Explorer (3rd)
Recalls (10)
FORD IS RECALLING MODEL YEARS 1995-2003 WINDSTAR, 2000-2003 EXCURSION DIESEL, 1993-1997 AND 1999-2003 F-250 SD THROUGH F-550 SD DIESEL, 1992-2003 E-150 THROUGH E-550, 1995-2002 EXPLORER, 1997 AND 2002 MERCURY MOUNTAINEER, 1995-1997 AND 2001-2003 RANGER, AND 1994 F53 VEHICLES EQUIPPED WITH THE TEXAS INSTRUMENTS SPEED CONTROL DEACTIVATION SWITCH (SCDS). THE SCDS MAY LEAK INTERNALLY AND THEN OVERHEAT, SMOKE, OR BURN.
DOPE, INC. IS RECALLING 42,540 COMBINATION CORNER AND BUMPER LAMP ASSEMBLIES OF VARIOUS PART NUMBERS SOLD FOR USE AS AFTERMARKET EQUIPMENT FOR VARIOUS PASSENGER VEHICLES. THESE HEADLAMPS FAIL TO CONFORM TO THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 108, "LAMPS, REFLECTIVE DEVICES, AND ASSOCIATED EQUIPMENT." THESE LAMPS DO NOT CONTAIN THE REQUIRED AMBER SIDE REFLECTORS.
SABERSPORT IS RECALLING 16,270 COMBINATION CORNER AND BUMPER LAMP ASSEMBLIES OF VARIOUS PART NUMBERS SOLD FOR USE AS AFTERMARKET EQUIPMENT FOR VARIOUS PASSENGER VEHICLES. THESE HEADLAMPS FAIL TO CONFORM TO THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 108, "LAMPS, REFLECTIVE DEVICES, AND ASSOCIATED EQUIPMENT." THESE LAMPS DO NOT CONTAIN THE REQUIRED AMBER SIDE REFLECTORS.
CERTAIN CURVED TEMPERED REPLACEMENT GLASS MANUFACTURED BY HANGZHOU SAFETY GLASS LTD AND SUPPLIED TO SAFELITE BY AUTO TEMP INC., IDENTIFIED AS DOT-430, AND SOLD FOR USE ON CERTAIN DOMESTIC AND FOREIGN VEHICLES MAY NOT BREAK INTO SMALL PIECES AS EXPECTED OF TEMPERED GLASS AND FAILS TO CONFORM TO FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 205, "GLAZING MATERIALS."
CERTAIN CK MOTORSPORTS COMBINATION HEADLIGHTS, CLEAR CORNER, BUMPER, AND SIDE MARKER LIGHTS SOLD AS REPLACEMENT LAMPS FOR USE ON THE PASSENGER VEHICLES LISTED ABOVE. SOME COMBINATION LAMPS THAT ARE NOT EQUIPPED WITH AMBER SIDE REFLECTORS FAIL TO CONFORM TO FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 108, LAMPS, REFLECTIVE DEVICES, AND ASSOCIATED EQUIPMENT.
CERTAIN PRO-A MOTORS CORNER LAMPS, TURN SIGNALS, AND HEADLIGHTS SOLD AS REPLACEMENT LAMPS FOR USE ON CERTAIN PASSENGER VEHICLES LISTED ABOVE. SOME COMBINATION LAMPS THAT ARE NOT EQUIPPED WITH AMBER SIDE REFLECTORS FAIL TO CONFORM TO FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 108, LAMPS, REFLECTIVE DEVICES, AND ASSOCIATED EQUIPMENT.
ON CERTAIN SPORT UTILITY VEHICLES, THE LIFTGATE GLASS STRUT MAY BECOME DISENGAGED OR THE HINGE MAY FRACTURE ALLOWING THE GLASS TO FALL AND POSSIBLY BREAK.
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.
VEHICLE DESCRIPTION: SPORT UTILITY VEHICLES. THE RIGHT SIDE TIRES MAY HAVE HORIZONTAL CUTS ON THE EDGE OF THE TREAD THAT COULD HAVE OCCURRED DURING VEHICLE ASSEMBLY.
THIS IS NOT A SAFETY RECALL IN ACCORDANCE WITH THE SAFETY ACT. HOWEVER, IT IS DEEMED A SAFETY IMPROVEMENT CAMPAIGN BY THE AGENCY. VEHICLE DESCRIPTION: 2002 FORD EXPLORER AND MERCURY MONTAINEER SPORT UTILITY VEHICLES. THE BRACKETS CONNECTING THE LEFT CYLINDERS TO EACH SIDE OF THE LIFTGATE GLASS COULD ROTATE OUT OF POSITION IF EITHER THE URETHANE BOND OR TORQUE ARE NOT SUFFICIENT.
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Frequently Asked Questions
What are the most common 2002-2005 Ford Explorer problems?
The 2002-2005 Ford Explorer has accumulated 11,841 NHTSA complaints. The most frequently reported problem areas are Electrical System, Brakes, Transmission. As with any used vehicle, a pre-purchase inspection and vehicle history report are recommended.
Which Ford Explorer engine is most reliable?
The 2002-2005 Ford Explorer was offered with 8 engine options. Based on NHTSA complaint data, the 5.4L 8-cyl has the lowest complaint density and is considered the most reliable choice for buyers.
Is the 2002-2005 Ford Explorer a good used car?
The 2002-2005 Ford Explorer can be a solid used car purchase depending on trim, mileage, and maintenance history. With 11,841 total NHTSA complaints on record, prospective buyers should review the known problem areas and check for open recalls before buying.
How many NHTSA complaints does the 2002-2005 Ford Explorer have?
The 2002-2005 Ford Explorer has 11,841 complaints filed with NHTSA as of our latest data pull. Complaint counts reflect owner-reported issues and do not necessarily indicate defects or safety risks on their own.
What recalls affect the 2002-2005 Ford Explorer?
There are 10 NHTSA recalls affecting some 2002-2005 Ford Explorer vehicles. Recall status varies by VIN — check the NHTSA recall database at recalls.nhtsa.dot.gov with your specific VIN to confirm which campaigns apply.
What should I check before buying a used Ford Explorer?
Before buying a used Ford Explorer, verify all open recalls are completed via the NHTSA VIN lookup tool. Pay particular attention to Electrical System, Brakes, Transmission, which are the most commonly reported problem areas. Request maintenance records, have an independent mechanic inspect the vehicle, and run a vehicle history report to check for prior accidents or title issues.
Does the Explorer have NHTSA crash test ratings?
NHTSA has not published crash test ratings for the 2002-2005 Ford Explorer. Not all vehicles are tested each year. For the latest NHTSA safety information, visit nhtsa.gov/ratings.
Data from NHTSA federal complaints database. 11,841 complaints analyzed. Data confidence: high. Last updated: 2026-04-07.