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FaultScore report

2002 Ford F Series problems

Owners have filed 43 complaints about the 2002 Ford F Series with NHTSA between 2003 and 2022. The largest single group is the engine & cooling. Across this model's run it ranks 7 of 9 worst.

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

FaultScore 40/100

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

How this is worked out

The numbers

43

Complaints

1

Crashes reported

1

Fires reported

0

Injuries reported

100,000 mi

Median mileage at failure

Half of reported failures happened before this

13%

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 58 vs 50 Severity 24 vs 50 Early failure 21 vs 50
The dashed ring is 50 — the national norm. Further out is worse.
Complaint volume — 58
Against the median year of the Ford F Series. 50 means typical for this model; 100 means roughly double.
Severity — 24
4.7% of these complaints involved a crash, fire, injury or death, against a national rate of 9.7%.
Early failure — 21
13% 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

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

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

Engine & Cooling 17 39.5%

0 crashes, 1 fires · median 104,971 mi

Fuel & Propulsion 8 18.6%

Median failure at 102,000 miles

Transmission & Drivetrain 4 9.3%

Median failure at 40,000 miles

Acceleration & Cruise Control 3 7.0%

1 crashes, 0 fires · median 154,000 mi

Electrical System 3 7.0%

Median failure at 70,000 miles

Other & Unspecified 2 4.7%

Median failure at 29,265 miles

Brakes 2 4.7%

Median failure at 118,500 miles

Steering 2 4.7%

Median failure at 90,067 miles

Stability & Traction Control 1 2.3%

Median failure at 190,000 miles

Body & Structure 1 2.3%

Median failure at 134,549 miles

When it fails

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

10,000 – 24,999 miles 2 5.0%
25,000 – 49,999 miles 7 17.5%
50,000 – 74,999 miles 5 12.5%
75,000 – 99,999 miles 6 15.0%
100,000 – 149,999 miles 9 22.5%
150,000+ miles 11 27.5%

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 Apr 2022

NHTSA investigations into the 2002 Ford F Series

An investigation is the step before a recall: the agency has seen enough complaints to look into a pattern itself. An open one means it thinks something may be wrong and nothing has been fixed yet.

DP05005 Opened 22 Sep 2005 Closed 4 Jan 2006 ENGINE AND ENGINE COOLING:ENGINE

SPARK PLUG EJECTION FROM CYLINDER HEAD

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 A...

Recalls on the 2002 Ford F Series

A complaint is one owner's allegation. A recall is the point at which the manufacturer or a regulator agreed the defect is real and dangerous enough to fix for free — however old the car is.

United States — NHTSA

03V094000

STRUCTURE

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.

Risk: THIS OVERHEATING CONDITION CAN CAUSE THE RUNNING BOARD TO MELT OR CAUSE A FIRE.

Recalls cover specific build ranges, so check your own vehicle by VIN at nhtsa.gov/recalls or, in Canada, Transport Canada.

Complaints that involved harm

Reports where the owner recorded a crash, a fire, an injury or a death.

at 75,000 miles Lake Tapps, WA Fire

ENGINE AND ENGINE COOLING

I WOKE UP LAST WEEK TO THE SOUND OF A CAR ALARM. I LOOKED OUTSIDE AND THE FRONT OF MY FORD F 150 WAS ENGULFED IN FLAMES. IT WAS SO HOT THE TIRES MELTED INTO THE DRIVEWAY. WE HAD NOT DRIVEN THE TRUCK IN SEVERAL DAYS. IT APPEARS THE FIRE STARTED IN THE ENGINE AS THE ENTIRE FRONT OF THE VEHICLE IS INCINERATED.

NHTSA complaint #10192067 — an unverified report by a vehicle owner.

at 19,889 miles Frankfort, IN Crash

VEHICLE SPEED CONTROL:CRUISE CONTROL

CRUISE CONTROL WAS ON AS WE PROCEEDED UP A HILL. WHEN DRIVER TRIED TO DISENGAGE THE CRUISE CONTROL IT WOULD NOT DISENGAGE. ENGINE CONTINUED TO EXCEL, GOING FASTER. IT REACHED SPEEDS OF ALMOST 80 MPH. HITTING BRAKES WOULD NOT STOP CRUISE CONTROL, NOR SLOW THE VEHICLE. *NLM

NHTSA complaint #10018996 — an unverified report by a vehicle owner.

The most recent complaints

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

Cartersville, GA

FUEL/PROPULSION SYSTEM

I was driving my truck and it began vibrating; shortly thereafter it was running as if half the engine was working , with a loss of power. I pulled the fuel filter and there was trash all in the filter. I bought another filter and replaced it and ran the truck again and it was working fine. Shortly thereafter the same thing happened again, loss of power, running like half the engine was working and then stalled. After a few minutes it started up but ran terrible. I got it home. I pulled the fuel filter and it was loaded with trash again. I called the Ford dealer and spoke to a mechanic and he advised he has fixed numerous trucks like mine and the gas tank was deteriorating from the inside and clogging my fuel filter. He said there is a recall for the truck and that the fuel tank needs to be replaced. Please help me as this truck only has 75,000 miles and is like brand new, garage kept and well taken care of. Thank you for your time in this matter and I look forward to hearing from you soon.

NHTSA complaint #11462328 — an unverified report by a vehicle owner.

at 119,000 miles Kaysville, UT

ENGINE

DRIVING ON THE FREEWAY A SPARK PLUG CAME OUT OF THE ENGINE CAUSING THE VEHICLE TO SHAKE AND LOOSE POWER. THE DEALER AND A SHOP I TOOK THE VEHICLE TO STATED THAT THIS IS A FREQUENT PROBLEM WITH THIS ENGINE.

NHTSA complaint #10672488 — an unverified report by a vehicle owner.

at 134,549 miles Windsor, CT

POWER TRAIN

WHILE BACKING INTO MY TRUCK STARTED MAKING A LOAD NOISE, IT WAS OBVIOUS IT WAS IN THE FRONT END. TRYING TO TURN THE STEERING WHEEL, IT WAS STUCK. STOPPED THE TRUCK, LOOKED UNDER THE FRONT OF TRUCK AT STEERING, I NOTICED THAT THERE WAS A HOLE IN THE FRAME, IT WAS THEN THAT I SAW THE STEERING LINK, AGAINST THE RIGHT CV AXLE. THE IDLER ARM HAD SOME HOW RIPPED OFF THE FRAME, LEAVING NA HOLE WHERE THE IDLER ARM WAS, THE FRAME OF THE TRUCK HAD WEAKENED, CAUSING THE METAL TO WEAKEN AND SEPARATE, THANK AGAIN FORD.

NHTSA complaint #10639169 — an unverified report by a vehicle owner.

at 134,549 miles Windsor, CT

STEERING

WHILE BACKING INTO MY TRUCK STARTED MAKING A LOAD NOISE, IT WAS OBVIOUS IT WAS IN THE FRONT END. TRYING TO TURN THE STEERING WHEEL, IT WAS STUCK. STOPPED THE TRUCK, LOOKED UNDER THE FRONT OF TRUCK AT STEERING, I NOTICED THAT THERE WAS A HOLE IN THE FRAME, IT WAS THEN THAT I SAW THE STEERING LINK, AGAINST THE RIGHT CV AXLE. THE IDLER ARM HAD SOME HOW RIPPED OFF THE FRAME, LEAVING NA HOLE WHERE THE IDLER ARM WAS, THE FRAME OF THE TRUCK HAD WEAKENED, CAUSING THE METAL TO WEAKEN AND SEPARATE, THANK AGAIN FORD.

NHTSA complaint #10639169 — an unverified report by a vehicle owner.

at 134,549 miles Windsor, CT

STRUCTURE:BODY

WHILE BACKING INTO MY TRUCK STARTED MAKING A LOAD NOISE, IT WAS OBVIOUS IT WAS IN THE FRONT END. TRYING TO TURN THE STEERING WHEEL, IT WAS STUCK. STOPPED THE TRUCK, LOOKED UNDER THE FRONT OF TRUCK AT STEERING, I NOTICED THAT THERE WAS A HOLE IN THE FRAME, IT WAS THEN THAT I SAW THE STEERING LINK, AGAINST THE RIGHT CV AXLE. THE IDLER ARM HAD SOME HOW RIPPED OFF THE FRAME, LEAVING NA HOLE WHERE THE IDLER ARM WAS, THE FRAME OF THE TRUCK HAD WEAKENED, CAUSING THE METAL TO WEAKEN AND SEPARATE, THANK AGAIN FORD.

NHTSA complaint #10639169 — an unverified report by a vehicle owner.

at 190,000 miles Houston, TX

SERVICE BRAKES

FAILURE OF THE ABS MODULE HAS LED TO A NEAR MISS ACCIDENT THAT WAS AVOIDED VIA STEERING AROUND THE OBSTRUCTION INSTEAD OF BRAKING. THE OBDII MODULE IS THROWING CODE C1185 AS A PART OF THE FAILURE OF THE ABS CONTROLLER..

NHTSA complaint #10627892 — an unverified report by a vehicle owner.

at 190,000 miles Houston, TX

ELECTRONIC STABILITY CONTROL (ESC)

FAILURE OF THE ABS MODULE HAS LED TO A NEAR MISS ACCIDENT THAT WAS AVOIDED VIA STEERING AROUND THE OBSTRUCTION INSTEAD OF BRAKING. THE OBDII MODULE IS THROWING CODE C1185 AS A PART OF THE FAILURE OF THE ABS CONTROLLER..

NHTSA complaint #10627892 — an unverified report by a vehicle owner.

at 212,003 miles Kiel, WI

VEHICLE SPEED CONTROL:ACCELERATOR PEDAL

GAS PETAL STICKS AND WHEN PUSHED ON TRUCK ACCELERATES RAPIDLY, THIS HAPPENS WHEN STARTING OUT FROM A STOP AND DURING ALL DRIVING.

NHTSA complaint #10585196 — an unverified report by a vehicle owner.

at 206,000 miles Pierre, SD

ENGINE

WAS DRIVING DOWN THE ROAD AT 35 MPH AND HEARD A POP THEN THE ENGINE STARTED TO RUN ROUGH. TOOK TO THE MECHANIC SAID THAT I HAD A BLOWN SPARK PLUG.

NHTSA complaint #10574581 — an unverified report by a vehicle owner.

at 154,000 miles Bowling Green, KY

VEHICLE SPEED CONTROL

THROTTLE BODY LINKAGE "PLASTIC COVER CLAMSHELL" CRACKED IN HALF AT PLASTIC HINGE (OXIDIZED PLASTIC) . LOOSE PLASTIC COVER WEDGED OPEN THROTTLE FULLY CAUSING "DANGEROUS LIFE THREATENING" DRIVING STUCK AT FULL THROTTLE. I HAVE THE COVER AND PHOTOS IF YOU WANT ME TO SEND THEM.

NHTSA complaint #10566358 — an unverified report by a vehicle owner.

at 154,000 miles Bowling Green, KY

FUEL SYSTEM, GASOLINE

THROTTLE BODY LINKAGE "PLASTIC COVER CLAMSHELL" CRACKED IN HALF AT PLASTIC HINGE (OXIDIZED PLASTIC) . LOOSE PLASTIC COVER WEDGED OPEN THROTTLE FULLY CAUSING "DANGEROUS LIFE THREATENING" DRIVING STUCK AT FULL THROTTLE. I HAVE THE COVER AND PHOTOS IF YOU WANT ME TO SEND THEM.

NHTSA complaint #10566358 — an unverified report by a vehicle owner.

at 180,000 miles Wisconsin Dells, WI

ENGINE

A SPARK PLUG EJECTED FROM THE RIGHT SIDE HEAD OF THE ENGINE HEAD WHILE RUNNING DOWN THE HWY AT 60 MPH. THE HEAD MIGHT BE DAMAGED. I HAVEN'T HAD A CHANCE TO GET IT FIXED. BEEN A FORD TRUCK GUY ALL MY LIFE & I CAN'T BELIEVE FORD HASN'T ACCEPTED ANY RESPONSIBILITY OF ANY PORTION OR KIND FOR THIS. MY ESTIMATED EXPENSE TO REPAIR THIS IS $1,000 TO $3,000 DEPENDING ON ANY DAMAGE TO THE HEAD ETC.. I PAID $4200 FOR THE TRUCK IN APRIL OF 2013...IT IS IN VERY GOOD CONDITION & TO GOOD TO JUNK IN MY OPINION. BESIDES I CAN'T AFFORD TO BUY ANOTHER TRUCK SO I HAVE TO TRY TO FIX IT. THIS IS BEYOND DISAPPOINTING, IT IS A MAJOR BLOW TO THE BUDGET ETC. ETC. ETC......

NHTSA complaint #10562084 — an unverified report by a vehicle owner.

at 66,000 miles North Andover, MA

ELECTRICAL SYSTEM

SPARK PLUG EJECTED WHILE DRIVING ON HIGH WAY. THIS IS THE SECOND TIME A PLUG HAS EJECTED. THE FIRST TIME THE TRUCK HAD 39000 MILES, ORIGINAL FACTORY TORQUED SPARK PLUGS.

NHTSA complaint #10547716 — an unverified report by a vehicle owner.

at 66,000 miles North Andover, MA

ENGINE

SPARK PLUG EJECTED WHILE DRIVING ON HIGH WAY. THIS IS THE SECOND TIME A PLUG HAS EJECTED. THE FIRST TIME THE TRUCK HAD 39000 MILES, ORIGINAL FACTORY TORQUED SPARK PLUGS.

NHTSA complaint #10547716 — an unverified report by a vehicle owner.

at 66,000 miles North Andover, MA

FUEL/PROPULSION SYSTEM

SPARK PLUG EJECTED WHILE DRIVING ON HIGH WAY. THIS IS THE SECOND TIME A PLUG HAS EJECTED. THE FIRST TIME THE TRUCK HAD 39000 MILES, ORIGINAL FACTORY TORQUED SPARK PLUGS.

NHTSA complaint #10547716 — an unverified report by a vehicle owner.

at 192,000 miles Wisconsin Rapids, WI

ELECTRICAL SYSTEM

SPARK PLUG BLEW OUT OF ENGINE. THIS IS THE SECOND TIME IN A YEAR ON TWO DIFFERENT PLUGS. THESE ARE THE ORIGINAL PLUGS.

NHTSA complaint #10535663 — an unverified report by a vehicle owner.

at 192,000 miles Wisconsin Rapids, WI

ENGINE

SPARK PLUG BLEW OUT OF ENGINE. THIS IS THE SECOND TIME IN A YEAR ON TWO DIFFERENT PLUGS. THESE ARE THE ORIGINAL PLUGS.

NHTSA complaint #10535663 — an unverified report by a vehicle owner.

at 111,943 miles Mineral Wells, TX

ENGINE

DRIVING ON HIGHWAY 30 MPH AND #3 SPARK PLUG BLEW OUT .

NHTSA complaint #10459830 — an unverified report by a vehicle owner.

at 95,000 miles Fremont, NH

FUEL SYSTEM, DIESEL:STORAGE:TANK ASSEMBLY

THE FUEL TANK STRAPS ON MY 2002 FORD F350 ROTTED OUT TO WERE THE FUEL TANK WAS HANGING ALL MOST HITTING THE GROUND, COULD HAVE BEEN A MAJOR DIESEL SPILL WITH 38 GALLON OF FUEL.

NHTSA complaint #10453464 — an unverified report by a vehicle owner.

at 163,000 miles Blackstone, MA

ENGINE AND ENGINE COOLING

BLEW SPARK PLUG OUT OF HEAD WHILE ACCELERATING TO GET ON HIGHWAY. HAD GAS SPILL ON MOTOR. IT HAS THE 5.4 TRITON MOTOR.

NHTSA complaint #10441566 — an unverified report by a vehicle owner.

at 122,580 miles Clarksville, TN

ENGINE AND ENGINE COOLING

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.

NHTSA complaint #10440589 — an unverified report by a vehicle owner.

at 148,000 miles Terre Haute, IN

FUEL SYSTEM, GASOLINE

FUEL TANK STRAPS FAILED WHILE DRIVING RESULTING IN THE TANK DROPPING. THE FRONT OF THE TANK CONTACTED THE ROAD SURFACE RESULTING IN A LEAK AND SPILLING OF APPROXIMATELY 21 GALS OF FUEL ON THE ROAD. NO FIRE RESULTED BUT THE HAZMAT TEAM WAS REQUIRED TO CLEAN UP THE SPILLED FUEL. THE 2002 F 150 WAS TOWED TO A FORD DEALER FOR REPAIR.

NHTSA complaint #10416378 — an unverified report by a vehicle owner.

at 124,592 miles Cape Coral, FL

FUEL SYSTEM, OTHER

I HAVE A 2002 FORD F 150 XLT SUPERCREW WITH THE 139 INCH WHEELBASE. UPON ARRIVING HOME MY WIFE SAID SHE NOTICED SOMETHING HANGING BELOW THE TRUCK.. I WENT OUT TO INSPECT. THE FRONT FUEL TANK RETAINING STRAP WAS HANGING THERE. THE BOLT SIDE HAD ROTTED AWAY APPROXIMATELY 6 INCHES DOWN FROM TOP. REAR STRAP WAS INSPECTED AND SHOWED SIGNS OF RUST BUT STILL IN PLACE AND FUNCTIONING AS INTENDED..I HAVE MOVED THE VEHICLE INSIDE TO AVOID USING IT AND WILL ORDER NEW STRAP IN MORNING. I HAD HEARD FORD WAS LOOKING INTO THIS PROBLEM HAS IT BEEN RESOLVED ? DO I HAVE RECOURSE ? THANKS.

NHTSA complaint #10416307 — an unverified report by a vehicle owner.

at 102,000 miles South Lyon, MI

FUEL SYSTEM, GASOLINE

FUEL TANK STRAPS RUSTED AND BROKEN CAUSING TANK TO ALMOST FALL OUT

NHTSA complaint #10380816 — an unverified report by a vehicle owner.

at 175,000 miles Wind GAP, PA

ENGINE AND ENGINE COOLING

SPARK PLUG BLEW OUT OF ENGINE WHILE DRIVING.

NHTSA complaint #10376430 — an unverified report by a vehicle owner.