Bulletins


BulletinBulletin dateReplacement BulletinItem no.SummaryAdded
FUEL SYSTEM, DIESEL - STORAGE - TANK ASSEMBLY
04211510/31/20050521310013388Fuel gauge slow to update after refueling. *eh04/18/2005
FUEL SYSTEM, GASOLINE
0113407/09/200104252620982Fuel hesitation while making hard sweeping right hand turns (such as a highway on-ramp)09/05/2001
FUEL SYSTEM, GASOLINE - DELIVERY - HOSES, LINES/PIPING, AND FITTINGS
1553201/01/2002630018Information on vehicles exhibitng fuel line damage due to pinching/squeezing of the fuel return line. *tt04/11/2002
FUEL SYSTEM, OTHER
1871907/01/200510017860Malfunction indicator lamp coming on with diagnostic trouble codes (dtcs) p0171, p0172, p0174 and/or p0175 (fuel system too rich or lean). *tt12/05/2005
1821710/01/200410010731Multiple vehicles - fuel level indication concerns - service tip. various models including 2005 super duty f-series, excursion, expedition, explorer, mountaineer and aviator. *tt12/07/2004
1822410/01/200410010735Runs rough or misfire - diagnostic trouble codes p0300-p0308 or p0316. *tt12/07/2004
1731611/01/200310008166Fuel signal to instrument cluster service tip. *tt07/22/2004
1749401/01/200410007334Distance to empty not displayed. *tt06/10/2004
039805/12/200310002780Malfunction indicator lamp (mil) illumination with diagnostic trouble codes p0442, p0455, p0456, p0457, p1442 or check fuel cap lamp illuminated with diagnostic trouble code p0457. *tt09/17/2003
FUEL SYSTEM, OTHER - STORAGE - FUEL GAUGE SYSTEM
0521301/01/20060621210019379Malfunction indicator lamp on with pcm diagnostic trouble code p0463 and/or ic diagnostic trouble code b1201 - fuel gauge drops to empty or slow to update after refueling. *tt03/13/2006
1812109/01/200410011332Fuel gauge slow to update. *tt01/18/2005

Consumer Complaints


Fail datemilesoccurencesPurchase date
FUEL SYSTEM, GASOLINE
10/17/201090870
 I noticed one day that my gas gauge showed empty when i knew i had gas, the next time i started the engine my gas gauge worked. from that day it works sometimes and sometimes it doesn't. i am afraid that it will give out completely one day and can't afford to fix it. i have read many complaints about this problem and wonder why there is not a recall as i feel ford should take responsibility here as it is clearly a defect.
12/25/201014995
 2002 ford explorer at 15000 miles; bought truck used from my brother. he never drove it because he had a company car. fuel pump went out while driveing it home, door adjar light never went out, check engin light came on(should have taken it right back to my brother).$650.00 to replace fuel pump, $100.00 to fix door adjar light(fixed myself), $600.00 to fix check engin light and that problem was different depending on which place checked the error codes. now the fuel gage is going all over the place and very poor mpg. was told the sending unit is probable cause. now this 2002 explorer still under 20,000 miles. what next!!
11/09/200974000
 Tl- the contact owns a 2002 ford explorer. while driving at approximately 45 mph, the fuel gauge reading began to fluctuate erratically . the vehicle was taken to the dealer for diagnostics. the technicians stated sugar was found in the fuel system. the technicians replaced the fuel pump,cleaned the fuel tank, and replaced the fuel filter. after the repairs, the fuel gauge continued to read empty constantly. the vehicle was not repaired. the approximate failure mileage was 74,000. tlb
11/09/200974000
 Tl- the contact owns a 2002 ford explorer. while driving at approximately 45 mph the fuel gauge reading began to fluctuate erratically . the vehicle was taken to the dealer for diagnostics. the technicians stated sugar was found in the fuel system. the technicians replaced the fuel pump,cleaned the fuel tank, and replaced the fuel filter. after the repairs, the fuel gauge continued to read empty constantly. the vehicle was not repaired. the approximate failure mileage was 74,000. ds
05/17/2011
 Fueling system/fuel pump failure. this is my second 2002 ford explorer and i'm having the same issue. the first explorer i had i replaced the fuel pump and continued to have the same. now the current 2002 explorer i have now is experience the same exact issue. i'm just amazed at how many complaints there are about this problem from other buyers and it still isn't considerated a recall. very frustrated!
03/01/2006
 Explorer gas will not pump. clicks every few seconds
01/21/2011108000
 I have a 2002 ford explorer, original plugs in it from dealer. today i had a plug ejected from the engine resting on top of the head. luckily i kow about cars and had vehicle towed to repair shop. incident is common in fords and could lead to possible injury, since ejected plug could lead up to excessive gasoline vapors which could be ignited by loose plug causing fire.
12/26/2010115000
 Accelerator pedal was hard to press, rpm remained high 3000 - 4000. evetaully the car would not stop, accellerator was stuck - go was going 70 mph. had to stut of engine mechanic replace accellerator cable - noted cable was kinked and frayed - very dangerous and that i should report it.
02/14/2007
 The fuel gauge, most of the time, does not work.
08/30/201064
 Even with a full tank of gas the gas gauge will go to 0 and the check gauge light comes on because the sender assembly unit of the gas gauge does not work. there had been another 2002 explorer brought in for the same problem that morning. the part is not available and is on back order. the part cost $76.79 but the labor will be $270! this is a lot of money for us to pay due to an fords egineering problem. are many other 2002 explorers experiencing the same problems? many times, because the fuel sending unit is corrupted, it will put too much fuel in injectors, which has caused my car to bog down especially dangerous at intersections and at hwy entrance ramps.
06/13/2010119000
 Came home to find stoing gasoline fumes and a stream of gas leaking on the driveway from under the explorer. climbed underneath it to find a hose leaking.
09/15/2008120001
 1) 2002 ford explorer will crank but not start when weather is hot (2) many times at home when weather is hot. consequences: unable to use car for a month. (3) ford dealer ($250) changed fuel idle box. did not correct problem.(4) ford now wants to change fuel pump for $1000.00 mileage is 12000 . *tr .
10/16/2008112085
 Tl*the contact owns a 2002 ford explorer. the contact noticed fuel leaking from a hose after refilling the vehicle with fuel. she drove the vehicle to a local repair shop and the mechanic stated that the assembly line connected to the fuel tank was defective. the manufacturer stated that there were no recalls. the dealer advised her to bring in the vehicle to be serviced. the vehicle has not been repaired. the current mileage was 113,000 and failure mileage was 112,085.
08/19/2008865431
 My fuel tank light keeps coming on, stating that i need to check my cap. when i check the cap it is on tight and have no idea why the light comes on.. it's not on all the time... *tr
10/15/2007110001
 Fuel pump failed while driving into my driveway with only 11,000 miles on the car. cost $ 950.00 to replace the pump at dealer. this could be dangerous if it occurred while driving on freeway. a few weeks earlier i noticed a one time occurrence when the car didn't want to accelerate while driving at approx. 55 mph but problem corrected itself. *tr
04/28/2008404351
 The fuel system on my ford explorer went out completely at 40,000 miles. also, the black panels between the windows are faded and peeling. *tr
03/10/2008350001508/01/2003
 Where to start... broken cruise control, headlight switch has a short, driver side passenger window doesn't roll down, trouble going into gear, car suddenly dies at interstate speeds, loud grinding sound from the engine bay (like an electric knife sharpener) that is getting increasingly more frequent, service engine soon light will not go off, brakes squeal and don't stop the vehicle properly, support for the hatch (which is cracked 8 inches or so in two places) doesn't lift hatch completely, and the fuel economy is down to 4-6 mpg in the city. i hate it! i don't feel like my girlfriend is safe driving it, and i think ford should be forced to make their wrongs into rights! *tr
07/01/2006111/03/2003
 2002 explorer has problems picking up speed and over use of gas. *ts the consumer also had problems with the transmission, gear adjustment, difficult high altitude driving even after gear change, air suction into the engine and transmission, accelerator and ses light illuminated. the vehicle was taken to the dealer but they refused to provide any assistance. *nm updated 07/06/06. *jb
06/09/2006111/03/2005
 On or about november 3, 2005, i purchased a break model used ford explorer xlt 2002 from norm reeves honda car dealer in cerritos, ca. the car had 78,000 miles on it at the time of purchase. i signed the papers and took the possession of the car. it has not been more than 2 months that the car started giving me trouble on the pick up of the speed, transmission, gear adjustment, over use of the gas, difficult high altitude driving even after change of gears, air suction into the engine and transmission, accelerator and signs like service engine soon on the front panel, although i have been getting regular lube and tune on the car after every 3000 miles. while driving the, occasionally, the car gives a thundering noise on the tires as if it is dragging itself and running on the road. this makes me fear that my car is not safe for me to drive! the norm reeves honda super store car dealer knew that the car is defective and they simply wanted to get rid of a used 2002 ford explorer xlt vehicle from the fleet as they primarily sell honda cars and similar vehicles. despite repeated requests, the norm reeves honda super store and their sister company ford of cerritos refused to provide service on the car since i stopped payments on the car loan. other ford car dealers have test driven this car and observed the same defects as i have mentioned. my purpose of writing this complaint with the nhtsa is to request the intervention of nhtsa immediately as the questioned vehicle is likely to endanger my life on the local roads and/or on highway/freeways. due to major defects in the car, i can meet with a serious accident and can be crippled or suffer such pecuniary losses that are irreplaceable and/or i can die also with out any fault of mine. please recall firestone tires v. ford motor company case law. criminal charges against norm reeves honda, ford of cerritos and their ceos to follow. please contact me and the dealers asap. respectfully submitted, amardeep singh gill. *nm
07/20/200547500101/01/2002
 After a short drive to and from the gas station i noticed a strong fuel smell from our 2002 ford explorer. noticed wet spot on the diveway the following day. a short 6 drive consumed nearly a quarter tank of gas. no action has been taken as of yet. have not driven the car since. are any other reports of such failures? is it safe to drive the car?
04/30/2004101/12/2004
 Ford explorer caught fire while driving. *bf the consumer has a report which stated the fire was caused by a gas leak. *jb *nm
09/15/200210132
 September 2002: fuel injector for #3 cylinder failed, causing gasoline to be sprayed over engine. discovered in driveway during vehicle warm-up. no indication of problem except for smell. october 2003: fuel injector for #3 cylinder failed, causing gasoline to be sprayed over engine. failure occured at some point during driving. discovered only due to fuel smell. no other indication. dealer fixed both times. concerned about occupant safety -appears as though fire could easily ignite, and lead to serious injury or death. no warning that system has failed.
108/01/2002
 The consumer stated the gasoline fumes entered the vehicle after filling the vehicle with gasoline. this problem occurred intermittently. the manufacturer and dealer were contacted. *ak *sc
30003
 Fuel system has a leak that results in fuel spills, allowing fumes to enter passenger's compartment. dealership cannot fix problem.*ak
10/01/20015
 Vehicle experiences periods of stalling at low speeds. applying brakes there is a loss of brakes and steering. no prior warning before stalling. existing problem 5 times, taken into the delaer. *ak dealer replaced fuel pump, main control valve body, transmission oil pan, idle air control valve and programmed pcm. vibration like anti-lock brake system is kicking in. dealer could not duplicate. overdrive comes in and out at odd speeds. no problem found.
04/20/2002203/30/2001
 When making a sudden stop or from a stop position vehicle would momentarily hesitate before jerking into gear when applying accelerator pedal. vehicle has been to dealer on three occasions, and was unable to locate cause of problem. *ak when making a sudden stop the truck will not accelerate. it will just make a grinding noise. consumer has to put vehicle in park and restart. vehicle runs rough and changes gears while driving, consumer would like ford to either fix the problem correctly, repurchase or replace the vehicle. *jg
11/01/20014
 Fuel fumes were getting into the vehicle while driving. vehicle been to dealer on four occasions, but problem was reoccurring. feel free to provide any further information.*ak
FUEL SYSTEM, GASOLINE - DELIVERY
01/10/200418000206/01/2002
 Fuel indicator reads incorrectly. the part was repaired once. however, the problem still exists. *ak *nm
FUEL SYSTEM, GASOLINE - DELIVERY - FUEL PUMP
09/15/2008120001
 1) 2002 ford explorer will crank but not start when weather is hot (2) many times at home when weather is hot. consequences: unable to use car for a month. (3) ford dealer ($250) changed fuel idle box. did not correct problem.(4) ford now wants to change fuel pump for $1000.00 mileage is 12000 . *tr .
06/10/2008560001
 2002 ford explorer- a nightmare of problems that keep getting worse. it has 56k miles on it and i am about to replace the transmission. fuel pump , 2 rear springs, 2 wheel bearings and the drivers side window motor have already been replaced. neither of the 2 rear windows roll down and the back hatch lift replace on recall is broken yet again. this is the biggest hunk of junk on 4 wheels. ford needs to do something. thank god i didn't buy it new because that really would have been a rip off. *tr
10/15/2007110001
 Fuel pump failed while driving into my driveway with only 11,000 miles on the car. cost $ 950.00 to replace the pump at dealer. this could be dangerous if it occurred while driving on freeway. a few weeks earlier i noticed a one time occurrence when the car didn't want to accelerate while driving at approx. 55 mph but problem corrected itself. *tr
06/28/200795200510/25/2004
 This 2002 ford explorer eddie bauer abruptly stops while driving at any speed without any notice or indication that the ignition will fail to keep the car running. this car has been to two ford dealerships and one reputable and established independent automotive repair shop. this car was at a toyota dealership for almost 30 days and this car was returned to me with this potentially fatal defect still undiagnosed. none of the aforementioned dealerships could determine the true underlying problem. at the toyota dealership a brand new starter was installed because of a no start condition showing no power to the starter and blown fuses for the injectors, fuel pump, and the computer. the same defect showed itself one day later after traveling over 70 miles with no sign of failure. *tr
06/27/2002105/01/2001
 Drivers side saftey belt has broken too, air vent has broken too, sunroof design problem too, fuel pump failed at 14000 mi too
FUEL SYSTEM, GASOLINE - DELIVERY - HOSES, LINES/PIPING, AND FITTINGS
02/10/2008142000109/20/2007
 2002 ford explorer fuel filter replacement fire hazard. fuel line retaining clips (50 cent part) are only available from ford in a $200 fuel line assembly. not using these clips causes to much slack in the fuel line to filter connection. their intent to rope the consumer into a $200 purchase may cause alternate, read:unsafe solutions by the customer. the feeling is that ford is extremely negligent in not making these 'locking r-clips' available separately at the dealership parts counter, or in the aftermarket for the replacement of a regular maintenance item. (fuel filter). ford has been contacted twice regarding this oversight on their part and refuse to offer the clips by themselves. *tr
12/23/200485000607/28/2004
 At 74000 miles our transmission went out completely while we were on vacation! the dealership where we bought the vehicle, said that we were the only one's who have had this problem (yeah right!) it cost us $6000 out of our pocket to fix. at 86000 miles the rear window cracked right below the window. ford and the dealership refuses to fix it. again, stayton ford told us that,we were the only people who have had this particular issue. at around 85000, 95000 and 105000 miles, the rear seals leaked. we were promised each time that they would last for at least 50000 miles. we were always a few miles away from getting them replaced for free since they're limited warranty is only good for 10000 miles. at 111000 miles the electrical system went haywire. even when all of the door and hatch are closed, the dome light continues to go on and off (making it hard to drive at night) because it senses that a door is a jar. sometimes, the key pad that's located on the drivers side window sets off the alarm when we push the first number on the key. totally unreliable vehicle that i'm afraid to drive! *nm
05/01/2006520001
 Dt*: the contact stated there was a smell of gasoline in and around the vehicle. the smell became progressively worse, and the fuel mileage decreased over time. the vehicle was taken to a private repair shop, where the mechanic determined there was a leak in the fuel line above the tank. the parts were ordered, and the manufacturer was notified. updated 11/30/06. *jb
04/30/200420011101/12/2004
 While driving approximately for two hours. the driver stopped at a toll booth. suddenly white smoke started emitting from under the hood followed black smoke. the vehicle caught fire within seconds and was a total lost. the fire department says the gas line may have melted the manifold. please describe any further information. *jb
FUEL SYSTEM, GASOLINE - STORAGE
06/01/200322000911/01/2002
 Dt*: the contact stated the vehicle has intermittently stalled possibly due to outdoor heat. the vehicle stalled or would not start on nine different occasions. the vehicle was taken to the service dealer after each incident where the inertia switch, the fuel pump and the pcm module were changed. this problem occurred eight times while the vehicle stopped, while it was started, at an intersection, and once with the vehicle in motion at 35 mph. the contact also stated the gas storage tank had developed a hole and was leaking gas.
12/01/20041201/22/2002
 Gas guage will drop to empty and the digital readout will say that there are 0 miles to empty even though i have a quarter of a tank left. if i wait a little nit it will slowly go back up to where it belongs. i called dealer and they said they know nothing of this default and don;t know how to fix it.
12/15/2001
 Consumer stated that while driving the fuel sending unit is not working properly and the vehicle will run out without warning. dealer notified ts
FUEL SYSTEM, GASOLINE - STORAGE - TANK ASSEMBLY
08/22/2003208/27/2002
 Consumer stated that while making a left turn he heard a loud humming noise and had difficulty turning vehicle. the vehicle was taken to the dealer and the technician indicated that the power steering rod failed. this problem occurred in july. in august the consumer made a turn and the vehicle shut off in the middle of an intersection which caused the steering wheel to lock up. the vehicle was taken to the dealer who indicated that the fuel tank needed to be replaced. the glass in the rear hatch rattled. the vehicle was purchased new and the consumer believes it should not be experiencing these types of problems. *ak *nlm
FUEL SYSTEM, GASOLINE - STORAGE - TANK ASSEMBLY - FILLER PIPE AND CAP
07/17/2009171000
 Tl*the contact owns a 2002 ford explorer. the contact stated that the service engine soon and check gas cap indicators illuminated and caused the vehicle to shut off. in addition, the gas tank was very difficult to fill up while placing fuel in the tank. the contact called the manufacturer regarding these issues. he feels that it is a safety hazard for the vehicle to shut off without warning. the vin was unknown. the current and failure mileages were 171,000.
10/01/200850000
 Tl*the contact owns a 2002 ford explorer. the contact stated that every time gasoline is pumped into the vehicle, fuel would spew out and splash onto the contact. the dealer stated that the repairs would cost $1,000, even though there was a recall for the 2002 ford expedition. the contact feels that the manufacturer should be responsible for the repairs. the current mileage was 70,000 and failure mileage was 50,000.
12/20/20036300010012/15/2003
 2002 ford explorer xlt. i can not put gas on it because it overflows rapidly and throws the gas out of the tank. i was told that it was a common problem with the tank breader and it would cost around $ 600.00 to fix it. it is a safety issue because the gas comes right back at you and can cause a major fire. ford should voluntary fix this defective problem at no charge.*ak
FUEL SYSTEM, OTHER
11/21/20091185871
 Accelerator pedal sticks when wide open throttle scenario presents itself in real world application ! 2002 ford explorer automatic,tranny, four wheel drive. *tr
03/15/2008400001
 When i tried to remove my key from the ignition, the entire ignition cylinder came out!! my car had to be towed and have a new cylinder installed! a year later, it happened again!!! so i have had to replace my ford ignition cylinder twice and my car only has 60,000 miles on it now---so probably had only about 40,000 miles the first time it happened and 50,000 the second time. also-- now my fuel gauge says empty all the time, even after i just filled it with gas! and it's too expensive to fix! i did get the driver seatbelt fixed, because it didn't tighten, but now it's too hard to pull out and use! lastly, both inside mirror covers have just cracked off when lifting open, and i can't afford to replace both of the entire visors! we have 3 fords and this is the only one that's ever had problems. dates are spread out so it's too hard to complete that part of the form below. *tr
10/09/2008820001
 Throttle stuck and car would not slow down, almost caused an accident, put car in neutral but engine kept on racing, searched internet on found that the throttle cable is defective, ford changed design from 12 to 9 wire design, saw alot of posts on internet with similar experiences, can't believe no recall. car accelerated on its own. *tr
12/04/200430000106/29/2001
 1. driving approximately 30 minutes on the evening (7:30 pm) of 12-4-04 to a holiday party with just myself and my wife. upon arriving within seconds of the location an anonoymous dirver stopped our vehicle and made us aware that there was a fire coming from under our vehicle, a 2002 ford explorer xlt. as we jumped out of the vehicle and saw the fire a neighbor watching called the local fire department. within minutes the fire department arrived and tried to extinguish the fire. being unsuccesful it took the fire department approximately an hour to stop the fire at which time the vehicle was destroyed. there was nothing to be repaired as the vehicle was destroyed. and there had been no indication that there was anything wrong with the vehicle prior to this incident.*ak
05/04/20042
 I own a 2002 ford explorer 4 door. the rear left window was failing to go down, and when it did it would take time for it to go back up again. my mother purchased a 2003 ford explorer as well and my niece and they too experienced the same problem. i also had problems with my air leaking and was informed that some form of an invisible gas was leaking into my vehicle. i have an infant daughter and was concerned that she was breathing this.*ak
FUEL SYSTEM, OTHER - STORAGE - FUEL GAUGE SYSTEM
01/20/2007750003
 The middle panel under the glass in the back of the car has cracked. i suspect it was due to cold weather. i have since seen other explorers with this problem and notice that there are a lot of complaints online about this. in addition, this past summer my shifter snapped off the barrel. i had 4 kids in the car at the time. ford responded by telling me that i had 75k miles and no warranty and i didn't typically get my car serviced there so they weren't going to be willing to work with me to get it resolved. when i told him i had my 'regular' mechanic look at it he said that the labor rate was probably cheaper with him than at ford. well - now tell me why i would service my car at a ford dealership? oh yeah...in case i get cracks or shifters fall off and maybe they'll 'work with me' on the price. big incentive. oh yeah, my fuel gauge doesn't work - another common problem. my previous explorer (about 10 years back) had the same problem . the guy up the street has an explorer (2003) and it doesn't work either. *jb
11/14/20042309/02/2001
 Even with a full tank of gas the gas gauge will go to 0 and the check gauge light comes on because the sender assembly unit of the gas gauge does not work. when we took our explorer to dub miller ford in rosenberg on nov. 19th, there had been another 2002 explorer brought in for the same problem that morning. the part is not available and is on back order. the part cost $76.79 but the labor will be $270! this is a lot of money for us to pay due to an ford's egineering problem. are many other 2002 explorers experiencing the same problems? thanks! shelley and gale towns. *ak
08/24/20041
 When the fuel tank was filled up it registered empty twelve hours later. however, fuel tank read full. vehicle has ran out of gas on more than one occasion. consumer drove the vehicle to dealer for inspection, and mechanic determined that fuel sending unit needed to be replaced. *ak
07/20/20045131808/02/2002
 13jan03-rear windshield washer inoperative reinstall rear washer hoses. 5nov03-clicking noise from rear a/c; replace motor assembly temperature blend. 5nov03&13nov03-l/r power mirrors inop; fuse blows; replaced mirror rear view outside sail mount 13nov03-fuel guage inop read 1/2 tank but tank was full; 20nov03-instrument cluster fuel gauge inop; 24nov03-removed and replaced instrument cluster; 18mar04-fuel guage inop & l/r power mirrors inop, fuse blows; could not duplicate problem at this time about fuel guage; tested bce for short, traced to mirror switch, replaced switch and blown fuse; 20 july 04-l/r power mirrors inop; replaced fuse; 20 july 04 - rear winshield washer inop; access washer hose and reconnect; 20 july 04- air conditioner not cooling properly; replaced blower motor for poor operation; motor assembly-heater-a/c blower replaced. 20 july 04 - mechanics broke the drivers door switch cover- 23 july 04 -reordered door panel and replaced drivers door switch cover.*ak
03/03/2004480001
 While driving, the gas gauge would read wrong. this would cause the consumer to not know how much fuel was in the vehicle. *jb
03/10/20041
 While filling up at the gas station the fuel gauge malfunctioned. the fuel tank registered a full tank, but 12 hours later, a false reading occurred. consumer took the vehicle to the dealer for inspection, and the mechanic replaced the fuel sending unit due to worn out parts. *ak