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FaultScore report

2002 Ford F Series (Light) problems

Owners have filed 17 complaints about the 2002 Ford F Series (Light) with NHTSA between 2003 and 2018. The largest single group is the engine & cooling. Across this model's run it ranks 5 of 5 worst.

Read the complaints What breaks Worst years for the Ford F Series (Light) All 2002 cars
B

FaultScore 29/100

Higher is worse. Measured against the other years of the Ford F Series (Light).

How this is worked out

The numbers

17

Complaints

0

Crashes reported

0

Fires reported

0

Injuries reported

107,590 mi

Median mileage at failure

Half of reported failures happened before this

12%

Failed under 36,000 miles

Inside a typical bumper-to-bumper warranty

What kind of bad

The letter says how bad. This says what kind — whether this year drew an unusual number of complaints, unusually dangerous ones, or failures that arrived unusually early.

Complaint volume 50 vs 50 Severity 0 vs 50 Early failure 20 vs 50
The dashed ring is 50 — the national norm. Further out is worse.
Complaint volume — 50
Against the median year of the Ford F Series (Light). 50 means typical for this model; 100 means roughly double.
Severity — 0
0% of these complaints involved a crash, fire, injury or death, against a national rate of 9.7%.
Early failure — 20
12% of failures with a mileage on record happened under 36,000 miles, against a national rate of 29%.

How 2002 compares with every other Ford F Series (Light)

Click any bar to open that year's report.

Complaints filed with NHTSA, by model year. Bar colour is the FaultScore grade: A B C D F ungraded

What breaks on a 2002 Ford F Series (Light)

Every complaint is filed against a part. Follow any row for the complaints about that part alone.

Engine & Cooling 10 58.8%

Median failure at 135,000 miles

Fuel & Propulsion 2 11.8%

Median failure at 185,250 miles

Suspension 1 5.9%

Median failure at 6,500 miles

Body & Structure 1 5.9%

Median failure at 76,000 miles

Brakes 1 5.9%

Median failure at 76,000 miles

Electrical System 1 5.9%

Median failure at 107,590 miles

Transmission & Drivetrain 1 5.9%

Median failure at 76,000 miles

When it fails

Odometer readings owners gave when they filed. About half of all complaints include one.

1,000 – 9,999 miles 1 5.9%
25,000 – 49,999 miles 1 5.9%
50,000 – 74,999 miles 1 5.9%
75,000 – 99,999 miles 4 23.5%
100,000 – 149,999 miles 3 17.6%
150,000+ miles 7 41.2%

When owners complained

A spike years after the car went on sale usually means a part wearing out on schedule across the whole fleet — the kind of pattern no single owner can see from inside their own car.

Feb 2003 peak 4 Jul 2018

The most recent complaints

In the owners' own words, exactly as filed with NHTSA.

at 90,000 miles Ashland, VA

ENGINE

WE PURCHASED A CAR FROM NAB AUTOS IN FREDERICKSBURG, VA. AFTER THE 7TH DAY OF DRIVING IT, THE MOTOR BLEW UP. WRONG SPARK PLUGS WERE INSTALLED BY DEALER. ALSO THE TRUCK HAD BEEN RACED WITH NITROUS WHICH WE WERE UNAWARE OF UNTIL WE TRIED TO FIND OUT WHAT HAPPENED TO MOTOR. I HAVE DOCUMENTATION FROM THE REPAIR SHOP. MY 18 YEAR OLD SON DRIVES THIS VEHICLE WHICH BEGAN LOSING POWER AND SHAKING BEFORE HE WAS ABLE TO PULL OFF TO THE SIDE OF THE HIGHWAY.

NHTSA complaint #11109867 — an unverified report by a vehicle owner.

at 76,000 miles Union Dale, PA

POWER TRAIN

CROSS FRAME MEMBER WHICH CONTAINS THE TRANSMISSION MOUNT WAS EXTREMELY RUSTED OUT AND CRACKED. STATE SAFETY INSPECTION REP INDICATED IT WOULD NOT PASS INSPECTION IN THE NEAR FUTURE. FORD NO LONGER MANUFACTURES THE FRAME MEMBER. I WAS LUCKY AFTER A LONG SEARCH TO FIND A DEALER WHICH STILL HAD THE PART AVAILABLE. PART # IS: XL3Z6A023CA. THE VEHICLE HAS BEEN OPERATED IN WARWICK NY SINCE NEW AND IN NORTHEASTERN PA SINCE 2007. I BELIEVE IF THE FRAME MEMBER WOULD FAIL THE TRANSMISSION WOULD DROP DOWN. I HAVE PHOTOS OF THE RUSTED UNIT. IF YOU CARE TO SEE THEM PLEASE SEND AN E-MAIL ADDRESS AND I'LL ATTACH THEM TO A E-MAIL. SOMETHING MUST BE DONE TO REQUIRE MANUFACTURES TO USE BETTER MATERIAL FOR PICKUP TRUCK FRAMES AND BRAKE LINES. I HAVE ALSO REPORTED PROBLEMS WITH BRAKE LINES ON THIS TRUCK RUSTING OUT. ONE INCIDENT, I REPORTED, OCCURRED AFTER BACKING UP A RV IN A CAMPSITE AFTER JUST DRIVING OVER 150 MILES ON THE INTERSTATE HIGHWAY. PROVIDENCE PROTECTED ME AS I COULD HAVE LOST THE BRAKES WHILE TRAVELING ON THE INTERSTATE! *JS .

NHTSA complaint #10616892 — an unverified report by a vehicle owner.

at 76,000 miles Union Dale, PA

STRUCTURE

CROSS FRAME MEMBER WHICH CONTAINS THE TRANSMISSION MOUNT WAS EXTREMELY RUSTED OUT AND CRACKED. STATE SAFETY INSPECTION REP INDICATED IT WOULD NOT PASS INSPECTION IN THE NEAR FUTURE. FORD NO LONGER MANUFACTURES THE FRAME MEMBER. I WAS LUCKY AFTER A LONG SEARCH TO FIND A DEALER WHICH STILL HAD THE PART AVAILABLE. PART # IS: XL3Z6A023CA. THE VEHICLE HAS BEEN OPERATED IN WARWICK NY SINCE NEW AND IN NORTHEASTERN PA SINCE 2007. I BELIEVE IF THE FRAME MEMBER WOULD FAIL THE TRANSMISSION WOULD DROP DOWN. I HAVE PHOTOS OF THE RUSTED UNIT. IF YOU CARE TO SEE THEM PLEASE SEND AN E-MAIL ADDRESS AND I'LL ATTACH THEM TO A E-MAIL. SOMETHING MUST BE DONE TO REQUIRE MANUFACTURES TO USE BETTER MATERIAL FOR PICKUP TRUCK FRAMES AND BRAKE LINES. I HAVE ALSO REPORTED PROBLEMS WITH BRAKE LINES ON THIS TRUCK RUSTING OUT. ONE INCIDENT, I REPORTED, OCCURRED AFTER BACKING UP A RV IN A CAMPSITE AFTER JUST DRIVING OVER 150 MILES ON THE INTERSTATE HIGHWAY. PROVIDENCE PROTECTED ME AS I COULD HAVE LOST THE BRAKES WHILE TRAVELING ON THE INTERSTATE! *JS .

NHTSA complaint #10616892 — an unverified report by a vehicle owner.

at 76,000 miles Union Dale, PA

SERVICE BRAKES

CROSS FRAME MEMBER WHICH CONTAINS THE TRANSMISSION MOUNT WAS EXTREMELY RUSTED OUT AND CRACKED. STATE SAFETY INSPECTION REP INDICATED IT WOULD NOT PASS INSPECTION IN THE NEAR FUTURE. FORD NO LONGER MANUFACTURES THE FRAME MEMBER. I WAS LUCKY AFTER A LONG SEARCH TO FIND A DEALER WHICH STILL HAD THE PART AVAILABLE. PART # IS: XL3Z6A023CA. THE VEHICLE HAS BEEN OPERATED IN WARWICK NY SINCE NEW AND IN NORTHEASTERN PA SINCE 2007. I BELIEVE IF THE FRAME MEMBER WOULD FAIL THE TRANSMISSION WOULD DROP DOWN. I HAVE PHOTOS OF THE RUSTED UNIT. IF YOU CARE TO SEE THEM PLEASE SEND AN E-MAIL ADDRESS AND I'LL ATTACH THEM TO A E-MAIL. SOMETHING MUST BE DONE TO REQUIRE MANUFACTURES TO USE BETTER MATERIAL FOR PICKUP TRUCK FRAMES AND BRAKE LINES. I HAVE ALSO REPORTED PROBLEMS WITH BRAKE LINES ON THIS TRUCK RUSTING OUT. ONE INCIDENT, I REPORTED, OCCURRED AFTER BACKING UP A RV IN A CAMPSITE AFTER JUST DRIVING OVER 150 MILES ON THE INTERSTATE HIGHWAY. PROVIDENCE PROTECTED ME AS I COULD HAVE LOST THE BRAKES WHILE TRAVELING ON THE INTERSTATE! *JS .

NHTSA complaint #10616892 — an unverified report by a vehicle owner.

at 150,000 miles Seattle, WA

ENGINE

SPARK PLUG FAILURE AS ACCELERATING FROM A STOP LIGHT, AND ENGINE PROBLEM RESULTING FROM 7 CYLINDER OPERATION. GOT IT TO A MECHANIC AND HE WAS ABLE TO SLEEVE THE SPARK PLUG THREAD AND INSTALL A NEW PLUG. NOW THE SAME IS STARTING AGAIN. I AM TAKING THE VEHICLE TO THE MECHANIC TO MAKE PERMANENT REPAIRS FOR ALL THE SPARK PLUG. THIS MAY END UP WITH THE ENGINE HEADS BEING REMOVED IN ORDER TO MAKE COMPLETE REPAIRS, AND THE COST FOR THAT WILL BE THOUSANDS OF DOLLARS. THIS IS A FORD ENGINE DESIGN PROBLEM THAT FORD HAS BEEN AWARE OF, YET THEY CONTINUE TO DENY ANY RESPONSIBILITY.

NHTSA complaint #10610719 — an unverified report by a vehicle owner.

at 66,000 miles LAS Vegas, NV

ENGINE

OIL LEAKING PASSENGER SIDE REAR ON TO THE STARTER AND EXHAUST SYSTEM.

NHTSA complaint #10526147 — an unverified report by a vehicle owner.

at 200,500 miles Hortonville, WI

ENGINE

A SPARK PLUG WORKED LOOSE FROM THE HEAD AND BLEW OUT CAUSING DAMAGE TO THE HEAD AND THE IGNITION COIL. ALL 8 PLUGS HAD TO BE REPLACED, TWO DAMAGED SPARK PLUG HOLES REPAIRED AND TWO IGNITION COILS REPLACED.

NHTSA complaint #10474326 — an unverified report by a vehicle owner.

at 200,500 miles Hortonville, WI

FUEL/PROPULSION SYSTEM

A SPARK PLUG WORKED LOOSE FROM THE HEAD AND BLEW OUT CAUSING DAMAGE TO THE HEAD AND THE IGNITION COIL. ALL 8 PLUGS HAD TO BE REPLACED, TWO DAMAGED SPARK PLUG HOLES REPAIRED AND TWO IGNITION COILS REPLACED.

NHTSA complaint #10474326 — an unverified report by a vehicle owner.

at 120,000 miles Dayton, OH

ENGINE AND ENGINE COOLING:COOLING SYSTEM:RADIATOR ASSEMBLY

TRUCK STARTED MAKING NOISE EVERY TIME THERE WAS A BUMP. HANDLING FELT LOOSE. DISCOVERED THAT THE RADIATOR CORE SUPPORT HAD RUSTED COMPLETELY AWAY ON THE PASSENGER SIDE. THE MECHANIC REFERRED TO THE CONDITION AS "ROT". THIS SUPPORTS THE RADIATOR, A/C AND PROVIDES AN ATTACHMENT FOR THE FRONT FENDERS. I BOUGHT 4 VEHICLES THE SAME YEAR. CHECKED THE OTHER 3 AND THEY HAVE THE SAME ISSUE. I WILL BE FILING REPORTS ON THEM TOO.

NHTSA complaint #10458426 — an unverified report by a vehicle owner.

at 210,000 miles Dayton, OH

ENGINE AND ENGINE COOLING:COOLING SYSTEM:RADIATOR ASSEMBLY

CHECKED THE CONDITION OF THIS TRUCKS RADIATOR CORE SUPPORT AFTER ANOTHER TRUCK BOUGHT THE SAME YEAR HAD ONE THAT ROTTED AWAY AND FAILED. THIS PART SUPPORTS THE RADIATOR, A/C AND PROVIDES AN ATTACHMENT FOR THE FRONT FENDERS. THIS VEHICLE'S RADIATOR CORE SUPPORT IS RUSTED COMPLETELY THROUGH IN SPOTS AND LARGE FLAKES OF RUST FALL OFF WHEN IT IS DISTURBED. IT WILL NEED TO BE REPAIRED AND 3 OTHERS BOUGHT THE SAME YEAR HAVE THE SAME ISSUE.

NHTSA complaint #10458434 — an unverified report by a vehicle owner.

at 181,000 miles Dayton, OH

ENGINE AND ENGINE COOLING:COOLING SYSTEM:RADIATOR ASSEMBLY

CHECKED THE CONDITION OF THIS TRUCKS RADIATOR CORE SUPPORT AFTER ANOTHER TRUCK BOUGHT THE SAME YEAR HAD ONE THAT ROTTED AWAY AND FAILED. THIS PART SUPPORTS THE RADIATOR, A/C AND PROVIDES AN ATTACHMENT FOR THE FRONT FENDERS. THIS VEHICLE'S RADIATOR CORE SUPPORT IS RUSTED COMPLETELY THROUGH IN SPOTS AND LARGE FLAKES OF RUST FALL OFF WHEN IT IS DISTURBED. IT WILL NEED TO BE REPAIRED AND 3 OTHERS BOUGHT THE SAME YEAR HAVE THE SAME ISSUE.

NHTSA complaint #10458436 — an unverified report by a vehicle owner.

at 180,000 miles Dayton, OH

ENGINE AND ENGINE COOLING:COOLING SYSTEM:RADIATOR ASSEMBLY

CHECKED THE CONDITION OF THIS TRUCKS RADIATOR CORE SUPPORT AFTER ANOTHER TRUCK BOUGHT THE SAME YEAR HAD ONE THAT ROTTED AWAY AND FAILED. THIS PART SUPPORTS THE RADIATOR, A/C AND PROVIDES AN ATTACHMENT FOR THE FRONT FENDERS. THIS VEHICLE'S RADIATOR CORE SUPPORT IS RUSTED COMPLETELY THROUGH IN SPOTS AND LARGE FLAKES OF RUST FALL OFF WHEN IT IS DISTURBED. IT WILL NEED REPAIRED AND 3 OTHERS BOUGHT THE SAME YEAR HAVE THE SAME ISSUE.

NHTSA complaint #10458438 — an unverified report by a vehicle owner.

at 107,590 miles Kelso, WA

ELECTRICAL SYSTEM

SPARK PLUG BLEW OUT OF PLUG HOLE, STRIPPING THREADS OF INTAKE CYLINDER HEAD. PLUG WAS FOUND LAYING BETWEEN VALVE COVER AND INTAKE MANIFOLD.

NHTSA complaint #10436256 — an unverified report by a vehicle owner.

at 107,590 miles Kelso, WA

ENGINE AND ENGINE COOLING

SPARK PLUG BLEW OUT OF PLUG HOLE, STRIPPING THREADS OF INTAKE CYLINDER HEAD. PLUG WAS FOUND LAYING BETWEEN VALVE COVER AND INTAKE MANIFOLD.

NHTSA complaint #10436256 — an unverified report by a vehicle owner.

at 170,000 miles Fenton, MI

FUEL SYSTEM, GASOLINE

GAS TANK LEAK AT STRAP HOLDING TANK IN PLACE. 2002 FORD F-150 4X4 4.6 LITER. AT THIS TIME I CAN NOT FILL THE VEHICLES TANK TO FULL. THE PROBLEM WILL ONLY GET WORSE WITH TIME. AT THIS TIME THE VEHICLE IS ONLY FILLED TO 1/2 FULL.

NHTSA complaint #10355710 — an unverified report by a vehicle owner.

at 28,000 miles Methuen, MA

ENGINE AND ENGINE COOLING:ENGINE

DRIVING ON HIGHWAY.. HEAR A LARGE NOISE FROMN THE ENGINE BAY. TRUCK BREAKS DOWN AND I HAVE IT TOWED. 2002 FORD F-150 LIGTHNING. 3RD TIME ITS BEEN TO THE DEALERSHIP FOR THE SAME PROBLEM.. BLOWING A SPARK PLUG IN THE ENGINE BAY.. THIS TIME... WORSE THEN EVER... READ IT WAS A VERY BAD PROBLEM WITH OTHER TRUCK MADE THIS YEAR ETC.. ONLINE SO I'AM PUTTING A COMPLAINT IN..

NHTSA complaint #10122026 — an unverified report by a vehicle owner.

at 6,500 miles Ladson, SC

SUSPENSION:REAR:AXLE:SPINDLE

REAR WHEELS HAVE ENOUGH PLAY IN THEM THAT THERE IS A NOTICEABLE CLUNK WHEN TURNING. TOOK THE TRUCK TO THE DEALER AND THE END PLAY OF THE AXLES ARE .020. FORD MANUFACTURER SAID UP TO .030 IS TOLERABLE AND I WILL HAVE TO LIVE WITH THE CLUNKING SOUND. I DID NOT PAY $30,000 FOR A TRUCK TO LISTEN TO A CLUNKING SOUND!

NHTSA complaint #10005364 — an unverified report by a vehicle owner.