2002 Ford F-150 recalls and problems

The 2002 Ford F-150 has 2 recalls and 821 owner complaints on file with NHTSA; the most reported problem area is engine.

Pictured: a 2001 model; the 2002 may differ in details. Photo: 2001 Ford F-150 by MercurySable99, CC BY-SA 4.0, via Wikimedia Commons

How the 2002 compares

Average

Fewest complaintsMost complaints

Average complaint count among 27 F-150 model years — 16th most.

2recalls

821complaints

51crashes

95fires

60injuries

90,000median miles

Owner complaints filed with NHTSA, not verified and not adjusted for sales. Ranking compares this model's own years only.

Does your car have an open recall?
Recalls apply to specific vehicles. Only a VIN lookup on NHTSA's official site shows whether yours is affected and still unrepaired.

Check your VIN →

2 recalls

Fuel System

Jul 29, 2011 · NHTSA campaign 11V385000 · 1,100,000 vehicles

Problem: Ford is recalling certain 1997 through 2003 model year Ford f-150, 2004 model year Ford f-150 heritage, 1997 through 1999 model year f-250 less than 8,500 LBS. Gross vehicle weight rating (GVWR), and 2002 and 2003 Lincoln blackwood vehicles manufactured from June 20, 1995, through August 4, 2004, originally sold, or currently registered in, Connecticut, Delaware, Illinois, Indiana, Iowa, Kentucky, Maine, Maryland, Massachusetts, Michigan, Minnesota, Missouri, New Hampshire, New Jersey, New York, Ohio, Pennsylvania, Rhode Island, Vermont, West Virginia, Wisconsin, and the District of Columbia. Prolonged exposure to road deicing chemicals May cause severe corrosion of the fuel tank straps which secure the tank to the vehicle.

Original NHTSA wording

FORD IS RECALLING CERTAIN 1997 THROUGH 2003 MODEL YEAR FORD F-150, 2004 MODEL YEAR FORD F-150 HERITAGE, 1997 THROUGH 1999 MODEL YEAR F-250 LESS THAN 8,500 LBS. GROSS VEHICLE WEIGHT RATING (GVWR), AND 2002 AND 2003 LINCOLN BLACKWOOD VEHICLES MANUFACTURED FROM JUNE 20, 1995, THROUGH AUGUST 4, 2004, ORIGINALLY SOLD, OR CURRENTLY REGISTERED IN, CONNECTICUT, DELAWARE, ILLINOIS, INDIANA, IOWA, KENTUCKY, MAINE, MARYLAND, MASSACHUSETTS, MICHIGAN, MINNESOTA, MISSOURI, NEW HAMPSHIRE, NEW JERSEY, NEW YORK, OHIO, PENNSYLVANIA, RHODE ISLAND, VERMONT, WEST VIRGINIA, WISCONSIN, AND THE DISTRICT OF COLUMBIA. PROLONGED EXPOSURE TO ROAD DEICING CHEMICALS MAY CAUSE SEVERE CORROSION OF THE FUEL TANK STRAPS WHICH SECURE THE TANK TO THE VEHICLE.

Risk: As a result of the corrosion, one or both straps May fail allowing the fuel lines to separate from the tank, or in some cases, causing the tank to contact the ground. Either scenario May result in a fuel leak presenting a fire hazard.

Original NHTSA wording

AS A RESULT OF THE CORROSION, ONE OR BOTH STRAPS MAY FAIL ALLOWING THE FUEL LINES TO SEPARATE FROM THE TANK, OR IN SOME CASES, CAUSING THE TANK TO CONTACT THE GROUND. EITHER SCENARIO MAY RESULT IN A FUEL LEAK PRESENTING A FIRE HAZARD.

Remedy & notes

Ford will notify owners and instruct them to take their vehicles to a Ford or Lincoln dealer to have the fuel tank straps replaced with straps that have increased corrosion protection. Early in this campaign, if replacement straps are not available, dealers May install a cable support under the strap as an interim repair or a steel reinforcement over the existing strap as a permanent repair. Any repairs will be performed free of charge. The safety recall began on September 16, 2011. Owners May contact Ford motor company customer relationship center at 1-866-436-7332. Ford's recall campaign number is 11S21

Ford's recall campaign number is 11S21.owners 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 <a href=http://www.safercar.gov>http://www.safercar.gov</a> .

Vehicle Speed Control

Sep 7, 2005 · NHTSA campaign 05V388000 · 4,500,000 vehicles

Problem: On certain pickup trucks and sport utility vehicles equipped with speed control, the speed control deactivation switch May overheat, smoke, or burn.

Original NHTSA wording

ON CERTAIN PICKUP TRUCKS AND SPORT UTILITY VEHICLES EQUIPPED WITH SPEED CONTROL, THE SPEED CONTROL DEACTIVATION SWITCH MAY OVERHEAT, SMOKE, OR BURN.

Risk: A fire at the switch could occur.

Original NHTSA wording

A FIRE AT THE SWITCH COULD OCCUR.

Remedy & notes

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)

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.

Recall text as published by NHTSA and the manufacturer.

What owners complain about

Engine262

Electrical System106

Fuel System86

Vehicle Speed Control86

Owner complaints filed with NHTSA; one complaint can name several areas. Not verified by NHTSA.

Complaints by year filed

NHTSA investigations

Fuel Tank Strap Failure Due to Corrosion

EA11006 · opened May 4, 2011 · closed Aug 19, 2011 · led to recall 11V385000

Summary

One or both of the steel straps holding up the fuel tank and attaching it to the truck frame can corrode and fail (break or separate).If one strap fails, the tank may tilt and drop and possibly contact the road surface.If both straps break, the entire tank may drop to the road.If either failure occurs while the vehicle is being driven, contact with the road can abrade the tank and create a hole from which gasoline can spill.When the tank drops, it remains attached to the vehicle only by the fuel filler hose and/or supply lines, or in rare instances, by the skid plate, if present.In some cases the weight of the tank sufficiently strained the hoses and fittings and caused separation and subsequent fuel leaks from those connections.The fire hazard created by leaking gasoline is increased by the possible presence of sparks created by the metal tank being dragged along the road.Corrosion of the straps appears to be caused by prolonged exposure to road deicers, frequently road salt, used to treat snow or ice covered roads.States in which large quantities of deicers are applied to roads during the winter season (salt belt states) account for the predominant portion of strap failures.Vehicles in these salt belt states are prone to experience corrosion related failures more frequently and earlier in a vehicle?s life cycle.Ford reports approximately 97 percent of reports it received relating to strap failure involve vehicles that were operated in these high corrosion areas, and 95 perc…

SPARK PLUG EJECTION FROM CYLINDER HEAD

DP05005 · opened Sep 22, 2005 · closed Jan 4, 2006

Summary

ON SEPTEMBER 6, 2005, ODI RECEIVED A PETITION REQUESTING THAT THE AGENCY INVESTIGATE ALLEGATIONS OF ENGINE SPARK PLUG EJECTION IN CERTAIN MODEL YEAR 1997 THROUGH 2004 FORD VEHICLES WITH TRITON V-8 AND V-10 ENGINES.ODI RECEIVED A TOTAL OF 474 NON-DUPLICATIVE COMPLAINTS ON THE SUBJECT VEHICLES WHERE THE COMPLAINANT, OR THE DEALER REPAIRING THE VEHICLE, REPORTED THAT A SPARK PLUG DETACHED FROM THE CYLINDER AND/OR EJECTED FROM THE ENGINE.AS OF DECEMBER 8, 2005, ODI IS NOT AWARE OF ANY ALLEGATIONS WHERE THE ALLEGED DEFECT RESULTED IN A LOSS OF VEHICLE CONTROL, A CRASH, AN INJURY, OR A FATALITY IN ANY OF THE 10,319,810 SUBJECT VEHICLES.IN ADDITION, ODI IS AWARE OF ONLY TWO INCIDENTS WHERE THE VEHICLE STALLED WITHOUT RESTART.INFORMATION CONTAINED IN THE ODI CONSUMER COMPLAINTS AND OBTAINED FROM 72 TELEPHONE INTERVIEWS WITH COMPLAINANTS SHOWED THE FOLLOWING:(1) 99% OF THE COMPLAINTS WERE ON MY 1997 TO 2002 SUBJECT VEHICLES.(2) MOST THE COMPLAINANTS REPORTED HEARING A LOUD POP WHILE DRIVING OR UPON STARTING UP THE VEHICLE FOLLOWED BY A LOUD, REPETITIVE CLICKING OR POPPING SOUND.(3) MANY OF THE COMPLAINANTS REPORTED THAT THE POPPING SOUND WAS ACCOMPANIED BY SOME LOSS OF VEHICLE POWER; HOWEVER, IN 99% OF THE INCIDENTS REPORTED, THE VEHICLE DID NOT STALL.IN THE VERY FEW INCIDENTS WHERE THE VEHICLE DID STALL, MOST VEHICLES COULD BE RESTARTED.(4) ONLY A SMALL PERCENTAGE OF THE COMPLAINANTS CITED THAT THEY SMELLED GAS OR A SLIGHT BURNING SMELL WHEN THE INCIDENT OCCURRED.(5) IN ALL BUT A VER…

ENGINE COMPARTMENT FIRES

EA05005 · opened Mar 22, 2005 · closed Aug 2, 2006 · led to recall 05V388000

Summary

EA05-005 IS CLOSED WITH FORD?S ACTIONS IN RECALLS 05V-017, 05V-388, AND 06V-286, RECALLING APPROXIMATELY 6.7 MILLION VEHICLES EQUIPPED WITH TEXAS INSTRUMENTS SPEED CONTROL DEACTIVATION SWITCHES (SCDS).THE BRAKE SYSTEMS IN THESE RECALLED VEHICLES GENERATE A VACUUM THAT CAN POTENTIALLY CAUSE THE SCDS TO FAIL AND, IN CERTAIN SWITCH INSTALLATION ORIENTATIONS, CATCH FIRE.FORD IS ALSO INCLUDING THE ENTIRE POPULATION OF 1998 EXPLORERS.FORD HAS INFORMED ODI THAT TESTING TO DETERMINE THE CAUSE OF FAILURES IN THE 1998 EXPLORERS WILL CONTINUE AFTER THIS INVESTIGATION IS CLOSED.ODI BELIEVES THAT THE VEHICLES EXHIBITING THE FACTORS CAUSING SCDS FAILURE DESCRIBED IN THIS REPORT CORRELATE WELL WITH THE OBSERVED FAILURE RATES ON THESE VEHICLES BY MODEL AND MODEL YEAR.THE CLOSING OF THIS INVESTIGATION DOES NOT CONSTITUTE A FINDING BY NHTSA THAT A SAFETY-RELATED DEFECT DOES NOT EXIST IN THE NON-RECALLED VEHICLES MANUFACTURED WITH SCDS THAT ARE NOT INCLUDED IN FORD?S RECALLS.ODI WILL CONTINUE TO MONITOR THE NON-RECALLED POPULATION FOR INCIDENCE OF ENGINE COMPARTMENT FIRES.THE AGENCY RESERVES THE RIGHT TO TAKE FURTHER ACTION IF WARRANTED BY THE CIRCUMSTANCES.SEE ATTACHED CLOSING REPORT FOR DETAILS.

2002 vs. other Ford F-150 years

Owner complaints by model year; the darker bar is the 2002. Click a bar to switch year.

Questions

Does the 2002 Ford F-150 have recalls?

Yes — NHTSA lists 2 recall campaigns covering the 2002 Ford F-150, the latest from Jul 29, 2011 (fuel system). A recall applies to specific vehicles: enter your VIN at nhtsa.gov/recalls to see whether yours is affected and still open.

What are the most common problems with the 2002 Ford F-150?

Owner complaints filed with NHTSA most often mention engine (262), electrical system (106), fuel system (86). Complaints are consumer reports and are not verified by NHTSA.