NHTSA vehicle safety data
2002 Ford Expedition Recalls, Ratings & Complaints
The 2002 Ford Expedition has 4 NHTSA recall campaigns and 340 owner complaints on file as of November 3, 2026. Recall repairs are usually free at an authorized Ford dealer.
NHTSA recall and complaint data for the 2002 Ford Expedition, plus NCAP crash-test ratings. Recall data is refreshed daily from NHTSA.
2002 Ford Expedition owner complaints
Owners have filed 340 complaints with NHTSA about the 2002 Ford Expedition, describing incidents dated January 1, 2002 to July 17, 2024.
Most-cited components
- Engine 122 complaints
- Vehicle Speed Control 58 complaints
- Electrical System 45 complaints
- Tires 28 complaints
- Service Brakes 22 complaints
- Fuel/Propulsion System 20 complaints
Of the 340 complaints on file, 19 report a crash and 69 a fire; across all 340 complaints, owners report 27 injuries and 2 deaths (owner-reported, not verified by NHTSA).
Newest complaints
ODI #11603537 · Filed
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…
ODI #11592816 · Filed
The contact's fiancée owns a 2002 Ford Expedition. The contact stated that there was smoke coming from the driver's side front end of the vehicle. The contact stated that while his fiancée was attempting to drive the vehicle the following day, the brake pedal was depressed but was firm, requiring…
ODI #11470581 · Filed
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.
Owner-reported
2002 Ford Expedition mileage at failure
259 of the 340 complaints on file for the 2002 Ford Expedition give the vehicle's mileage when the problem happened.
| Component | Median | Middle half | Based on |
|---|---|---|---|
| Engine | Median 105,000 miles | Middle half 75,000–130,000 miles | Based on 109 complaints |
| Vehicle Speed Control | Median 60,000 miles | Middle half 35,000–115,000 miles | Based on 35 complaints |
| Electrical System | Median 85,000 miles | Middle half 60,000–120,000 miles | Based on 35 complaints |
A component's median is its 50th percentile, and its middle half runs from its 25th to its 75th percentile.
Owners give the mileage themselves, often as a round number, and NHTSA doesn't check it. A complaint that names several components counts under each one, and mileages that can't be right, such as 999,999, or 50 miles on a five-year-old car, are left out.
These figures describe the complaints owners filed. They don't predict when a particular vehicle will have a problem, and vehicles that never had one aren't counted.
Complaints received before December 15, 2002 rarely give a mileage, so they aren't counted here.
Mileage from NHTSA's complaints file of October 31, 2026. How these figures are worked out
NHTSA defect investigations
NHTSA's investigations file lists the 2002 Ford Expedition in 2 investigations. A listed model year means only that an investigation names it; it says nothing about any particular vehicle. An open investigation is not a finding that a safety defect exists, and NHTSA can close one without a recall.
- Engineering Analysis EA05-005: ENGINE COMPARTMENT FIRES
Closed August 2, 2006
- Recall 05V-388
- Recall 06V-286
- Recall 07V-078
- Recall 07V-336
- Recall 07V-347
- Recall 07V-488
- and 1 more on the investigation page
- Defect Petition DP05-005: SPARK PLUG EJECTION FROM CYLINDER HEAD
Closed January 4, 2006
FMVSS 108/AFTERMARKET HEADLAMP ASSEMBLIES
NHTSA #06E067000 · Exterior Lighting — Headlights · NHTSA notice
Reported August 1, 2006 · MAXZONE AUTO PARTS CORPORATION
Potentially affected: 19,413 vehicles
Owners notified July 28, 2006
Defect description
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.
Safety consequence
DECREASED LIGHTING VISIBILITY MAY RESULT IN A VEHICLE CRASH.
Manufacturer remedy
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.
Notes
THIS RECALL ONLY PERTAINS TO AFTERMARKET REPLACEMENT EQUIPMENT AND HAS NO RELATION TO ANY ORIGINAL EQUIPMENT INSTALLED ON VEHICLES MANUFACTURED BY FORD MOTOR COMPANY.CUSTOMERS MAY CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S VEHICLE SAFETY HOTLINE AT 1-888-327-4236 (TTY: 1-800-424-9153); OR GO TO HTTP://WWW.SAFERCAR.GOV.
FUEL LEAK/FIRE
NHTSA #06E056000 · Fuel System, Gasoline · NHTSA notice
Reported June 13, 2006 · UFI FILTERS USA
Potentially affected: 58,640 vehicles
Owners notified August 4, 2006
Defect description
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.
Safety consequence
FAILURE OF THIS CONNECTION COULD LEAD TO FUEL SPILLAGE AND, IN THE PRESENCE OF AN IGNITION SOURCE, A FIRE COULD OCCUR.
Manufacturer remedy
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.
Notes
THIS RECALL ONLY PERTAINS TO UFI FILTERS USA (PUROLATOR) AFTERMARKET FUEL FILTERS AND HAS NO RELATION TO ANY ORIGINAL EQUIPMENT INSTALLED ON THE LISTED PASSENGER VEHICLES.CUSTOMERS MAY CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S VEHICLE SAFETY HOTLINE AT 1-888-327-4236 (TTY: 1-800-424-9153); OR GO TO HTTP://WWW.SAFERCAR.GOV.
SPEED CONTROL DEACTIVATION SWITCH
NHTSA #05V388000 · Vehicle Speed Control · NHTSA notice
Reported September 7, 2005 · FORD MOTOR COMPANY
Potentially affected: 4,500,000 vehicles
Ford campaign 05S28 · Owners notified September 12, 2005 · Vehicles built through August 20, 2002 (per NHTSA) · Recall influenced by NHTSA's Office of Defects Investigation
Defect description
ON CERTAIN PICKUP TRUCKS AND SPORT UTILITY VEHICLES EQUIPPED WITH SPEED CONTROL, THE SPEED CONTROL DEACTIVATION SWITCH MAY OVERHEAT, SMOKE, OR BURN.
Safety consequence
A FIRE AT THE SWITCH COULD OCCUR.
Manufacturer remedy
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)
Notes
FORD RECALL NO. 05S28.CUSTOMERS MAY ALSO CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S VEHICLE SAFETY HOTLINE AT 1-888-327-4236 (TTY 1-800-424-9153), OR GO TO HTTP://WWW.SAFERCAR.GOV.
SOUTHERN COMFORT/RUNNING BOARDS
NHTSA #03V094000 · Structure · NHTSA notice
Reported March 7, 2003 · SOUTHERN COMFORT CONVERSIONS
Potentially affected: 3,674 vehicles
Owners notified March 7, 2003 · Vehicles built August 1, 2000 – March 3, 2003 (per NHTSA)
Defect description
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.
Safety consequence
THIS OVERHEATING CONDITION CAN CAUSE THE RUNNING BOARD TO MELT OR CAUSE A FIRE.
Manufacturer remedy
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.
Notes
CUSTOMERS CAN ALSO CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S AUTO SAFETY HOTLINE AT 1-888-DASH-2-DOT (1-888-327-4236).
Other Ford Expedition model years
Check your 2002 Ford Expedition VIN
Not every recall applies to every VIN in a given year. Enter the 17-character VIN from your Ford Expedition at nhtsa.gov/recalls to see whether your specific vehicle has an unrepaired recall.
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