2002 Ford F-150 Electrical System

1. DRIVING APPROXIMATELY 35-40 MPH IN TOWN IN VEHICLE. VEHICLE HAS APPROXIMATELY 75,000 MILES. HEARD A LOUD EXPLOSION AND TRUCK IMMEDIATELY BEGAN TO SPUTTER. HAD TO PULL OVER. BARELY MADE IT TO AUTO SHOP A COUPLE OF MILES DOWN THE ROAD. 2. DIAGNOSED AS A BLOWN SPARK PLUG WHICH DAMAGED THE BLOCK, HEAD AND ENGINE. THE AUTO REPAIR COMPANY TOLD ME THAT ONLY FORD DEALER COULD REPAIR THIS DAMAGE. ESTIMATED AT $3500 TO $4000 TO REPAIR. 3. HAVE YET TO DECIDE WHAT TO DO, AS WE STILL OWE A SUBSTANTIAL AMOUNT OF MONEY ON THIS VEHICLE. *TR

INTERMITTENT STARTING PROBLEM CAUSED BY THE ANTI THEFT UNIT IN THAT IT WON'T ALLOW THE TRUCK TO START. IF ALLOWED TO SIT FOR AN HOUR OR SO IT USUALLY STARTS. FORD DEALERSHIPS SAY THAT THEY HAVE TO HAVE IT WHEN THE PROBLEM IS OCCURRING. WELL, NOW THE PROBLEM SEEMS PERMANENT, AS IT WON'T START AT ALL. WHEN ASKED IF SYSTEM CAN BE TURNED OFF THEY SAY "NO, IT IS A SAFETY ISSUE" THEIR SAFETY ISSUE HAS PUT ME IN PERIL ON MORE THAN ONE OCCASION. ONE BEING ON A BOAT RAMP WITH RISING WATER AND A VEHICLE THAT WON'T START. HOW SAFE IS THAT? THE VEHICLE IS AT THE DEALER NOW, AND THEY TELL ME THEY MUST DUPLICATE THE NOT STARTING SO THEY CAN SEE WHAT'S WRONG, IN FACT IT IS NOT STARTING. *TR

I HAVE A 2002 FORD F-150 SUPERCREW, ABOUT 6 MONTHS AGO MY ELECTRICAL PANEL STARTED HAVING A MIND OF ITS OWN EVERYTIME IT RAINS. MY RADIO, WINDSHIELD WIPERS, BLINKERS, TAIL LIGHTS AND INTERIOR LIGHTS GO OFF AND ON. I HAVE ALMOST BEEN IN SEVERAL ACCIDENTS DUE TO THIS PROBLEM NOT BEING ABLE TO SEE BECAUSE OF WINDSHIELD WIPERS NOT WORKING AND ALSO BECAUSE OF BLINKERS NOT WORKING. THE PROBLEM IS GETTING WORSE AND I BELIEVE FORD SHOULD FIX THIS SINCE IT IS DEFINITELY SEVERAL LARGE SAFETY ISSUES. *TR

TL*THE CONTACT OWNS A 2002 FORD F-150. WHILE DRIVING 25 MPH, HE HEARD A LOUD BANGING NOISE COMING FROM THE ENGINE. UPON INSPECTION HE NOTICED THE SPARK PLUGS WERE LOOSE AND THE COIL HAD BLOWN OFF. THE DEALER STATED THAT THERE WAS A DEFECT WITHIN THE ENGINE THAT CAUSED THE FAILURE. THEY REPLACED THE COILS AND THE SPARK PLUGS. APPROXIMATELY THREE MONTHS LATER THE FAILURE OCCURRED AGAIN. THE DEALER STATED THAT A DEFECT WITHIN THE ENGINE CAUSED THE FAILURE. THEY REPLACED THE COILS AND SPARK PLUGS. THE FAILURE MILEAGE WAS 102,000 AND CURRENT MILEAGE 113,000.

FORD MOTOR COMPANY DOES NOT INSTALL THE FUSE NECESSARY TO OPERATE THE TOWING HARNESS LAMPS ON THE 2002 F150. LOCAL FORD DEALER INSTALLED A FUSE AND THEN DISCOVERED THAT THE PIN BENEATH THE FUSE BOX WAS BENT. THE FUSE BOX HAD TO BE REMOVED IN ORDER TO STRAIGHTEN OUT THE PIN AND THEN RE-INSTALLED. FORD REFUSED TO COVER THE COST ($200.00) SAYING THE VEHICLE WAS OUT OF WARRANTY. CONTENTION IS THAT THIS EITHER CAME FROM THE FACTORY THIS WAY OR THE DEALER BENT THE PIN WHEN THEY INSTALLED THE FUSE. NEITHER FORD MOTOR COMPANY OR THE LOCAL FORD DEALER WILL ACCEPT RESPONSIBILITY. THE BENT PIN MADE THE PARKING LAMPS INOPERABLE WHICH WOULD BE HAZARDOUS FOR TOWING ANYTHING AT NIGHT. *TR

MY F-150 PICKUP JUST STARTED SMOKING THEN WITH IN SECONDS WAS FULLY ENGULFED IN FLAMES RESULTING IN ME JUMPING OUT TO SAVE OWN LIFE. THANKFULLY NO ONE ELSE WAS WITH ME. *JB

WAS HAVING PROBLEMS STARTING THE VEHICLE. SOMETIMES IT WOULD START, SOMETIMES IT WOULDN'T. *TR

TL*THE CONTACT OWNS A 2002 FORD F150. THE CONTACT STATED THAT THE GARAGE PARKED VEHICLE SPONTANEOUSLY CAUGHT ON FIRE UNDER THE HOOD. THE VEHICLE WAS DESTROYED, BUT ONLY THE TRUCK BED REMAINED. THE CONTACT COULD OBTAIN A FIRE REPORT. *AK RETURNED USPS, 2ND ATTEMPT MADE 04/20/07 FAILED. *LJ

IN LATE SUMMER OF 2006, MY 2002 FORD F-150 BEGAN EXPERIENCING CHASSIS ELECTRICAL SYSTEM MALFUNCTIONS. EVERY TIME THERE WAS A RAINSTORM. SPECIFICALLY, THE WINDSHIELD WIPERS CEASED TO WORK, THE INTERIOR DOME LIGHT WOULD FLASH ON & OFF, THE BLOWER MOTOR FOR THE HEATER WOULD CONTINUE TO RUN AFTER SHUTTING OFF IGNITION, THE KEYLESS ENTRY SYSTEM WOULD NOT WORK, THE ABS WARNING LIGHT WOULD COME ON. I TOOK THE VEHICLE TO FORD DEALER # 1 WHO, WHEN I DESCRIBED THE SYMPTOMS, STATED IMMEDIATELY THAT THE PROBLEM WAS DUE TO WATER LEAKING PAST THE LOWER WINDSHIELD SEAL AND SHORTING OUT THE GEM MODULE AND THE FUSE BLOCK MOUNTED ON THE INTERIOR FIREWALL. DEALER STATED "THIS IS AN EXPENSIVE REPAIR, YOU MIGHT WANT TO DO THE WORK YOURSELF". AS I DIDN'T FEEL I HAD THE ABILITY TO REPAIR, I LET IT GO FOR SEVERAL WEEKS. IN LATE NOVEMBER OF 2006, I WAS DRIVING TO WORK BEFORE SUNRISE, IN A VERY HEAVY RAIN, WHEN THE WIPERS SHUT OFF AND THE DOME LIGHT CAME ON MAKING IT IMPOSSIBLE TO SEE. I TOLD MY PARENTS ABOUT THIS & THEY INSTRUCTED ME TO TAKE VEHICLE TO FORD DEALER # 2 FOR REPAIR AT THEIR EXPENSE. DEALER # 2 WAS AWARE OF THE CONDITION AS WELL. THE ESTIMATE FOR REPAIR WAS $553 TO REPAIR THE ELECTRICAL COMPONENTS DAMAGED BY THE MOISTURE, AND THE VEHICLE WOULD THEN HAVE TO BE TAKEN TO A GLASS SHOP TO HAVE THE WINDSHIELD RE-SEALED. THE WORK WAS DECLINED, AND I CONTACTED FORD CUSTOMER SERVICE EXPLAINING THAT AS THIS WAS A SAFETY RELATED ISSUE, KNOWN TO BOTH DEALERSHIPS, I FELT THEY SHOULD ABSORB SOME OF THE EXPENSE OF MAKING VEHICLE DRIVABLE DURING ANY WEATHER CONDITION. REQUEST WAS DENIED. MY CONTENTION IS THAT SINCE DRIVING IN A RAINSTORM WITHOUT WIPERS AND AN ERRATIC ELECTRICAL SYSTEM, AND SINCE BOTH DEALERSHIPS WERE ACQUAINTED WITH THE CONDITION, THERE SHOULD HAVE BEEN A VOLUNTARY RECALL, OR AT THE VERY LEAST, A TSB ADVISING OWNERS OF THE POTENTIAL PROBLEM. *JB

WIPERS AND RADIO WORK ONLY WHEN IN PARK. LIGHTS REMAIN ON EVEN WHEN IN OFF POSITION. VEHICLE WILL SPORADICALLY NOT START. PROBLEM STARTED IN THE FALL OF 05 AND PERSISTED UNTIL SUMMER 06, AT WHICH TIME ALL SYMPTOMS DISAPPEARED. NOW IN THE FALL OF 06, ALL SYMPTOMS HAVE RETURNED. *JB

TRUCK MAKES NOISE AND WILL NOT START THE KEY PAD WILL NOT LET ME IN MY TRUCK AND THE TRUCK ACTS LIKE IT WANTS TO START BUT ANTI THEFT SYSTEM WON'T LET IT START. ARE THERE ANY RECALLS ON THIS PROBLEM. *NM

THE TRUCK WAS DRIVEN BACK FROM THE STORE, A DISTANCE OF A FEW MILES, THEN PARKED IN MY DRIVEWAY. APPRXIMATELY 30 MINUTES LATER I HEAD WHAT SOUNDED LIKE A COMPRESSOR RUNNING OUT IN THE STREET. WENT OUT INTO THE DRIVEWAY AND FOUND THE STARTER WAS TURNING OVER THE ENGINE. THE TRUCK HAD BEEN TURNED OFF WHEN PARKED AND THE KEY WAS REMOVED. WENT BACK INSIDE GOT THE KEY, AND TURNED THE IGNITION SWITCH TO THE "RUN" POSITION. TRUCK STARTED AND RAN. TURNED OFF IGNITION AND REMOVED KEY, BUT THE STARTER CONTINUED TO TURN ENGINE. DID THIS SEVERAL TIMES BEFORE LETTING THE ENGINE RUN FOR APPROXIMATELY 5 MINUTES, THEN FINALLY WAS ABLE TO TURN OFF IGNITION AND STARTER DID NOT CRANK THE ENGINE. NEXT MORNING TRUCK WOULD NOT START. TRUCK WAS TOWED AND HAD TO HAVE STARTER REPLACED BECAUSE IT HAD BURNED OUT. THE TRUCK HAS ONLY 15,000 MILES. CALLED LOCAL FORD SERVICE DEPARTMENT WHERE TRUCK WAS PURCHASED AND THEY SAID THEY WERE UNAWARE OF ANY PROBLEMS WITH STARTERS. OBVIOUSLY THERE IS A PROBLEM WITH STARTER ENGAGING BY ITSELF.

SINCE PURCHASE OF VEHICLE THREE COILS HAVE GONE BAD AND HAD TO BE REPLACED. I WAS TOLD BY THE MECHANIC AT A FORD DEALERSHIP TO NOT WASH THE MOTOR ON THE VEHICLE. I WAS ALSO TOLD THAT THEY HAVE HAD SEVERAL PROBLEMS WITH THE COIL CONFIGURATION ON ALL FORD, LINCOLN, AND MERCURY VEHICLES SINCE THEY SWITCHED TO INDIVIDUAL COILS FOR EACH CYLINDER. THIS IS VERY EXPENSIVE TO REPLACE AND IT HAS TO BE CHECKED ON THE COMPUTER TO TELL WHICH ONE IS BAD. *JB

DT*: THE CONTACT STATED THE POWER WINDOWS, HORN AND TURN SIGNALS FAILED INTERMITTENTLY. THE FUSES WERE REPLACED BY THE CONTACT AND THE WINDOWS, HORN AND TURN SIGNALS RESUMED PROPER FUNCTION. WHEN THE IGNITION WAS ENGAGED, SMOKE EMITTED FROM UNDER THE DASH BOARD AND FROM UNDER THE HOOD. A SERVICE DEALER INSPECTED THE VEHICLE. THE MANUFACTURER WAS NOT CONTACTED.

DT*: THE CONTACT STATED WHILE DRIVING 10 MPH, A BURNT SMELL WAS NOTICED. UPON INSPECTION, A RED WIRE UNDER THE DRIVER SEAT WAS ON FIRE. ALSO, THE ELECTRICAL WIRING HARNESS FOR THE POWER SEATS AND SEAT HEATER WAS INOPERABLE. THE VEHICLE WAS TAKEN TO A SERVICE DEALER WHO DETERMINED THAT THE WIRES RUBBING AGAINST THE SEAT FRAME CAUSED THE FIRE. THE DEALER REPLACED THE 3 WIRING HARNESSES CONNECTED FROM THE DASH TO ALL SEATS IN THE VEHICLE. THE MANUFACTURER WAS ALERTED AND DENIED THE CLAIM.

2002 F-150 HAS HAD THE ALTERNATOR REPLACED 4 TIMES PREVIOUSLY IN THE LAST 2 YEARS. THIS TIME THE GAUGES ALL DROPPED TO NOTHING, JUMPED BACK UP AND TRUCK LOST POWER. WOULD NOT RESTART IMMEDIATELY, WHEN RESTARTED, GAUGES WENT TO FULL POWER, DROPPED TO NOTHING, THEN BOUNCED BACK AND FORTH. WITHIN 20 MILES, BATTERY LEVEL DROPPED TO ALMOST NOTHING. *NM

MANUFACTURER USES FAULTY ELECTRONIC COMPONENT IN VEHICLE IGNITION SYSTEM. NO PART OF SYSTEM PROVIDES FOR INDICATION OF POTENTIAL FAILURE OR COMPLETE FAILURE. ONCE PART FAILS, THE VEHICLE EXPERIENCES RANDOM MISFIRING IN CYCLINDER WHICH CAUSES DAMAGE TO SPARK PLUG THREADS OF ALUMINUM CYLINDER HEAD. EVENTUALLY SPARK PLUG IS BLOWN FROM CYCLINDER HEAD RESULTING IN LOSS OF POWER AND FUNCTION. RESULTING DAMAGE TO ALUMINUM CYLINDER HEAD REQUIRES REPLACEMENT AT COST OF @ $3,000. REPLACEMENT PARTS ARE IDENTICAL TO FAILED PARTS AND POTENTIAL REPEAT FAILURES CONTINUE. NO CORRECTIVE ACTION TO PARTS HAS BEEN REPORTED AND NO IMPROVEMENTS TO VEHICLE SENSING SYSTEM HAVE BEEN MADE. FORD MOTOR COMPANY DISCLAIMS ANY RESPONSIBILITY FOR DAMAGES EXCEPT THOSE COVERED UNDER INITIAL VEHICLE WARRANTY OR THOSE COVERED UNDER EXTENDED WARRANTY. IF WARRANTY DOES NOT COVER FAILURE OF ELECTRICAL COMPONENTS THEN FORD MOTOR COMPANY WILL NOT COVER COLLATERAL DAMAGES ( FAILURE OF CYLINDER HEAD SPARK PLUG THREADS). FORD MOTOR COMPANY PUBLISHED INTERNAL TECHNICAL SERVICE BULLETIN TO REPAIR FACILITIES THAT REQUIRES USE OF OSCILLISCOPE TO DETERMINE IF ELECTRICAL PART IS EXPERIENCING PROBLEM. FORD REPAIR FACILITY REFUSED TO RETURN DAMAGED CYLINDER HEAD AND FAULTY COIL-ON-PLUG ASSEMBLY STATING THAT THEY WERE REQUIRED CORE RETURNS. *NM

AFTER RAINING 4X4 INDICATOR LIGHT FLASHES , WINDSHIELD WIPERS AND RADIO SHUT ON AND OFF WHILE DRIVING. *NM

DT: IN JUNE WHILE OWNER WAS SITTING THERE WAS A HONKING NOISE. OWNER WAS UNAWARE IF THE HONKING WAS FROM OTHER CARS OR FROM THE ALARM. THEN ,HE HEARD A LOUD POP. HE WENT OUTSIDE AND SAW THE TRUCK ENGULFED IN FLAMES. THE TRUCK HAD BEEN DRIVEN ABOUT 14.5 MILES FOR 20 MINUTES BEFORE BEING PARKED. THE VEHICLE WAS SITTING FOR ABOUT 15 MINUTES IN DRIVEWAY. WHEN OWNER SAW THE FIRE THE TRUCK WAS ALREADY ENGULFED IN FLAMES. THE FIRE WAS COMING FROM THE HOOD. IT BURNED FOR ABOUT 15 MINUTES. THE FIRE DEPARTMENT PUT OUT THE FIRE, IT TOOK ABOUT 5 MINUTES FOR THEM TO EXTINGUISH THE FIRE. THERE WAS NO WARNING LIGHTS ON IN THE VEHICLE NOR ANY OTHER TYPE OF WARNING THAT THERE WAS A PROBLEM. THERE WERE NO PROBLEMS WITH THE ELECTRICAL SYSTEM, AND OWNER DIDN'T REALLY USE THE CRUISE CONTROL. THERE WERE NO OTHER MAJOR PROBLEMS WITH THE VEHICLE. THE OWNER WAS UNAWARE OF ANY RECALLS ON THE VEHICLE. THE VEHICLE WAS TOTALED.. PART OF THE GARAGE BURNED AS WELL. THE FIRE REPORT STATED THAT THE BRAKE DEACTIVATING SWITCH WITHIN THE MASTER CYLINDER CAUSED THE FIRE. THE FIRE REPORT IS AVAILABLE FOR INVESTIGATORS TO VIEW. THE FIRE REPORT STATED THE FIRE WAS MOSTLY CONCENTRATED IN THE LEFT REAR COMPARTMENT OF ENGINE. THERE WAS A POLICE REPORT.*AK

SPARK PLUG BLEW OUT OF HEAD ON MY 2002 FORD F150 (5.4L TRITON V8) PICKUP ON THE PASSENGER SIDE OF MOTOR. NO WARNING, EVERYTHING WAS WORKING PROPERLY THEN IT JUST BLEW WHILE DRIVING. LOST POWER & COASTED TO THE SIDE OF THE ROAD. TRUCK HAD TO BE TOWED TO THE LOCAL FORD DEALER. HEAD IS BEING REPLACED, TRUCK IS STILL UNDER WARRANTY. TIME TO GET IT BACK WILL BE ABOUT A WEEK & A HALF.

DT: 2002, F150, FORD PICK-UP TRUCK. VEHICLE CAUGHT FIRE WHICH STARTED UNDER THE HOOD, TWO FIREMEN AND A FIRE EXPERT NAMED BUD STRINGER SAID THAT THE FIRE STARTED IN THE ENGINE COMPARTMENT ON THE FRONT DRIVER'S SIDE. CONSUMER STATED THEY HAD NO PREVIOUS PROBLEM WITH THE VEHICLE. IT CAUGHT FLAMES AROUND 25 MINUTES AFTER IT HAD BEEN PARKED. FIRE CAUSED SMOKE DAMAGE TO INSIDE AND OUTSIDE OF CONSUMER'S HOME. *AK

WATER LEAK FROM THE WINDSHIELD INTO THE DASH BOARD DAMAGING ELECTRONIC COMPONENTS FOR THE AMOUNT OVER $800.00, THE VEHICLE IS A 2002 FORD 150, IT HAD A THE TIME OF THE INCIDENT ONLY 33,000 MILES BUT IT WAS OUT OF WARRANTY FOR ABOUT 5 WEEKS. THEREFORE THEY WOULDN'T FIX IT WITHOUT A CHARGE.

MY VEHICLE IS A 2002 F-150 AND THE CRUISE CONTROL MALFUNCTIONED. I TOOK IT IN TO BE REPAIRED AND LEARNED THAT THE DEACTIVATION SWITCH LEAKED BREAK FLUID INTO THE SERVO CAUSING IT TO SHORT OUT. I ALSO LEARNED THAT FORD HAS ADMITTED THEY HAVE THIS PROBLEM IN VEHICLES FROM 1997 TO 2003, BUT HAVE ONLY RECALLED 2000 AND 2001 YEAR MODELS. THE TOTAL COST OF THE REPAIR WAS $380 AND I THINK FORD SHOULD BE HELD ACCOUNTABLE FOR THIS COST

2002 FORD F150 CAUGHT ON FIRE WHILE PARKED IN THE DRIVEWAY. *MR THE VEHICLE WAS PARKED THEN APPROXIMATELY THIRTY MINUTES LATER, THE HORN BEGAN TO HUNK AND THE CONSUMER HAD COME OUTSIDE AND FOUND THE VEHICLE ENGULFED IN FLAMES IN THE CAB PORTION OF THE VEHICLE. *SC *JB

THERE WAS A STRONG SMELL COMING OUT OF THE AIR CONDITIONER VENTS IN THE WARM MONTHS. THAT I DESCRIBE AS A URINE ODOR. THE DEALERSHIP INSTALLED A FAN IN THE AIR CONDITIONER THAT COMES ON 15 MINUTES AFTER THE CAR IS TURNED OFF TO DRY OUT THE AIR UNIT.