Camarillo, CA, USA

problem #93

Jan 052011

F-150 8-cyl

  • 115,000 miles
2 spark plugs passenger side nearest radiator 'blew', vehicle has had all reccomended oil changes, including one a week prior to the incident. This particular incident also shredded all the spark plug wires on the passenger side. This has happened 2 more times involving all spark plugs now on passenger side of vehicle.

- Abilene, KS, USA

problem #92

Sep 012011

F-150 8-cyl

  • Automatic transmission
  • 65,000 miles
The contact owns a 2002 Ford F-150. The contact stated that while driving approximately 25 mph, the vehicle suddenly stalled without warning. The vehicle was able to be coasted off the road and was towed to a dealer. After diagnosis, the dealer advised him that a spark plug had blown through the aluminum head and needed to be replaced. The vehicle was repaired for the steel ring being placed where the plugs were stripped. The manufacturer was contacted and they offered no assistance. The failure mileage was approximately 65,000. Updated 03/05/12 updated 03/07/12

- Castro Valley, CA, USA

problem #91

Dec 302011

F-150 8-cyl

  • 110,568 miles
While at a stop light waiting to proceed on the arrow, I accelerated and heard very loud pop and a violent shake. Pulled over out of traffic and check under the hood and found that the right rear spark plug ejected out of head. It should be noted that this the second time for this to happen my vehicle the first time the had 71000 miles and now. Ford will not do any thing about this requiring problem with it's Ford F-150 5.4 Triton engine 2002.

- Maryland Hts, MO, USA

problem #90

Dec 262011


  • 163,000 miles
Blew spark plug out of head while accelerating to get on highway. Had gas spill on motor. It has the 5.4 Triton motor.

- Blackstone, MA, USA

problem #89

Dec 212011

F-150 8-cyl

  • 94,146 miles
I was traveling 60 mph on the freeway when a sparkplug was ejected from the engine, breaking the coil attachment from the engine. I found both the spark plug and the coil lying on top of the engine.

- Newberg, OR, USA

problem #88

Dec 182011


  • 122,580 miles
My truck threw a spark plug while driving down the road. This is the second time it has done this and the same exact one as before.

- Clarksville, TN, USA

problem #87

Dec 182011


  • 55,000 miles
The contact owned a 2002 Ford F-150. While driving in reverse at approximately 2 mph, the contact noticed smoke emitting from underneath the hood. The contact immediately exited the vehicle. A police report of the incident was filed. The fire department extinguished the massive flames, which extended 50 feet into the air. The vehicle was towed to a salvage facility for further investigation. The manufacturer was not notified of the failure. The approximate failure mileage was 55,000.

- Miami, FL, USA

problem #86

Nov 172011

F-150 8-cyl

  • 107,590 miles
Spark plug blew out of plug hole, stripping threads of intake cylinder head. Plug was found laying between valve cover and intake manifold.

- Kelso, WA, USA

problem #85

Oct 152011


  • 98,000 miles
Upon starting the vehicle a spark plug blew out of the head. 5.4 L triron engine. Threads in head damaged beyond repair. Fuel vapors escaping cylinder. Spark plug has never been removed/replaced to my knowledge.

- Belfair, WA, USA

problem #84

Aug 022011

F-150 4WD 8-cyl

  • miles
Went to make an appointment with Firestone to have my plugs changed per Ford manual on my 2002 F150 5.4 liter V8. It was told to me that they would not touch the vehicle as I should contact Ford directly. They claim the plugs explode. We then called the Ford dealer service department in sayville the woman stated at sayville Ford service department the plugs would cost to replace $ $383 unless the plugs explode inside the engine when removed then it would cost 1/2 hour more per plug as they are having problems with the plugs exploding it could run up to a total cost of$ $800 max to remove. Something about new sleeve has to be replaced when it explodes. I was really irate we are only talking about plugs. I then contacted Ford at 1 800 392-3673 at customer relationship center claims they know nothing about this problem well I have a problem with this if Firestone will not touch the vehicle and there own Ford dealers explains they have a major problem then how do you not know about it. Problem. I have a big problem with this not only concerns about engine also the cost factor with regards with the removal of defected plugs I believe they already knew of this problem and as usual they are trying to pass the defect to the consumer. It needs to be stopped.

- Riverhead, NY, USA

problem #83

Jul 102011

F-150 8-cyl

  • Automatic transmission
  • 102,000 miles
The contact owns a 2002 Ford F-150. The contact stated that spark plug number six blewout, damaging the engine coil and reducing the power of the vehicle. There was no warning prior to the failure. The vehicle was taken to an independent mechanic where the contact was informed that the failure was a factory defect. The vehicle was not repaired. The failure and current mileages were 102,000. Updated 10/12/11 updated 10/24/11

- Ninilthik, AK, USA

problem #82

Jul 112011


  • 200,000 miles
The contact owns a 2002 Ford F150. The contact stated while the vehicle was parked he heard a loud noise and noticed the vehicle was on fire. The fire department stated the fire initiated in the engine. There was no mention of a fire report being filed. The VIN information was not available. The failure and current miles was 200,000.

- Providence Forge, VA, USA

problem #81

May 302011

F-150 8-cyl

  • 191,365 miles
2002 Ford F-150, 4.6 Triton engine keeps blowing the spark plugs out of the heads.

- Mobile, AL, USA

Read the next 20 complaints »