2002 Ford Explorer

The 2002 Ford Explorer was a popular SUV known for its truck-like build and decent off-road capabilities. It came with several engine and transmission options. The base engine was a 4.0L SOHC V6 producing around 210 horsepower and 254 lb-ft of torque. A more powerful 4.6L SOHC V8, making approximately 240 horsepower and 282 lb-ft of torque, was also available. The transmissions offered were a 5-speed automatic and a 5-speed manual (only with the 4.0L). Owners generally liked the Explorer’s spaciousness, towing capacity, and relatively simple mechanics. Common complaints often revolved around fuel economy, certain reliability issues, and the overall age of the vehicle now.

Engine

4.0L SOHC V6

• Timing Chain Issues
  • Description/Symptoms: Rattling noise on startup, especially when cold. Can lead to rough running or even engine failure if not addressed.
  • Solution: Replacement of timing chains, tensioners, and guides.
  • Estimated Cost to Fix: $1,200 - $2,000+
  • Recalls: None Found
• Intake Manifold Cracks
  • Description/Symptoms: Engine misfires, rough idle, and potential coolant leaks. A hissing sound may be audible.
  • Solution: Replacement of the intake manifold.
  • Estimated Cost to Fix: $400 - $800+
  • Recalls: None Found

4.6L SOHC V8

• Spark Plug Blowout
  • Description/Symptoms: Sudden loud popping noise, followed by engine misfire and loss of power. Spark plugs can eject from the cylinder head.
  • Solution: Repair or replacement of cylinder head (installing thread inserts) and replacement of spark plug.
  • Estimated Cost to Fix: $500 - $1,500+ (depending on the extent of the damage)
  • Recalls: None Found
• Oil Leaks
  • Description/Symptoms: Oil dripping from the engine, often noticed under the vehicle. Can lead to low oil levels and potential engine damage. Common leak locations include valve cover gaskets, oil pan gasket, and rear main seal.
  • Solution: Replacement of the leaking gaskets or seals.
  • Estimated Cost to Fix: $100 - $500+ (per leak location)
  • Recalls: None Found

Transmission

5-Speed Automatic (5R55E)

• Valve Body Issues
  • Description/Symptoms: Harsh or erratic shifting, slipping between gears, or failure to shift.
  • Solution: Replacement or rebuild of the valve body.
  • Estimated Cost to Fix: $500 - $1,200+
  • Recalls: None Found
• Torque Converter Failure
  • Description/Symptoms: Shuddering or vibration at low speeds, especially when accelerating. Can lead to complete transmission failure.
  • Solution: Replacement of the torque converter.
  • Estimated Cost to Fix: $600 - $1,500+
  • Recalls: None Found

Suspension

• Front Ball Joint Failure
  • Description/Symptoms: Clunking or popping noise when going over bumps or turning. Loose or wobbly steering.
  • Solution: Replacement of the ball joints.
  • Estimated Cost to Fix: $200 - $500+ per side
  • Recalls: None Found
• Rear Leaf Spring Sagging/Breakage
  • Description/Symptoms: Rear end of the vehicle sitting lower than normal. Reduced ride quality. Cracking or breakage of the leaf springs.
  • Solution: Replacement of the leaf springs.
  • Estimated Cost to Fix: $300 - $800+ per side
  • Recalls: None Found

Electrical

• Window Motor Failure
  • Description/Symptoms: Window not moving up or down. Clicking sound from the door when the switch is activated.
  • Solution: Replacement of the window motor.
  • Estimated Cost to Fix: $150 - $400+ per window
  • Recalls: None Found
• Blend Door Actuator Failure
  • Description/Symptoms: Inconsistent temperature control. Clicking sound behind the dashboard.
  • Solution: Replacement of the blend door actuator.
  • Estimated Cost to Fix: $150 - $400+
  • Recalls: None Found

Exterior

• Rust (Especially in Rocker Panels and Lower Body)
  • Description/Symptoms: Visible rust forming on the lower areas of the vehicle. Can lead to structural damage if left untreated.
  • Solution: Rust repair and panel replacement (if necessary).
  • Estimated Cost to Fix: $200 - $2,000+ (depending on the severity)
  • Recalls: None Found

Interior

• Cracked Dashboard
  • Description/Symptoms: Cracks appearing on the dashboard surface, especially in areas exposed to sunlight.
  • Solution: Dashboard replacement or cover.
  • Estimated Cost to Fix: $200 - $1,000+
  • Recalls: None Found
• Broken Door Handle (Interior)
  • Description/Symptoms: Interior door handle breaking or becoming loose, making it difficult to open the door from the inside.
  • Solution: Door Handle replacement
  • Estimated Cost to Fix: $50 - $200+

Summary

The 2002 Ford Explorer, while a capable SUV in its day, is now facing age-related reliability issues. Engine problems such as timing chain issues and spark plug blowouts, combined with transmission issues like valve body failure, can lead to significant repair costs. Suspension wear and electrical problems further contribute to the potential expenses of maintaining this vehicle. Rust is also a common concern. Potential buyers should carefully inspect these areas and factor in the possibility of needing to address these issues to maintain the vehicle in good working order.