2002 Ford Expedition

Here’s a breakdown of common issues and complaints for the 2002 Ford Expedition, formatted for your website and focusing on specific components and configurations.

The 2002 Ford Expedition is a full-size SUV known for its spaciousness, towing capacity, and comfortable ride. Engine options for the 2002 Expedition include a 4.6L V8 producing approximately 232 horsepower and 291 lb-ft of torque, and a 5.4L V8 engine which produces approximately 260 horsepower and 350 lb-ft of torque. Both engines were paired with a 4-speed automatic transmission. Owners generally appreciate the Expedition’s ability to haul families and cargo but often report issues related to age, such as rust, electrical problems, and failing suspension components. Fuel economy is a common point of criticism.

Engine

4.6L V8

• Spark Plug Blowout
  • Description/Symptoms: Spark plugs can eject from the cylinder head due to weak threads, causing a loud popping noise, misfire, and loss of power. This is more common on early production 2V engines.
  • Solution: Repair or replace the cylinder head with a kit that includes threaded inserts, or replace the entire cylinder head.
  • Estimated Cost to Fix: $500 - $2000+
  • Recalls: None Found

5.4L V8

• Spark Plug Blowout
  • Description/Symptoms: Similar to the 4.6L, the 5.4L can suffer from spark plug blowout due to weak cylinder head threads.
  • Solution: Similar to the 4.6L, repair with threaded inserts or replace the cylinder head.
  • Estimated Cost to Fix: $500 - $2000+
  • Recalls: None Found
• Intake Manifold Cracking/Coolant Leaks
  • Description/Symptoms: The plastic intake manifold can crack, leading to coolant leaks, overheating, and potential engine damage.
  • Solution: Replace the intake manifold with an updated design (if available).
  • Estimated Cost to Fix: $400 - $800
  • Recalls: None Found

Transmission

4R70W 4-Speed Automatic Transmission

• Delayed or Harsh Shifting
  • Description/Symptoms: Transmission shifts roughly or hesitates, particularly between 1st and 2nd gear.
  • Solution: Fluid flush, replace valve body, or complete transmission rebuild/replacement.
  • Estimated Cost to Fix: $150 (flush) - $3000+ (rebuild/replace)
  • Recalls: None Found
• Torque Converter Failure
  • Description/Symptoms: Shuddering at low speeds, especially under light acceleration. Can also cause stalling.
  • Solution: Replace the torque converter.
  • Estimated Cost to Fix: $800 - $1500
  • Recalls: None Found

Suspension

• Air Suspension Failure (If Equipped)
  • Description/Symptoms: The rear of the vehicle sags, the compressor runs constantly, or the “check air suspension” light illuminates.
  • Solution: Replace the air springs (bags), compressor, or ride height sensors. Consider converting to coil springs for a permanent fix.
  • Estimated Cost to Fix: $300 - $800+ per air spring; $300 - $600 for the compressor; $500 - $1500 for coil spring conversion.
  • Recalls: None Found
• Ball Joint Failure
  • Description/Symptoms: Clicking or popping noises from the front suspension, uneven tire wear, and loose steering.
  • Solution: Replace upper and lower ball joints.
  • Estimated Cost to Fix: $200 - $500 per side
  • Recalls: None Found

Electrical

• Blend Door Actuator Failure
  • Description/Symptoms: Climate control system only blows hot or cold air, or the air only comes out of certain vents.
  • Solution: Replace the faulty blend door actuator(s).
  • Estimated Cost to Fix: $150 - $400 per actuator
  • Recalls: None Found
• Window Motor Failure
  • Description/Symptoms: Windows fail to operate or move slowly.
  • Solution: Replace the window motor.
  • Estimated Cost to Fix: $150 - $300 per window
  • Recalls: None Found

Exterior

• Rust on Rocker Panels and Wheel Wells
  • Description/Symptoms: Visible rust developing on the lower body panels, especially around the rocker panels and wheel wells.
  • Solution: Rust repair or panel replacement.
  • Estimated Cost to Fix: $300 - $1000+ per panel, depending on severity.
  • Recalls: None Found
• Rear Liftgate Issues
  • Description/Symptoms: Difficult to open or close, latch mechanism failure, or strut failure causing the liftgate to fall.
  • Solution: Replace the liftgate struts, latch, or entire liftgate assembly.
  • Estimated Cost to Fix: $50 - $200 (struts), $100 - $400 (latch), $500+ (liftgate assembly)
  • Recalls: None Found

Interior

• Cracked Dashboard
  • Description/Symptoms: The dashboard develops cracks due to sun exposure and age.
  • Solution: Install a dashboard cover or replace the dashboard.
  • Estimated Cost to Fix: $50 - $200 (cover), $500 - $1500 (replacement)
  • Recalls: None Found

Summary

The 2002 Ford Expedition, while a capable SUV, is prone to several age-related issues. Engine issues like spark plug blowout and intake manifold problems can be costly. Transmission problems can range from minor inconveniences to major repairs. Suspension and electrical gremlins can also lead to unexpected expenses. While some issues are relatively minor and inexpensive to fix, others can be significant investments. Potential buyers should carefully inspect the vehicle for rust, test all electrical components, and be aware of the potential for costly engine and transmission repairs.