2002 Ford Explorer Structure Problems
Owners have filed 486 complaints with NHTSA about structure problems on the 2002 Ford Explorer, 15% of all complaints for this model year. Half of the reports with a mileage happened before 66,400 miles. The words owners use most often: “rear window” (18% of reports).
- 486structure complaints
- 66,400median miles at failure
- 4mention a crash
- 57mention an injury
- 2related recalls
- $980typical repair cost reported by owners
- 34%of reports with a speed happened at 50+ mph
What owners describe
Phrases that appear unusually often in these complaints compared with complaints about other cars.
- Rear window: mentioned in 87 of 486 complaints (18%)
- PE04045 pco: mentioned in 68 of 486 complaints (14%)
- Liftgate glass: mentioned in 48 of 486 complaints (10%)
- Panel below: mentioned in 39 of 486 complaints (8%)
How much does it cost to fix?
Owners who wrote down what they paid or were quoted put the typical structure repair on the 2002 Ford Explorer at $980, and half of them between $680 and $1,500.
Based on 24 NHTSA complaints about this problem alone that state a repair bill or quote (2004–2011), converted to 2026 dollars with the U.S. consumer price index. These are owners' own figures, not a quote: they include dealer quotes, and owners who file complaints often faced larger repairs, so they can run higher than typical shop prices. Prices vary by shop, region and warranty coverage. How we calculate this.
At what mileage do structure problems happen?
Based on 317 complaints that reported the odometer reading.
How serious are the reports?
Of 486 complaints, 4 mention a crash, 2 a fire, 57 an injury.
Ford Explorer structure complaints by model year
| Model year | Structure complaints | Share of that year | Median miles |
|---|---|---|---|
| 2026 Explorer | 2 | 5% | — |
| 2025 Explorer | 7 | 7% | 1,600 |
| 2023 Explorer | 10 | 9% | 10,000 |
| 2022 Explorer | 11 | 4% | 39,000 |
| 2021 Explorer | 24 | 5% | 61,500 |
| 2020 Explorer | 45 | 4% | 40,302 |
| 2019 Explorer | 150 | 50% | 63,125 |
| 2018 Explorer | 288 | 39% | 60,950 |
| 2017 Explorer | 657 | 39% | 76,000 |
| 2016 Explorer | 591 | 24% | 82,750 |
| 2015 Explorer | 410 | 23% | 90,000 |
| 2014 Explorer | 276 | 16% | 92,500 |
| 2013 Explorer | 439 | 20% | 70,000 |
| 2012 Explorer | 144 | 17% | 96,500 |
| 2011 Explorer | 110 | 9% | 101,000 |
| 2010 Explorer | 1 | 1% | 6,900 |
| 2009 Explorer | 2 | 6% | 105,000 |
| 2008 Explorer | 1 | 1% | 7,000 |
| 2007 Explorer | 11 | 5% | 80,000 |
| 2006 Explorer | 11 | 2% | 19,695 |
| 2005 Explorer | 151 | 30% | 77,300 |
| 2004 Explorer | 426 | 33% | 72,000 |
| 2003 Explorer | 354 | 31% | 70,000 |
| 2002 Explorer | 486 | 15% | 66,400 |
| 2001 Explorer | 29 | 8% | 100,000 |
| 2000 Explorer | 29 | 3% | 93,310 |
| 1999 Explorer | 47 | 3% | 100,000 |
| 1998 Explorer | 48 | 2% | 112,000 |
| 1997 Explorer | 50 | 3% | 84,000 |
| 1996 Explorer | 63 | 4% | 123,743 |
| 1995 Explorer | 39 | 5% | 112,762 |
When owners reported it
Related recalls (2)
Structure:body:hatchback/liftgate:hinge and attachments
Problem: 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.
Risk: If the hinge should fracture, there is a potential for the glass to fall and ultimately break and personal injuries could occur.
Fix: 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
Problem: 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.
Risk: This overheating condition can cause the running board to melt or cause a fire.
Fix: 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.
What owners report
Short excerpts of recent complaints, with personal details removed. Full reports are on NHTSA.gov.
September 2, 2023 at about 6 pm I pulled over to grab a couple water bottles from the rear of my 2002 Ford Explorer Sport cause my engine was overheating. I got out walked to the rear of my vehicle pushed my unlatch button on the tailgate and I lifted the glass part of the rear hatch. Both air…
Tl* the contact owns a 2002 ford explorer. The contact stated that while opening the real lift gate, the rear lift gate glass window suddenly shattered. During the incident, the person sustained a facial laceration which required medical treatment. The cause of the failure was not determined. The…
Summer,spring weather, all four, clear, glass windows do not slide up or down through its' power button, electronically.
Frequently asked questions
Do all 2002 Ford Explorers have structure problems?
No. NHTSA has 486 owner complaints about structure for the 2002 Ford Explorer (15% of the 3,295 complaints for this model year). Complaint data shows that the problem is reported, not how many of all cars sold are affected.
Was there a recall on the 2002 Ford Explorer structure?
Yes: 2 safety recalls list structure. Check your VIN on NHTSA.gov to see whether the fix was done on your car.
At what mileage do structure problems start?
The median reported mileage is 66,400 miles: half of the reports with a mileage came before that.
How much does it cost to fix structure problems on the 2002 Ford Explorer?
Owners report a typical cost of $980 (half paid between $680 and $1,500), from 24 complaints that state a repair bill or quote, in 2026 dollars.
What do owners say about structure problems on the 2002 Ford Explorer?
The most frequent phrase is “rear window”, in 87 of 486 complaints, followed by “pe04045 pco” (68).
Other 2002 Ford Explorer problems
- Power Train problems (1,502)
- Suspension problems (422)
- Engine and Engine Cooling problems (163)
- Air Bags problems (162)
- Steering problems (155)
- Vehicle Speed Control problems (152)
- Electrical System problems (148)
- Visibility problems (129)
See all 2002 Ford Explorer problems or structure problems across all Explorer years.