There are 19 owner-reported brakes complaints for the 2002 Ford Expeditionin NHTSA's database. These are unverified consumer reports and may not reflect confirmed defects.
The contact's fiancée owns a 2002 Ford Expedition. The contact stated that there was smoke coming from the driver's side front end of the vehicle. The contact stated that while his fiancée was attempting to drive the vehicle the following day, the brake pedal was depressed but was firm, requiring the contact's fiancée to step on the brake pedal to drive. The brake pedal remained on the floorboard and was inoperable, causing the contact's fiancée to shift to park(P) to stop the vehicle. The vehicle was towed to the dealer, where it was diagnosed that the speed control deactivation switch (SCDS) connectors had burned, and the brake fluid had leaked from the brake fluid reservoir. The dealer replaced the SCDS sensor and harness under NHTSA Campaign Number: 05V388000 (Vehicle Speed Control). The dealer declined to perform repairs for collateral damages. The contact stated that he was an auto-electrician mechanic who owned an auto shop. The vehicle was then towed to the contact's auto repair shop, where mechanics replaced the brake master cylinder and cleaned brake fluid off the engine bay. The vehicle was repaired. The manufacturer was notified of the failure and referred the contact to the NHTSA Hotline for assistance. The failure mileage was approximately 163,745.
2002 expedition mfg date 12/2001 right front brake separated at swagged fitting to short tubing to caliper. had just parked, stopped fine. next day all fluid had drained through separated hose.
re: IR 11467550. See attached photo.
TL* THE CONTACT OWNED A 2002 FORD EXPEDITION. WHILE THE VEHICLE WAS PARKED, THE CONTACT SMELLED A BURNING ODOR. THE CONTACT FOUND THAT THE MASTER CYLINDER CAUGHT FIRE. THE FIRE DEPARTMENT WAS NOT CONTACTED. A FIRE REPORT WAS NOT FILED. THERE WERE NO INJURIES. THE VEHICLE WAS TOWED TO CROWLEY FORD LINCOLN (225 NEW BRITAIN AVE, PLAINVILLE, CT 06062) WHERE IT WAS DEEMED DESTROYED. THE DEALER DID NOT GIVE A DIAGNOSIS, BUT CONTACTED THE MANUFACTURER MULTIPLE TIMES TO DETERMINE WHAT FORD SHOULD COVER. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE AND STATED THAT THE VIN WAS INCLUDED IN NHTSA CAMPAIGN NUMBER: 05V017000 (VEHICLE SPEED CONTROL). THE MANUFACTURER PROVIDED CASE NUMBER: CAS12637815 AND ADVISED THE CONTACT TO CALL HIS INSURANCE COMPANY. THE MANUFACTURER STATED THAT THEY WOULD SEND AN INSPECTOR. THE APPROXIMATE FAILURE MILEAGE WAS 183,000. UPDATED 09/07/17*LJ *CN
TL* THE CONTACT OWNS A 2002 FORD EXPEDITION. THE CONTACT STATED THAT SMOKE EMITTED FROM THE DRIVER'S SIDE OF THE VEHICLE. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC WHO REPLACED THE ENGINE AND THE TIMING BELT. THE CONTACT ALSO STATED THAT THE VEHICLE FAILED TO RESPOND TO DECELERATION ATTEMPTS AND THAT IT CAUGHT ON FIRE WHILE IT WAS PARKED AND UNOCCUPIED. THE VEHICLE WAS DESTROYED. A POLICE REPORT WAS FILED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 100,000.
BRAKE LINE RUPTURED IN REAR OF VEHICLE WHEN PULLING INTO SERVICE STATION HAULING MY TRAVEL TRAILER. WAS TOLD THE LINE WAS COMPLETELY RUSTED THROUGH AND THIS IS A COMMON PROBLEM ON THESE MODEL YEAR VEHICLES. I FIND TOTALLY CRAZY TO FIND BRAKE LINES RUSTING ON A VEHICLE OF THIS AGE. I WAS ALSO TOLD THE REAR CONTROL ARMS NEED TO BE REPLACED BECAUSE OF THE RUST. I KNOW THIS WAS AN ISSUE ON THE WINDSTARS AND IT WAS RECALLED FORD NEED TO TAKE CARE OF THIS. THANK GOD IT HAPPENED AT THE STATION AND NOT HAULING MY KIDS TO THE CAMPGROUND. THIS NEEDS TO BE ADDRESSED DUE TO THE FACT THERE ARE THOUSANDS OF THESE VEHICLES STILL ON THE ROADS.I KNOW IF I CALL FORD THEY WILL TELL ME ITS NOT IN WARRANTY THAT'S WHY I CONTACTED YOU. THEY COVER AIRBAGS AND SEATBELTS FOR LIFE THEY SHOULD COVER BRAKE LINES. *TR
ABOUT TWO WEEKS BEFORE MY CAR WOULDN'T GO INTO DRIVE I HAD IT TOWED TO THE DEALERS. THEY FIXED THE PROBLEM IT WAS A BRAKE SWITCH AND SOLENOID. THAT NEEDED REPLACING $300.00 LATER ITS FIXED. DURING THE WEEKEND MY CRUISE CONTROL LIGHT KEPT FLASHING. MY MOTHER, DAUGHTER AND I WERE WAITING FOR MY SON WHO WAS AT TRACK PRACTICE ON MONDAY 4-25-2011. WE WERE WAITING IN THE CAR AND LISTENING TO THE RADIO. I STARTED MY CAR TO MAKE SURE IT WAS GOING TO START. AS I STARTED IT WAS FULL OF SMOKE SO I OPEN THE HOOD AND THERE WAS A LITTLE SPARK FIRE. I LOOK INTO MY CAR TO FIND WATER AND I RETURNED TO ATTEND TO THE PROBLEM AND IT WAS IN FULL FLAME. I CALLED THE FIRE DEPARTMENT TO REPORT FIRE. THE PARKING LOT WAS FULL OF PARENTS AND CHILDREN ALSO WAITING FOR THERE CHILDREN. THERE'S SERIOUS FIRE DAMAGE UNDER THE HOOD WIRES AND SENSORS. I HAVE TAKEN PICTURES AS PROOF. OIL SPILLS FROM THE RESERVOIR. THANK GOD WE WERE THERE TO STOP IT FROM LOOSING THE VEHICLE AND OUR LIVES. I WANTED TO FIND OUT INFORMATION FOR MYSELF. WHAT I NEED TO DO? IS THIS FORDS FAULT FOR NOT INFORMING ME THAT THERE'S BEEN THOUSAND OF CASES OF MINE. I BOUGHT MY CAR LESS THAN A YEAR AGO. I WAS NEVER NOTIFIED OF ANY RECALLS OR FAULTY WIRING LET ALONE CAR FIRES??? MY KIDS AND I DON'T KNOW IF IT'S DRIVABLE. I HAVEN'T DROVE IT SINCE. I AM GOING TO FORD DEALERSHIP TOMORROW 4-29-11. *TR
TL*THE CONTACT OWNS A 2002 FORD EXPEDITION. IN 2006, THE VEHICLE WAS REPAIRED ACCORDING TO A RECALL. A COUPLE OF WEEKS LATER, THE BRAKE INDICATOR ILLUMINATED AND BRAKE FLUID BEGAN TO LEAK. THE CONTACT TOOK THE VEHICLE TO THE DEALER AND THEY REPAIRED THE FAILURE AT THE CONTACT'S EXPENSE. THE NHTSA CAMPAIGN ID NUMBER WAS UNKNOWN. THE FAILURE AND CURRENT MILEAGES WERE 83,000.
TL*THE CONTACT OWNS A 2002 FORD EXPEDITION. WHILE DRIVING 30 MPH, BOTH THE BRAKE AND ACCELERATOR PEDALS WERE IN THE UP POSITION. WHILE TURNING THE VEHICLE, THE ACCELERATOR PEDAL DROPPED. WITH THE ACCELERATOR PEDAL DOWN AND THE BRAKE PEDAL STILL UP, IT BECAME DIFFICULT FOR THE CONTACT TO DRIVE. SHE HAS NOT YET SPOKEN TO THE DEALER. THE VIN, ENGINE SIZE, NUMBER OF CYLINDERS, AND POWERTRAIN WERE UNKNOWN. THE CURRENT AND FAILURE MILEAGES WERE 116,000.
TL*THE CONTACT OWNS A 2002 FORD EXPEDITION. WHILE DRIVING APPROXIMATELY 5 MPH, THE CONTACT ATTEMPTED TO PARK THE VEHICLE ON A STEEP HILL. SHE DEPRESSED THE BRAKE PEDAL, BUT THE BRAKES DID NOT ENGAGE. SHE DID NOT PARK ON THE HILL BECAUSE SHE FEARED THE VEHICLE WOULD ROLL AWAY. THE DEALER STATED THAT THE EMERGENCY BRAKE WAS THE CAUSE OF THE FAILURE. THEY REPLACED BOTH BRAKE CABLES, ROTORS, AND REAR PADS. THE CURRENT AND FAILURE MILEAGES WERE 80,000.
MY 2002 EXPEDITION WAS RECALLED IN 2005 TO REPLACE THE CRUISE CONTROL WIRING HARNESS. A FUSED WIRING HARNESS WAS INSTALLED TO PROTECT THE LIVE CRUISE CONTROL CIRCUIT FROM INITIATING A FIRE IF THE BRAKE SENSING SWITCH MEMBRANE LEAKED BRAKE FLUID. YESTERDAY, 17 SEP 07, MY CRUISE CONTROL MALFUNCTIONED. THE BRAKE SENSING SWITCH AT THE MASTER BRAKE CYLINDER AND THE CRUISE CONTROL WIRING HARNESS COMING OUT OF THE SWITCH WERE SOAKED WITH BRAKE FLUID. BRAKE FLUID WAS ALL OVER THE ENGINE COMPARTMENT. I DISCONNECTED THE WIRING HARNESS THE AREA OF THE SWITCH INTO WHICH THE WIRING HARNESS WAS PLUGGED WAS FULL OF BRAKE FLUID. BRAKE APPLICATION CAUSED BRAKE FLUID TO LEAK OUT OF THE SWITCH. THE SWITCH MEMBRANE WAS INDEED BROKEN. I ASSUMED (WRONGLY) THAT THE NEW FUSED CRUISE CONTROL BUNDLE HAD PROBABLY SPARED ME A FIRE. I TOOK MY CAR TO FORD TODAY. THEY CALLED CORPORATE REGARDING PAYMENT ISSUES. I WAS INFORMED THAT FORD WAS NOT RESPONSIBLE FOR THE REPAIR BILL. THIS SPECIFIC COMPLAINT IS NOT ABOUT THE BILL PER SE, BUT ABOUT MY CONCERN FOR SAFETY. AS IT TURNED OUT, THE NEW FUSED HARNESS DID NOT BLOW THE FUSE--FORD DID NOT REPLACE THE HARNESS. I AM NOW CONCERNED THAT THE "HOT" FUSED WIRING HARNESS WAS ATTACHED TO THE BRAKE SENSOR WHILE IT WAS COMPLETELY IMMERSED IN BRAKE FLUID. THERE IS STILL A SIGNIFICANT RISK OF FIRE. I HAVE KEPT THE OLD BRAKE SWITCH, BUT AS PREVIOUSLY STATED, THE FUSED WIRING HARNESS WAS NOT REPLACED SINCE THE FUSE WAS NOT BLOWN (THE FUSE CANNOT BE REPLACED--THE ENTIRE BUNDLE MUST BE REPLACED PER A INFORMATION LABEL ATTACHED TO THE WIRING HARNESS) AND IS STILL ON THE CAR. SIGNIFICANT SAFETY ISSUES ARE: IS THERE STILL A RISK OF FIRE WHEN THE BRAKE SWITCH BRAKES/LEAKS AND, WHAT IS THE SAFETY IMPLICATION WITH REGARDS TO BRAKING GIVEN AN INCREASED RISK OF FAILURE AND SUBSEQUENT LEAKAGE OF THE BRAKE FLUID AT THE SWITCH? *TR
BRAKES ON A 2002 FORD EXPEDITION GOES TO THE FLOOR. THEN THERE IS NO EXPLANATION WHAT IS GOING ON. I HAVE TAKEN IT TO A DEALER AND THEY SAY THERE NOTHING WRONG. NO PARTS WERE REPLACED. THE DEALER TRIED EVERYTHING HE KNEW POSSIBLE BUT COULD NOT RESOLVE THE ISSUE. *NM
VEHICLE WAS PARKED AND IT CAUGHT ON FIRE. OWNER WAS NOTIFIED BY NEPHEW THAT THE VEHICLE WAS ON FIRE. THE FIRE DEPARTMENT WAS NOTIFIED, AND EXTINGUISHED THE BLAZE. A REPORT WAS TAKEN, AND THE CAUSE WAS DETERMINE DTO BE THE ABS SENSOR AND OR THE CRUISE CONTROL WHERE THE FIRE ORIGINATED. *AK
BRAKE PEDAL FELT ROUGH UPON STEPPING ON PEDAL (I HAVE A LITTLE MORE THAN 30K MILES ON THE VEHICLE) I DO WORK ON MY OWN VEHICLES AND I AM VERY KNOWLEGABLE WHEN IT COME TO BASIC REPAIRS I INSPECTED BOTH ROTERS ON THE FRONT OF THE VEHICLE AND FOUND THE DRIVER SIDE INNER PAD COMPLETELY WORN TO THE METAL THE OUTER PAD STILL HAS APPROXIMATELY 1/4 INCH BEFORE IT HITS THE INDICATOR OBVIOUSLY MY CALIPER IS STICKING I HAVE AN APPOINTMENT TOMORROW IM CURIOUS WHAT TEY WILL SAY. *AK
2002 EXPEDITION 5.4L - WHEN BRAKING, VEHICLE ACCELERATES. BRAKES WERE APPLIED AS HARD AS POSSIBLE YET THE VEHICLE ACCELERATED AGAINST THE BRAKES. THIS HAS HAPPENED 3 TIME BEFORE. SPEED OF VEHICLE RANGED FROM 5 OR 10 MPH TO 50 MPH AT TIME OF PROBLEM. VEHICLE HAS BEEN TAKEN TO LOCAL DEALER BUT NO PROBLEM WAS FOUND. THIS LAST TIME WE ALMOST REAR ENDED ANOTHER VEHICLE. APPEARS TO OCCUR ONLY WHEN SLOWING DOWN FOR A STOP. WILL TAKE VEHICLE TO DEALER YET AGAIN.*AK
2002 FORD EXPEDITION: RIGHT FRONT BRAKE(S) MAKING GRINDING NOISE WHEN DRIVING AND IS EXAGGERATED WHEN BRAKING. CALLED DEALER TO SCHEDULE SERVICE. ASKED SERVICE ADVISOR WHY WEAR INDICATOR(S) DID NOT WORK. SERVICE ADVISOR INFORMED ME THAT FORD HAS NOT INSTALLED BRAKES WITH WEAR INDICATORS FOR YEARS. I TOLD THE SERVICE ADVISOR THAT IT IS UNBELIEVABLE THAT A $30K VEHICLE WOULD NOT HAVE BPS WITH WEAR INDICATORS ESPECIALLY SINCE MY 1992 VW JETTA HAS BRAKE PADS WITH WEAR INDICATORS. I REMOVED THE RF TIRE TO EXAMINE THE BRAKE PAD(S) AND DISCOVERED THAT THE BRAKE PAD(S) DO IN FACT HAVE WEAR INDICATORS HOWEVER, THE BRAKE CALIPER IS STUCK WHICH CAUSED THE INSIDE BRAKE PAD TO WEAR PREMATURELY. THIS HAS SCARRED THE ROTOR. *JB
ON FOUR OCCASIONS WHEN APPLYING BRAKES, AND JUST BEFORE STOPPING, ENGINE WOULD SURGE AND SUDDENLY ACCELERATE. VEHICLE BEEN TO DEALER, AND DEALER WAS UNABLE TO DUPLICATE THE PROBLEM. FEEL FREE TO PROVIDE ANY FURTHER INFORMATION.*AK
WHILE DRIVING THERE'S A SQUEAKING NOISE. BRAKE CALIPERS ARE STICKING. PLEASE PROVIDE ANY FURTHER INFORMATION.*AK
WHILE DRIVING 30-40 MPH IN RAINY WEATHER CONSUMER APPLIED BRAKES AND THEY LOCKED UP, RESULTING IN A REAR END COLLISION, CONSUMER SUFFERED BRUISES. AIR BAGS NEVER DEPLOYED. *JG *AK
Complaints are unverified consumer reports submitted to NHTSA. A high complaint count may reflect vehicle popularity, not defect severity. Data sourced from NHTSA public records.
Data synced from NHTSA on May 4, 2026