The 2002 Explorer is a body-on-frame SUV with two notorious weak points: the 4.0L SOHC V6's timing chain cassettes and the 5R55W automatic transmission's internal failures. Both can leave you stranded and cost serious money.
4.0L SOHC V6 Timing Chain Cassette Failure
Common · high severity
Typical onset: 100,000-150,000 mi
Symptoms: Rattling noise on cold start that disappears after warmup, Check engine light with cam/crank correlation codes (P0340, P0345), Rough idle or stalling, Catastrophic engine failure if chains jump timing
Fix: Replace plastic timing chain cassettes, guides, tensioners, and chains on both banks. Requires removing front covers, valve covers, timing components. 12-16 hours labor. Many shops recommend full engine rebuild or replacement at this point due to potential internal damage from stretched chains. If caught early, cassette replacement alone runs 10-12 hours.
Estimated cost: $2,500-5,000
5R55W Transmission Internal Failure
Common · high severity
Typical onset: 90,000-140,000 mi
Symptoms: Harsh 2-3 or 3-4 shifts, Slipping in 3rd or 4th gear under load, No reverse or delayed engagement, Burnt transmission fluid smell, Whining or grinding noises
Fix: Forward clutch pack failure and servo bore wear are the usual culprits. Rebuild requires removal (6-8 hours), complete teardown, new clutches, bands, servos, solenoid pack, and torque converter. Many shops recommend remanufactured unit due to labor cost overlap. R&R plus rebuild: 14-18 hours total.
Symptoms: Howling or whining from rear end that increases with speed, Grinding noise during acceleration, Vibration at highway speeds, Metal shavings in differential fluid
Fix: Pinion bearing and seal replacement requires setting up pinion depth and backlash with special tools. If caught early: 4-5 hours for pinion bearing and seal. If run too long, ring and pinion damage requires full rebuild: 6-8 hours plus parts.
Estimated cost: $800-2,200
Lower Ball Joint Separation
Common · high severity
Typical onset: 80,000-120,000 mi
Symptoms: Clunking noise over bumps from front end, Steering wander or looseness, Uneven tire wear on inside edge, Visible play when prying on front wheels (vehicle raised)
Fix: Lower ball joints are riveted into the control arms. Proper repair involves drilling out rivets and bolting in new joints or replacing entire lower control arms (easier). 2.5-3.5 hours per side. Critical safety issue—complete separation causes loss of control. Both sides typically need service at same time.
Estimated cost: $600-1,000
Intake Manifold Runner Control (IMRC) Stuck or Failed
Occasional · low severity
Typical onset: 90,000-150,000 mi
Symptoms: Check engine light with P1518 code, Loss of power above 3,000 RPM, Rough idle in some cases, Rattling from intake manifold area
Fix: Plastic actuators and rods inside the intake manifold break or seize with carbon buildup. Requires upper intake removal, disassembly, and replacement of actuator/rod assembly. Can sometimes be cleaned if caught early. 3-4 hours labor.
Estimated cost: $450-750
4.6L V8 Spark Plug Ejection / Stripped Threads
Occasional · medium severity
Symptoms: Sudden misfire with loud popping or hissing sound, Check engine light with cylinder-specific misfire code, Spark plug blown completely out of head, Loss of compression on affected cylinder
Fix: 4.6L 2V engine has soft aluminum heads with shallow spark plug threads. Over-torquing or repeated removal causes thread failure. Repair involves HeliCoil or TimeSert insert. Head removal rarely needed. 2-4 hours depending on cylinder location and thread damage severity.
Estimated cost: $400-900
Transmission Cooler Line Corrosion at Radiator
Common · medium severity
Typical onset: 100,000+ mi
Symptoms: Transmission fluid leaking from radiator area, Low transmission fluid level, Slipping or harsh shifts due to low fluid, Pink or red fluid puddle under vehicle
Fix: Steel cooler lines rust at crimp fittings where they connect to radiator. Quick-disconnect fittings also fail. Replace both lines as a pair with improved aftermarket lines that use compression fittings. 1.5-2.5 hours labor. Critical to catch before transmission runs low and fails.
Estimated cost: $300-550
Owner tips
Change transmission fluid every 30,000 miles with Mercon V—the 5R55W will NOT make it to 150k on factory fill
Inspect lower ball joints every oil change starting at 60k miles; wear happens fast
On 4.0L SOHC, listen for ANY cold-start rattle and address immediately—waiting costs thousands
Use Motorcraft spark plugs only on 4.6L V8 and torque to EXACT spec (13-15 lb-ft)—no ugga-duggas
Flush rear differential at 75k miles; add friction modifier if you have limited slip
Buy the 4.6L V8 if you can find one in good shape, avoid the 4.0L SOHC unless timing chains are already done, and budget $3-5k for transmission work—it's not if, but when.
AI-assisted summary drawn from NHTSA recall data, our labor-times database, and platform knowledge. Not a substitute for a pre-purchase inspection on a specific vehicle.
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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.
Consequence: A VEHICLE FIRE COULD OCCUR WITH OR WITHOUT THE ENGINE RUNNING.
Remedy: FORD WILL NOTIFY OWNERS THAT DEALERS WILL INSTALL A FUSED WIRING HARNESS IN LINE WITH THE SCDS. ON 1999-2003 WINDSTAR VEHICLES WITH A LEAKING SCDS, DEALERS WILL ALSO INSPECT THE ABS CONTROL MODULE CONNECTOR AND REPAIR AS NECESSARY. REPAIRS WILL BE COMPLETED FREE OF CHARGE. THE SAFETY RECALL BEGAN ON OCTOBER 27, 2009. OWNERS MAY CONTACT FORD AT 1-888-222-2751.
EXTERIOR LIGHTING:HEADLIGHTS · 09E025000
2009-05-11
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.
Consequence: DECREASED LIGHTING VISIBILITY MAY RESULT IN A VEHICLE CRASH.
Remedy: DOPE, INC. WILL NOTIFY OWNERS AND OFFER A FULL REFUND FOR THE NONCOMPLIANT COMBINATION LAMPS. THE SAFETY RECALL BEGAN ON JULY 28, 2009. OWNERS MAY CONTACT DOPE, INC. AT 1-626-272-1798.
EXTERIOR LIGHTING · 09E012000
2009-04-07
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.
Consequence: DECREASED LIGHTING VISIBILITY MAY RESULT IN A VEHICLE CRASH.
Remedy: SABERSPORT WILL NOTIFY OWNERS AND OFFER A FULL REFUND FOR THE NONCOMPLIANT COMBINATION LAMPS. THE SAFETY RECALL BEGAN ON MAY 11, 2009. OWNERS MAY CONTACT SABERSPORT AT 1-909-598-7589.
VISIBILITY:GLASS, SIDE/REAR · 07E104000
2007-12-11
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."
Consequence: IN THE EVENT OF A VEHICLE CRASH, THE OCCUPANT(S) MAY BE SERIOUSLY INJURED BY SHATTERED GLASS.
Remedy: SAFELITE WILL NOTIFY ITS RETAIL CUSTOMERS AND REPLACE THE GLASS FREE OF CHARGE. RETAIL CUSTOMERS CAN CONTACT SAFELITE TOLL FREE AT 1-888-843-2906. SAFELITE WILL NOTIFY ITS WHOLESALE CUSTOMERS AND REIMBURSE WHOLESALE CUSTOMERS FOR CURRENT INVENTORY AND AT A SPECIFIED RATE FOR REPLACING THEIR CUSTOMER'S GLASS. WHOLESALE CUSTOMERS CAN CONTACT SAFELITE'S WHOLESALE DIVISION, SERVICE AUTOGLASS TOLL FREE AT 1-888-246-6298. THE RECALL BEGAN ON JANUARY 15, 2008.
EXTERIOR LIGHTING · 06E049000
2006-05-24
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.
Consequence: WITHOUT THE AMBER REFLECTORS, THE VEHICLE WILL BE POORLY ILLUMINATED, POSSIBLY RESULTING IN A VEHICLE CRASH WITHOUT WARNING.
Remedy: CK MOTORSPORT WILL NOTIFY OWNERS AND REPLACE THE NONCOMPLIANT LAMPS FREE OF CHARGE. THE RECALL BEGAN ON JULY 1, 2006. OWNERS MAY CONTACT CK MOTORSPORT AT 1-909-610-7211.
EXTERIOR LIGHTING · 06E026000
2006-03-23
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.
Consequence: WITHOUT THE AMBER REFLECTORS, THE VEHICLE WILL BE POORLY ILLUMINATED, POSSIBLY RESULTING IN A VEHICLE CRASH WITHOUT WARNING.
Remedy: PRO-A MOTORS WILL NOTIFY OWNERS AND OFFER TO REPURCHASE THE LAMPS. THE RECALL BEGAN ON APRIL 3, 2006. OWNERS MAY CONTACT PRO-A MOTORS AT 323-838-2988.
STRUCTURE:BODY:HATCHBACK/LIFTGATE:HINGE AND ATTACHMENTS · 04V442000
2004-09-13 · PE04045
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.
Consequence: IF THE HINGE SHOULD FRACTURE, THERE IS A POTENTIAL FOR THE GLASS TO FALL AND ULTIMATELY BREAK AND PERSONAL INJURIES COULD OCCUR.
Remedy: DEALERS WILL HAVE THE LIFTGATE GLASS STRUT BRACKETS AND GLASS HINGES REPLACED. FOR THE VEHICLES BUILT FROM AUGUST 1, 2000 THROUGH MARCH 3, 2002, THE DEALERS WILL REPLACE THE HINGES AND LIFTGATE STRUT BRACKET. ON VEHICLES BUILT FROM MARCH 3, 2002 THROUGH JUNE 23, 2003, THE DEALERS WILL ONLY REPLACE THE HINGES. THE RECALL BEGAN ON SEPTEMBER 30, 2004. A POSTCARD WAS SENT TO OWNERS ON DECEMBER 27, 2004, ADVISING THEM THAT PARTS ARE NOW AVAILABLE. OWNERS SHOULD CONTACT FORD AT 1-800-392-3673.
STRUCTURE · 03V094000
2003-03-07
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.
Consequence: THIS OVERHEATING CONDITION CAN CAUSE THE RUNNING BOARD TO MELT OR CAUSE A FIRE.
Remedy: DEALERS WILL REPLACE THE WIRING HARNESS ON THESE RUNNING BOARDS. OWNER NOTIFICATION BEGAN MARCH 7, 2003. OWNERS WHO TAKE THEIR VEHICLES TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND DO NOT RECEIVE THE FREE REMEDY WITHIN A REASONABLE TIME SHOULD CONTACT SOUTHERN COMFORT AT 1-800-745-6096.
TIRES:SIDEWALL · 01V171000
2001-05-24
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.
Consequence: OVER TIME, THE TIRE COULD FAIL, INCREASING THE RISK OF A CRASH.
Remedy: DEALERS WILL INSPECT THE TIRES AND, IF ANY SLICES ARE FOUND, THE CUT TIRES WILL BE REPLACED. OWNER NOTIFICATION BEGAN JUNE 7, 2001. OWNERS WHO TAKE THEIR VEHICLES TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND DO NOT RECEIVE THE FREE REMEDY WITHIN A REASONABLE TIME SHOULD CONTACT FORD AT 1-800-392-3673.
VISIBILITY:GLASS, SIDE/REAR · 01I010000
2001-04-10
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.
Consequence: ROTATION OF THE BRACKETS COULD POTENTIALLY CAUSE THE LIFT CYLINDERS TO DETACH FROM THE GLASS OR, IN SOME CASES, COULD POTENTIALLY CAUSE THE LIFTGATE GLASS TO BREAK. EITHER CONDITION IS MOST LIKELY TO OCCUR WHEN THE GLASS IS BEING CLOSED.
Remedy: FORD DEALERS WILL INSPECT THE VEHICLES FOR THE POSITION OF BOTH THE LEFT AND RIGHT LIFTGATGE GLASS LIFT CYLINDER BRACKETS. IF THE BRACKETS ARE IN THE PROPER POSITION, THE BRACKET RETAINERS WILL BE TIGHTENED TO A HIGHER TORQUE. IN CASES WHERE THE BRACKET IS NOT PROPERLY POSITION, THE BRACKET MUST BE RE-ALIGNED.
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