2002 Ford F-250 SD

Fatalities reported

Owners filed 245 complaints about this vehicle with federal regulators, most often about the engine and engine cooling. It has been recalled 5 times.

When it fails
020k40k60k90k120k200k
75,000 milesMedian miles at failure

205 complaints record an odometer reading. Failures cluster around 75,00090,000 miles.

What fails
ComponentReportsCrashesFiresInjuries
Engine and Engine Cooling36
041
Engine and Engine Cooling › Engine22
040
Engine and Engine Cooling › Engine › Diesel19
000
Electrical System17
010
Tires12
303
Service Brakes, Hydraulic10
200
Vehicle Speed Control8
121
Engine and Engine Cooling › Exhaust System8
000
Tires › Tread/Belt7
000
Steering6
101

5 safety recalls

Part 573 reports
Exterior Lighting › Brake Lights11V352000
Filed Jul 13, 201126,715 vehiclesFord Motor Company

Defect. FORD IS RECALLING CERTAIN MODEL YEAR 2011 RANGER TRUCKS BUILT FROM JANUARY 25, 2011, THROUGH APRIL 25, 2011 AT THE TWIN CITIES ASSEMBLY PLANT, AND SERVICE PARTS DISTRIBUTED TO DEALERS FOR CERTAIN 2004 THROUGH 2011 MODEL YEAR RANGER TRUCKS, 2002 THROUGH 2005 MODEL YEAR EXCURSION VEHICLES, AND 2002 THROUGH 2007 MODEL YEAR F-250, F-350, F-450, AND F-550 TRUCKS FOR FAILING TO COMPLY WITH THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 108, "LAMPS, REFLECTIVE DEVICES, AND ASSOCIATED EQUIPMENT." THE MULTI-FUNCTION SWITCH WAS SHIPPED WITH A SUBCOMPONENT (SLIDER) THAT MAY EXPERIENCE DEFORMATION. A MULTI-FUNCTION SWITCH WITH A DEFORMED SLIDER MAY MALFUNCTION CAUSING THE TURN SIGNAL, TAIL LIGHTS, HAZARD WARNING SIGNAL FLASHERS AND/OR BRAKE LIGHTS NOT TO ACTIVATE.

Risk. NON-FUNCTIONING LIGHTS COULD INCREASE THE RISK OF A CRASH.

Remedy. DEALERS WILL REPLACE THE SWITCHES FREE OF CHARGE. THE SAFETY RECALL BEGAN ON AUGUST 15, 2011. OWNERS MAY CONTACT FORD MOTOR COMPANY CUSTOMER RELATIONSHIP CENTER AT 1-866-436-7332.

Vehicle Speed Control09V399000
Filed Oct 13, 20094,500,000 vehiclesFord Motor Company

Defect. 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.

Risk. 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.

Wheels › Hub07E106000
Filed Dec 17, 2007130,000 vehiclesFederal-Mogul Corporation

Defect. CERTAIN FEDERAL-MOGUL REPLACEMENT WHEEL HUB ASSEMBLIES WITH THE BRAND NAMES: NATIONAL, CARQUEST P/NOS. 515020, 515021, 515025, 515053, 515054, 515059, AND 515060, SHIPPED BETWEEN JANUARY 23, 2006, AND DECEMBER 20, 2007, SOLD FOR LIGHT DUTY AND MEDIUM DUTY TRUCKS. THE INBOARD RETENTION NUT USED TO MAINTAIN HUB BEARING ASSEMBLY CAN LOOSEN RESULTING IN AN ABS LIGHT INDICATION, NOISE, AND/OR WHEEL SEPARATION.

Risk. WHEEL SEPARATION CAN RESULT IN A VEHICLE CRASH.

Remedy. FEDERAL-MOGUL WILL NOTIFY CUSTOMERS AND WILL REPLACE THE HUB ASSEMBLY FREE OF CHARGE. THE RECALL BEGAN ON FEBRUARY 7, 2008. OWNERS CAN CONTACT FEDERAL-MOGUL TOLL-FREE AT 877-489-6659.

Engine and Engine Cooling › Engine › Diesel07V553000
Filed Dec 5, 20071,176,000 vehiclesFord Motor Company

Defect. ON CERTAIN HEAVY DUTY TRUCKS EQUIPPED WITH 7.3L DIESEL ENGINES, THE CAMSHAFT POSITION SENSOR LOCATED ON THE ENGINE OF THE VEHICLE MAY FUNCTION INTERMITTENTLY, POSSIBLY RESULTING IN AN ENGINE STALL.

Risk. IN THE EVENT OF AN ENGINE STALL, A CRASH COULD RESULT WITHOUT WARNING.

Remedy. DEALERS WILL INSPECT THE SENSOR AND REPLACE IT WITH AN IMPROVED CAMSHAFT POSITION SENSOR FREE OF CHARGE. THE RECALL BEGAN ON DECEMBER 29, 2007. OWNERS MAY CONTACT FORD AT 1-866-436-7332.

Exterior Lighting06E026000
Filed Mar 23, 200661,944 vehiclesPro-A Motors, Inc.

Defect. 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.

Risk. 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.

What owners reported

Newest filings
Vehicle Speed Control
Filed May 1, 201789,745 milesVA

MY SPEED CONTROL STOPPED WORKING IN 2012. IT IS A FORD F-250 SUPER DUTY. VIN [XXX]. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6). *TR

Seat Belts
Filed Mar 30, 2017167,261 milesMO

THE SEAT BELTS COME UNBUCKLED WHEN DRIVING. THIS HAPPENS TO THE DRIVE'S SIDE MORE OFTEN THAN PASSENGER SIDE. THE BELT COME UNDONE ON HIGHWAY, IN TOWN, JUST STARTING OUT OR AFTER AN HOUR THERE ISN'T A WARNING BEFORE IT HAPPENS.THE SPEED OF THE TRUCK ALSO DOESN'T MAKE A DIFFERENCE. BUT IT IS HAPPENING MORE FREQUENT NOW. IT STARTED ABOUT 3 YEARS AGO BUT IT IS GETTING WORST.

Engine
Filed Jan 17, 2017120,000 milesTN

TRUCK DIES WHILE DRIVING WITHOUT ANY WARNING, CAN-NOT FIND THE PROBLEM AND FORD WILL NOT ACKNOWLEDGE THAT THERE IS AN ISSUE. *TR

Unknown or OtherFire
Filed Apr 27, 201665,000 milesTN

AFTER DRIVING ABOUT 30 MILES AND RETURNING HOME, THE TRUCK CAUGHT FIRE WHILE SITTING IN THE DRIVEWAY - ABOUT 20 MINUTES AFTER ENGINE WAS TURNED OFF. BY THE TIME SMOKE WAS SEEN, FLAMES WERE COMING FROM UNDER THE HOOD AND THE RIGHT FRONT TIRE WAS BURNING. THE FIRE DEPARTMENT PUT OUT THE FIRE BUT THE TRUCK WAS COMPLETELY DESTROYED. THE FLAMES SPREAD TO AN ADJACENT VEHICLE AND IT TOO WAS DESTROYED.

Engine
Filed Apr 17, 2016102,000 milesNM

AT 102000 MILES ENGINE EJECTED #8 SPARK PLUG WHILE DRIVING, TAKING THREADS WITH IT. LOCAL MECHANIC REPAIRED USING INSERT. AT 125000 MILES ENGINE EJECTED #3 SPARK PLUG IN SAME MANNER. SAME MECHANIC INSPECTED #8 WHILE REPAIRING #3 AND FOUND INSERT NOT HOLDING, PLUS TWO OTHER PLUGS BACKING OUT.

EngineFire
Filed Dec 16, 201584,000 milesWA

TL* THE CONTACT OWNS A 2002 FORD F-250 SD. THE CONTACT STATED THAT WHILE DRIVING 55 MPH, A LOUD ABNORMAL SOUND EMITTED FROM THE ENGINE COMPARTMENT. AFTER INSPECTING THE VEHICLE, THE CONTACT NOTICED THAT THE SPARK PLUG HAD EXPLODED OUT OF THE CYLINDER HEAD. THE FAILURE RECURRED SEVERAL TIMES. THE VEHICLE WAS TAKEN TO THE DEALER WHO ADVISED THAT THE ENGINE NEEDED TO BE REPLACED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE VEHICLE WAS NOT REPAIRED. THE FAILURE MILEAGE WAS 84,000.

Tires
Filed Aug 24, 2015269,580 milesAZ

ALL INCIDENTS INVOLVING BIG O AT TRUCK TIRES: 6/11/12 TREAD SEPARATION. NO DAMAGE TO VEHICLE OR CRASH. 12/31/12 TREAD SEPARATION. NO DAMAGE TO VEHICLE OR CRASH. 3/12/14 TREAD SEPARATION. NO DAMAGE TO VEHICLE OR CRASH. 4/11/14 TREAD SEPARATION. NO DAMAGE TO VEHICLE OR CRASH. 7/29/14 TREAD SEPARATION. NO DAMAGE TO VEHICLE OR CRASH. 3/26/15 TREAD SEPARATION. NO DAMAGE TO VEHICLE OR CRASH. 5/29/15 TREAD SEPARATION. HEAVY DAMAGE TO QUARTER PANEL OF VEHICLE.

Tires › Tread/Belt
Filed Aug 18, 2015134,900 milesVA

TL* THE CONTACT OWNS A 2002 FORD F-250 SD EQUIPPED WITH GOODRICH LONG TRAIL T/A TIRES, SIZE: P265/75/R15 (NA). WHILE TOWING ANOTHER VEHICLE, THERE WAS AN ABNORMAL VIBRATION POPPING NOISE FROM THE REAR PASSENGER SIDE TIRE. THE CONTACT OBSERVED THAT THE REAR TIRE POPPED AND NOTICED TREAD SEPARATION ON THE TIRE. THE TIRE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE VEHICLE FAILURE MILEAGE WAS 134,900 AND THE TIRE FAILURE MILEAGE WAS APPROXIMATELY 5,000.

Seat Belts
Filed Jul 29, 2015137,243 milesWA

TL* THE CONTACT OWNS A 2002 FORD F-250 SD. THE CONTACT STATED THAT THE DRIVER SEAT BELT WOULD NOT ENGAGE WITHOUT WARNING. THE VEHICLE WAS TAKEN TO THE DEALER WHERE IT WAS DIAGNOSED THAT THE DRIVER SEAT BELT BUCKLE ASSEMBLY FRACTURED AND NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURE. THE FAILURE MILEAGE WAS 137,243. THE VIN WAS NOT AVAILABLE.

TiresCrash
Filed Mar 16, 2015121,301 milesFL

HAVE HAD 2 SETS OF BFGOODRICH 285/75/16 122R D TIRES THAT HAVE FAILED WITH SEPARATION PROBLEMS. THE FIRST SET THAT FAILED 05/11, WE HAD BLOWOUT ACCIDENT ON INTERSTATE CAUSING OVER $3000 DAMAGE TO DRIVER FRONT. LUCKILY NO PERSONAL INJURIES BF GOODRICH REPLACED THE TIRES AT 100%, SAME TIRES. THE SECOND SET HAVE SAME SEPARATION PROBLEMS AS OF 03/15, AT APPROX. 30000 MILES ON 60000 MILE TIRES. THE TIRE KINGDOM STORE ADVISED UNSAFE TO DRIVE AND SAID THESE TIRES WERE MANUFACTURED AT SAME TIME THE RECALLS WERE. HE CALLED THE RECALL# AND WAS ADVISED TO REPLACE AT 100% SO WE REPLACED THEM WITH THE MICHELIN 285'S. NOW WE ARE BEING TOLD THE BF GOODRICH RECALL OFFICE WILL ONLY PAY 70% ON THE NEW TIRES. THAT IS UNACCEPTABLE FOR THIS SERIOUS DEFECT IN THESE TIRES. IT DOES APPEAR THE WARRANTY DOESN'T REALLY ADDRESS MANUFACTURER DEFECTS.THIS DEFECT IS NOT DUE TO WEAR, TEAR OR CONSUMER FAULT. HAD THE DEFECT NOT BEEN IN THE TIRE, THE TIRES WOULD STILL BE IN GOOD WORKING ORDER WITHOUT DANGER OF FAILURE THAT OCCURRED. WE FEEL THESE TIRES ARE UNSAFE AND WE HAVE ASKED BFGOODRICH TO REPLACE WITH DIFFERENT TIRE AT 100% SINCE WE DO NOT FEEL WE SHOULD BE RESPONSIBLE FOR WHAT APPEARS TO BE MANUFACTURER DEFECT. *TR

Tires
Filed Mar 16, 2015151,000 milesFL

HAVE HAD 2 SETS OF BFGOODRICH 285/75/16 122R D TIRES THAT HAVE FAILED WITH SEPARATION PROBLEMS. THE FIRST SET THAT FAILED 05/11, WE HAD BLOWOUT ACCIDENT ON INTERSTATE CAUSING OVER $3000 DAMAGE TO DRIVER FRONT. LUCKILY NO PERSONAL INJURIES BF GOODRICH REPLACED THE TIRES AT 100%, SAME TIRES. THE SECOND SET HAVE SAME SEPARATION PROBLEMS AS OF 03/15, AT APPROX. 30000 MILES ON 60000 MILE TIRES. THE TIRE KINGDOM STORE ADVISED UNSAFE TO DRIVE AND SAID THESE TIRES WERE MANUFACTURED AT SAME TIME THE RECALLS WERE. HE CALLED THE RECALL# AND WAS ADVISED TO REPLACE AT 100% SO WE REPLACED THEM WITH THE MICHELIN 285'S. NOW WE ARE BEING TOLD THE BF GOODRICH RECALL OFFICE WILL ONLY PAY 70% ON THE NEW TIRES. THAT IS UNACCEPTABLE FOR THIS SERIOUS DEFECT IN THESE TIRES. IT DOES APPEAR THE WARRANTY DOESN'T REALLY ADDRESS MANUFACTURER DEFECTS.THIS DEFECT IS NOT DUE TO WEAR, TEAR OR CONSUMER FAULT. HAD THE DEFECT NOT BEEN IN THE TIRE, THE TIRES WOULD STILL BE IN GOOD WORKING ORDER WITHOUT DANGER OF FAILURE THAT OCCURRED. WE FEEL THESE TIRES ARE UNSAFE AND WE HAVE ASKED BFGOODRICH TO REPLACE WITH DIFFERENT TIRE AT 100% SINCE WE DO NOT FEEL WE SHOULD BE RESPONSIBLE FOR WHAT APPEARS TO BE MANUFACTURER DEFECT. *TR

Service Brakes
Filed Aug 1, 201481,125 milesPA

ON MY FORD F-250 CREW CAB, ALL FOUR BRAKES AND ROTORS WENT BAD AND HAD TO BE REPLACED ON 10-08-2009 WITH 81,125 MILES ON THE VEHICLE. ON 11-10-2009 (ONE MONTH LATER) I HAD TO REPLACE A CALIPER ON THE LEFT REAR AXLE. ON 5-16-2013 WITH 100030 MILES (18,905 MILES LATER) I HAD TO INSTALL ANOTHER NEW CALIPER AND ROTOR ON LEFT REAR AXLE AND REPLACE BOTH BRAKE PADS. ON 8-1-14 WITH 106,861 MILES, (AGAIN WITH ONLY 25,736 MILES SINCE LAST BEING REPLACED) BOTH FRONT CALIPERS FROZE AND RUINED THE LEFT FRONT ROTOR THAT WILL NEED TO BE REPLACED. ALL REPLACEMENT PARTS USED WERE GENUINE FORD PARTS. I BOUGHT THE VEHICLE WHEN IT HAD APPROXIMATELY 54,000 MILES SO I DON'T KNOW HOW MANY TIMES THE BRAKES WERE REPAIRED PRIOR TO ME BUYING IT. FROM THE INTERNET I SEE THAT MANY OTHERS ARE HAVING THE SAME PROBLEMS. THESE BRAKE PARTS ARE UNSATISFACTORY. NOT ONLY IS IT UNSAFE WHEN THEY FREEZE FROM VIBRATION, BUT IT IS EXTREMELY COSTLY. I FEEL THAT THIS IS A HUGE PROBLEM AND A RECALL SHOULD BE MADE. THANK YOU. *TR

Electrical System
Filed Apr 2, 2014110,500 milesCA

THE VSM (VEHICLE SECURITY MODULE) FAILED. SYMPTOMS INCLUDE, BUT ARE NOT LIMITED TO: POWER DOOR LOCKS DO NOT WORK, KEY FOB DOES NOT WORK, AUTO HEADLIGHTS DO NOT WORK, RADIO DOESN'T TURN OFF WHEN KEY IS OUT OF THE IGNITION AND DOOR OPENS, NO AUDIBLE INDICATOR FOR KEY IN THE IGNITION, NO AUDIBLE INDICATOR FOR HEADLIGHTS ON WITH DOOR OPEN, DOME LIGHTS STAY ON. THIS PROBLEM IS WIDESPREAD WITH THIS MODEL YEAR AND THERE ARE MANY REPORTS ON FORUMS AROUND THE INTERNET. FORD HAS ALSO STOPPED MAKING THE ORIGINAL PART AND REPLACED ITS MANUFACTURE WITH A NEW PART WHICH SUPPOSEDLY DOES NOT EXHIBIT THE SAME RANDOM FAILURE RATE. HEADLIGHTS NOT WORKING IS A MAJOR LIFE SAFETY ISSUE. I DROVE WITHOUT HEADLIGHTS ON FOR SOME TIME (AS THE AUTO HEADLIGHTS DID NOT COME ON) AND DID NOT NOTICE IT UNTIL I WAS ON AN UNLIT STREET. ALL OF THE OLD VSMS SHOULD BE CHANGED TO THE NEW MODEL FREE OF CHARGE TO PREVENT THIS FROM HAPPENING. *TR

Tires
Filed Jul 16, 2013108,539 milesAZ

TL* THE CONTACT OWNS A 2002 FORD F-250 SD EQUIPPED WITH NITTO DURAGRAPPLER TIRES, SIZE 265/75/16. THE CONTACT STATED THAT WHILE DRIVING VARIOUS SPEEDS, THE FRONT PASSENGER'S SIDE TIRE EXPLODED. THE VEHICLE WAS MANEUVERED TO THE SIDE OF THE ROAD WHERE A SPARE TIRE WAS INSTALLED. THE VEHICLE WAS TAKEN TO A TIRE CENTER AND THEY INFORMED THE CONTACT THAT THERE WAS SEVERE TIRE SEPARATION ON THE REMAINING THREE TIRES. THE FOUR TIRES WERE REPLACED WITH NEW ONES. THE MANUFACTURER WAS NOTIFIED OF THE DEFECT. THE APPROXIMATE FAILURE MILEAGE WAS 108,539.

Service Brakes
Filed Jul 5, 201366,000 milesMD

TL* THE CONTACT OWNS A 2002 FORD F-250 SD. THE CONTACT STATED THAT WHILE STOPPED, HE DEPRESSED THE BRAKE PEDAL AND THE PEDAL ABNORMALLY TRAVELED TO THE FLOORBOARD ACCOMPANIED BY A LOUD POP. THE CONTACT INSPECTED THE VEHICLE AND NOTICED BRAKE FLUID LEAKING. THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURE. THE VEHICLE WAS NOT REPAIRED. THE APPROXIMATE FAILURE MILEAGE WAS 66,000. *TR

Exterior Lighting
Filed Jun 24, 2013102,746 milesIN

TL* THE CONTACT OWNS A 2002 FORD F-250 SD. THE CONTACT STATED WHILE DRIVING APPROXIMATELY 60 MPH THE CRUISE CONTROL FAILED TO ACTIVATE UPON ENGAGING. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC FOR DIAGNOSIS AND THEY STATED THAT THE BRAKE PRESSURE SWITCH NEEDED TO BE REPLACED. NHTSA RECALL CAMPAIGN ID NUMBER 11V352000 (EXTERIOR LIGHTING) WAS RELATED TO THE FAILURE. THE DEALER INFORMED THE CONTACT THAT THE VEHICLE WAS PREVIOUSLY REPAIRED UNDER THE RECALL; HOWEVER, IT DID NOT CORRECT THE PROBLEM. THE MANUFACTURER WAS NOTIFIED OF THE DEFECT. THE APPROXIMATE FAILURE MILEAGE WAS 102,746. UPDATED 8/5/13 *CN

Service Brakes
Filed Jun 24, 201374,000 milesPA

TL* THE CONTACT OWNS A 2002 FORD F-250 SD. THE CONTACT STATED THAT WHILE EXITING A RESIDENTIAL DRIVEWAY, THE CONTACT NOTICED THAT BRAKE FLUID HAD LEAKED ONTO THE FLOORBOARD. THE CONTACT INSPECTED THE VEHICLE AND DISCOVERED THAT THE FRAME EXHIBITED CORROSION. THE VEHICLE WAS NOT TAKEN TO A DEALER FOR AN INSPECTION. THE FAILURE WAS NOT REPORTED TO THE MANUFACTURER. THE FAILURE AND CURRENT MILEAGE WAS 74,000.

Service Brakes
Filed May 16, 201360,000 milesPA

TL* THE CONTACT OWNS A 2002 FORD F250 SD. THE CONTACT STATED THAT WHILE DRIVING APPROXIMATELY 30 MPH, THE BRAKE PEDAL TRAVELED RAPIDLY TO FLOOR UPON ENGAGING. THE VEHICLE FAILED TO SLOW DOWN UNTIL AFTER REPEATED PRESSURE WAS APPLIED TO THE BRAKE PEDAL. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC WHO STATED THE BRAKE LINES FRACTURED DUE TO CORROSION. THE VEHICLE WAS REPAIRED. IN ADDITION, THE ENTIRE UNDER CARRIAGE WAS COMPLETELY RUSTED BEYOND REPAIR. THE MANUFACTURER WAS NOTIFIED OF THE PROBLEM. THE APPROXIMATE FAILURE MILEAGE WAS 60,000.

Fuel System, Diesel
Filed Jan 30, 2013IA

2002 FORD F250 SUPERDUTY. CONSUMER WRITES IN REGARDS TO A STRONG DIESEL FUEL ODOR AND FINDING FUEL ON THE PASSENGER SIDE OF THE ENGINE COMPARTMENT IN THE CAB OF THE VEHICLE. THE DEALER INFORMED THE CONSUMER, THE DIESEL ENGINE WAS DESIGNED WITH COPPER SLEEVES OR CUPS AROUND THE FUEL INJECTORS. THE PURPOSE OF THE CUPS WERE TO SEPARATE THE ENGINE COOLING SYSTEM FROM THE PRESSURIZED FUEL SYSTEM. OVER A PERIOD OF TIME, THE ENGINE COOLANT REACTED WITH THE COPPER CUPS AND CREATED SMALL PIN HOLES OR CRACKS IN THE INJECTOR CUPS. SINCE THE FUEL SYSTEM WAS PRESSURIZED IT INJECTED DIESEL FUEL INTO THE COOLANT CIRCULATING IN THE ENGINE. EVENTUALLY THE DIESEL FUEL CAME OUT OF THE RADIATOR OVERFLOW AND ALL OVER THE PASSENGER SIDE OF THE ENGINE COMPARTMENT. SINCE THERE WAS NO WAY TO TELL, WHICH INJECTOR CUP WAS BAD, ALL OF THEM WOULD HAVE TO BE REPLACED ALONG WITH THE COOLANT HOSES AND THE RADIATOR WOULD NEED TO BE FLUSHED. THE ENGINE WOULD HAVE TO BE TAKEN APART, THE HEADS WOULD HAVE TO BE REMOVED AND THE INJECTOR CUPS REPLACE.*JB UPDATED 02/13/13

Engine
Filed Jul 29, 2012150,000 milesAR

WHILE DRIVING I BEGAN TO HEAR A LOUD POPPING NOISE COMING FROM THE ENGINE. AFTER STOPPING AND CHECKING THE ENGINE I NOTICE I HAD A BLOWN OUT SPARK PLUG AND BUSTED IGNITION COIL. I HAVE A 2002 FORD F 250 SD. I HAVE ATTEMPTED TO PUT IN A NEW PLUG BUT IT WILL NOT SCREW INTO THE HOLE. DAMAGE ESTIMATES ARE FROM $150.00 ON LABOR FEES AND $75-100 ON A TEMP. FIX HELICOIL OR HEAD REPLACEMENT FOR $2500.00. FORD MECH. SAID IT HAPPENS ALL THE TIME, DUE TO POOR DESIGN. *JS

20 of 245 complaints, reproduced as filed.

Across model years

Worst on record: 2019
YearComplaintsRecallsFiresDeathsAssessment
20269510Routine
202515700Do not drive
202438410Routine
2023431630Routine
20221211740Routine
20211631300Routine
20202631530Above average
20191,16412110Above average
20183971090Above average
20171,15515130Above average
2016288450Above average
2015296360Above average
201426100Routine
201321100Routine
201257100Routine
2011122121Fatalities reported
201032100Routine
200923111Fatalities reported
2008141230Routine
200754310Routine
2006274340Above average
2005295560Above average
20042544120Above average
20031786100Routine
2002 — this page2455182Fatalities reported
20012884193Fatalities reported
20002334253Fatalities reported
19992495130Above average
19981100Routine
199739270Routine
199611120Routine
19959130Routine
19942110Routine
19934110Routine
19923000Routine
19911000Routine

Compare every F-250 SD year →

Reading this record

2 deaths reported in complaints filed with NHTSA.

Complaint counts track how many cars were sold and how long they have been on the road as much as they track quality. A common model from 2013 has had a decade to accumulate reports; a rare one from last year has not. The signal worth weighing is in the severity columns, in whether the same component keeps appearing, and in whether the manufacturer eventually opened a recall for it.

Recall repairs are free for as long as the recall stands. Check whether a specific car still has open work at NHTSA's VIN lookup.

Most recent recall on file: Jul 13, 2011. Source: NHTSA Office of Defects Investigation.