Today’s Ford Explorer regularly tops the sales charts as the best-selling three-row SUV in America. Appreciated for its powerful engine and good comfort levels, it’s still hugely popular despite going into production over seven years ago. But the Explorer did not always enjoy such a solid reputation. One model year in particular ranks as not only one of the least reliable Fords ever built, but one of the least reliable models in the industry, since complaint and recall data started being recorded. Here’s why buyers should avoid the third-generation Explorer—and the 2002 model specifically.
2002 Ford Explorer’s Catastrophic Reliability Record
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On Car Complaints, which accumulates complaint data from consumers directly, the 2002 Ford Explorer has the worst record of any model, across all brands. Based on the number of failures, average mileage of failures, and costs to repair, the publication says this is “hands-down our worst vehicle on record” and advises consumers to “avoid it like the plague.”
The 2002 Ford Explorer marked the first model year of the relatively short-lived third generation. It was a complete redesign for the nameplate and the end of chassis commonality with the Ford Ranger. But, as much as the new independent rear suspension and fresh technologies promised a better SUV, the unproven tech ended up being disastrous for Ford, with several major defects.
Data from the National Highway Traffic Safety Administration (NHTSA) is just as damning. The 2002 Explorer has 14 recalls and 3,622 complaints on file.
The Main 2002 Ford Explorer Problems
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According to Car Complaints, these were the 2002 Explorer’s most common problems:
|
Issue |
Number of Complaints |
|
Transmission failure |
441 |
|
O/D light blinking |
386 |
|
Transmission slips when shifting and clunks |
151 |
|
Enclosed transmission had to be overhauled |
136 |
|
Difficulty shifting |
101 |
|
Hard/soft shifting, rattling noise, gear ratio out, O/D light on |
56 |
|
Won’t shift into third gear |
52 |
|
Transmission hesitates |
28 |
The vast majority of complaints were linked to the transmission. Car Complaints data shows the Explorer’s transmission would fail at an average mileage of 94,800 miles and would typically cost $2,840 to repair. The issue specifically affected the five-speed automatic transmissions (5R55W and 5R55S variants), which were prone to a range of issues.
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With no dipstick or easy way to check the condition of the transmission fluid, degraded fluid accelerated the wear of internal components. It did not help that these transmissions were referred to as having “lifetime” fluid. Failing solenoid packs, valve body failure, and servo bore wear were among the flaws affecting these transmissions, leading to one or more of the problems mentioned in the list above.
Several recalls were linked to build quality issues, such as broken liftgate glass brackets and fractured seat bolts, while lighting issues and a fire risk linked to running boards were also mentioned. The transmission was by far the most prevalent and costly flaw in 2002 Explorers, though, making it one of the least dependable Fords.
Ironically, the third-gen Explorer was supposed to resolve Ford’s public relations disaster after the Firestone tire controversy, whereby certain tires equipped to SUVs like the second-gen Explorer resulted in many fatal crashes. While the third-gen Explorer was less of a rollover risk than its predecessor, its serious transmission flaws damaged its reputation.
Related: Ford Is Catching Quality Problems Earlier, and It’s Paying Off Big Time
Final Thoughts
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While the 2002 Explorer has the most complaints, we’d recommend avoiding the third-gen Explorer entirely if you’re looking for an older but reliable SUV. Another alternative is to choose a model with the five-speed manual gearbox, which eliminates at least one major area of concern.
The number of Explorer complaints dropped significantly with the launch of the fourth-generation model for the 2006 model year. That would also be the last of the Explorers with traditional body-on-frame construction. Later versions transitioned to a more comfortable unibody structure.
The 2002 Explorer represents the nadir of the nameplate and its infamous flaws have inconvenienced thousands of owners. Subsequent Explorers have been a lot more dependable and have matured into one of America’s favorite three-row SUVs.
Related: Ford Vs. Jeep Reliability: It’s Not Even Close
