2002 Ford Explorer Problems
RepairPal has identified the most common problems with the 2002 Ford Explorer based on complaints from actual vehicle owners. We'll tell you what the problem is and what it'll take to fix it.
A failed heater blend door or actuator can cause the temperature control for the HVAC system to stop working. A clicking sound from the dash area would commonly indicate an actuator fault. If the heater gets stuck on the hottest setting, the heater blend door may be broken requiring replacement of the heater box to repair the issue.
The composite (plastic) intake manifold may crack near the thermostat housing and cause a coolant leak. Ford released an updated manifold that was reinforced to prevent a recurrence. No recall was issued for this problem but Ford did extend the warranty to seven years on some models from the date of purchase.
A cosmetic crack may develop on the plastic liftgate trim panel. Ford has released a service procedure to replace the applique without damage the the liftgate glass.
The intake manifold O-ring gaskets commonly leak, causing stalling and poor idle quality; the Check Engine Light will illuminate.
Various problems with the 5-speed automatic transmission were common. These problems can be more common on the 2002 models with build dates before March, 2002. There are many service bulletins describing the diagnoses and repairs, which include fluid leak repairs, transmission software updates, or internal failures requiring a costly repair.
A rattling noise from the engine may indicate that the timing chain cassette is worn. Our technicians tell us that installing an updated cassette and timing chain tensioner should correct this concern.
The rear window wiper may not fully contact the rear window. Our technicians tell us that replacing both the wiper blade and wiper arm will generally correct this issue.
The rear wiper may stop working. This could be due to a rear wiper motor that has failed requiring replacement.