FORD F-450 SD · model year

2002 FORD F-450 SD

15 NHTSA complaints, and 6 active recalls for this specific cohort.

NHTSA overall rating

Not crash-tested

New Car Assessment Program

The 2002FORDF-450 SD carries 15 consumer safety complaints in NHTSA's Office of Defects Investigation database for this specific model-year cohort. Within that volume, owners reported 0 crashes, 0 fires, 0 injuries, and 0 fatalities. No NCAP 5-star crash-test rating is available for this model year in the federal database.

Component-level analysis is where model-year complaints become actionable: the top complaint category for the 2002 F-450 SD is fuel system, diesel:storage:tank assembly with 2 filings, followed by fuel system, gasoline (2) and fuel system, other:storage:tank assembly (1). Concentration in one or two component groups is the classic signature of a systemic defect; a flat distribution usually reflects normal aging, warranty complaints, or isolated build-plant variability. This model year has 6 active recall campaigns, which means the manufacturer is obligated to remedy the covered defect at no charge for the life of the vehicle, the full NHTSA campaign numbers are listed below.

NHTSA currently has 177 investigation files overlapping the 2002 F-450 SD, and 8 remain open. Owners comparing this cohort against neighboring years should pair the counters above with the complaint-by-year trend on the parent model page, a spike in a single year often tracks to a platform refresh, a new transmission supplier, or an updated ECU calibration. Use the related-complaint feed below to read raw owner narratives before deciding whether any pattern here affects your specific use case.

15
Complaints
0
Crashes
0
Fires
0
Injuries
0
Deaths

Total Complaints

15 filings

Crashes Reported

0 reports

Source

NHTSA ODI

Federal complaints database

Complaints vs. fleet median (215)

At or below the fleet median complaint volume.

Complaints by Component

ComponentCount
FUEL SYSTEM, DIESEL:STORAGE:TANK ASSEMBLY2
FUEL SYSTEM, GASOLINE2
FUEL SYSTEM, OTHER:STORAGE:TANK ASSEMBLY1
POWER TRAIN:CLUTCH ASSEMBLY1
ENGINE AND ENGINE COOLING1
SEATS1
SERVICE BRAKES, HYDRAULIC:ANTILOCK/TRACTION CONTROL/ELECTRONIC LIMITED SLIP1
ENGINE AND ENGINE COOLING:EXHAUST SYSTEM:MANIFOLD/HEADER/MUFFLER/TAIL PIPE1
VEHICLE SPEED CONTROL:ACCELERATOR PEDAL1
FUEL SYSTEM, OTHER:DELIVERY:HOSES, LINES/PIPING, AND FITTINGS1
FUEL SYSTEM, DIESEL1
ELECTRICAL SYSTEM1
VISIBILITY/WIPER1

Recalls (6)

07E06600028/08/2007

EQUIPMENT:ELECTRICAL

CERTAIN CEQUENT 90 DEGREE 7-WAY RIGHT ANGLE ADAPTORS SOLD BY DISTRIBUTORS IN TOW PACKAGES FOR AFTERMARKET SALES TO TOW 5TH WHEEL RV TRAVEL TRAILERS. DUE TO INCORRECT WIRING OF THE HARNESS, THE TRAILER LIGHTS MAY NOT OPERATE PROPERLY.

07E10600017/12/2007

WHEELS:HUB

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 M

09V39900013/10/2009

VEHICLE SPEED CONTROL

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

11V35200013/07/2011

EXTERIOR LIGHTING:TAIL LIGHTS

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 TH

07V55300005/12/2007

ENGINE AND ENGINE COOLING:ENGINE:DIESEL

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.

06V28600001/08/2006

VEHICLE SPEED CONTROL

ON CERTAIN TRUCKS EQUIPPED WITH SPEED CONTROL, GASOLINE OR NATURAL GAS ENGINES, THE SPEED CONTROL DEACTIVATION SWITCH MAY OVERHEAT.

Recent Complaints

20180126ELECTRICAL SYSTEM

TL* THE CONTACT OWNS A 2002 FORD F-450 SD. THE CONTACT STATED THAT THE DRIVER AND PASSENGER SIDE POWER WINDOWS FAILED TO GO UP AND DOWN. ALSO, THE DOME LIGHTING FAILED TO TURN ON AND THERE WAS AN ABNORMAL CLICKING NOISE. THE CONTACT CALLED A LOCAL DEALER (HARRISONBURG FORD, 3155 S MAIN ST, HARRISONBURG, VA 22801) AND WAS INFORMED THAT THERE WERE NO RECALLS ON THE VEHICLE. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS NOT NOTIFIED AND REFERRED THE CONTACT TO NHTSA. THE FAILURE MILEAGE WAS 45,000.

Mileage: 45,000

20180126VISIBILITY/WIPER

TL* THE CONTACT OWNS A 2002 FORD F-450 SD. THE CONTACT STATED THAT THE DRIVER AND PASSENGER SIDE POWER WINDOWS FAILED TO GO UP AND DOWN. ALSO, THE DOME LIGHTING FAILED TO TURN ON AND THERE WAS AN ABNORMAL CLICKING NOISE. THE CONTACT CALLED A LOCAL DEALER (HARRISONBURG FORD, 3155 S MAIN ST, HARRISONBURG, VA 22801) AND WAS INFORMED THAT THERE WERE NO RECALLS ON THE VEHICLE. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS NOT NOTIFIED AND REFERRED THE CONTACT TO NHTSA. THE FAILURE MILEAGE WAS 45,000.

Mileage: 45,000

20120307FUEL SYSTEM, GASOLINE

TL* THE CONTACT OWNS A 2002 FORD F-450 SD. THE CONTACT STATED THAT THE FUEL TANK LINER ERODED AND CAUSED THE VEHICLE TO STALL. THE FAILURE WAS RECURRING. THE CONTACT WAS NOT GIVEN A REASON FOR THE FAILURE, BUT THE CONTACT STATED THAT HE BELIEVED THAT STEEL WAS BEING USED TO MANUFACTURER THE FUEL TANK AND WAS CAUSING THE FUEL TANK TO RUST AND ERODE PREMATURELY. THE VEHICLE WAS NOT RECENTLY REPAIRED. THE VIN WAS NOT AVAILABLE. THE FAILURE MILEAGE WAS 90,000 AND THE CURRENT MILEAGE WS 103,000.

Mileage: 90,000

20110215FUEL SYSTEM, GASOLINE

I'M CURRENTLY IN KENYA VOLUNTEERING AND DON'T HAVE MY OLD BILL OF SALE WITH ME BUT WILL HAPPILY PROVIDE IT UPON MY RETURN TO THE STATES. I COULD GIVE AN OFFICIAL PERSONAL INFORMATION THAT THEY COULD THEN USE TO LOOK UP THE VIN IF THEY WISHED. I WAS DRIVING DOWN THE ROAD WHEN MY TRUCK STARTED RUNNING ROUGH AND LOST ALL POWER WHILE TOWING A HEAVY 24' TRAILER. THE TRUCK WAS ABLE TO BE DRIVEN TO A MECHANIC WHERE HE TOLD ME THAT THE TANK HAD DELAMINATED AND CLOGGED THE FUEL PUMP. LUCKILY I WAS ABLE TO GET THE TRUCK PULLED OVER AND OFF THE ROAD AND HAVE SINCE SOLD THE VEHICLE. I HAVE READ ONLINE OF COUNTLESS OTHER INDIVIDUALS WITH THE TANK DELAMINATION PROBLEM AND NEITHER FORD MO. CO. OR NHTSA HAS DONE ANYTHING ABOUT THIS ISSUE... IF YOU WERE TO CALL ROB BARBER- HEAD OF PURCHASING FOR THE BRICKMAN GROUP, I WOULD BET THAT HIS COMPANY HAS HAD 100 TRUCKS AFFECTED BY THIS ISSUE THAT FORD REFUSES TO MAKE THE RECALL ON AND THUS NOT WARRANT. IT'S A SAFETY ISSUE BECAUSE THE DEFECT COULD LEAVE YOU PO

Mileage: 111,000

20100225FUEL SYSTEM, DIESEL:STORAGE:TANK ASSEMBLY

TL*THE CONTACT OWNS A 2002 FORD F450. THE CONTACT STATED THAT THE MATERIAL IN THE FUEL TANK HAS DETACHED FROM THE INNER STRUCTURE OF THE TANK. THE MATERIAL WAS IN THE FUEL INJECTOR AND CAUSED THE VEHICLE TO STALL AND SHUTS OFF INTERMITTENTLY WHILE DRIVING 65 MPH. THE CONTACT HAS TAKEN THE VEHICLE TO THE DEALER TO REPLACE THE FUEL TANK, FUEL PUMP, FUEL SENDER, FUEL FILTERS, AND THE FUEL INJECTORS. THE REPAIRS HAVE REMEDIED THE FAILURE. THE CONTACT STATED THAT THE VEHICLE COULD HAVE CAUSED A CRASH TO OCCUR WHEN IT STALLED. THE FAILURE MILEAGE WAS UNKNOWN.

20090826FUEL SYSTEM, DIESEL:STORAGE:TANK ASSEMBLY

I OWN A 2002 FORD F450 THAT I RELY HEAVILY ON IN MY SMALL LAWN MAINTENANCE BUSINESS. WHEN THAT TRUCK DOESN'T RUN, I DON'T EARN ANY MONEY AND IN FACT I AM IN THE RED. I HAVE DISCOVERED THROUGH THE BRIEFEST OF ON-LINE SEARCHES THOUGH THAT I AM ONLY ONE OF THOUSANDS WHO HAVE RUN IN TO THE PROBLEM I'M HAVING NOW. MY TRUCK RECENTLY FAILED DURING THE WORKDAY AND THE CAUSE WAS DIAGNOSED AS A RUSTY (SOME ARE SAYING DELAMINATED) FUEL TANK, WHICH ALONG WITH SEVERAL RELATED PARTS HAD TO BE REPLACED FOR A TOTAL COST OF OVER $4200. IN THE MIDDLE OF A RECESSION THAT'S GIVING SMALL BUSINESS OWNERS THE FIGHT OF THEIR LIVES, I HAD TO LOSE 2 DAYS OF WORK ON TOP OF A HUGE CHUNK OF CASH. AND AS IS ALSO TRUE WITH THE STORIES REPORTED BY OTHER FORD OWNERS, I DID NOT USE ANY BIO-DIESEL FUELS IN MY TRUCK. BECAUSE MY LIVELIHOOD DEPENDS ON IT, I HAVE MADE EVERY EFFORT TO KEEP THIS TRUCK IN FIRST RATE WORKING CONDITION. THIS GAS TANK DID NOT FAIL BECAUSE OF ANYTHING I DID OR DIDN'T DO. I WANT FORD TO M

Mileage: 109,666

20080626FUEL SYSTEM, DIESEL

IN AUGUST OF 2007 5 OF THE 8 AMBULANCES IN OUR MUNICIPAL FLEET BEGAN TO STALL AND LOOSE POWER AND NOT BE ABLE TO GET OVER 35-40 MPH. WE FOUND THE FUEL FILTERS FULL OF SILVER FLAKES. AFTER REMOVING THE FUEL TANK WE FOUND THE LINING OF THE FUEL TANK FLAKING OFF. EVEN THOUGH THESE UNITS WERE OUT OF WARRANTY FORD PAID 50% TO REPLACE THE TANKS, FUEL PUMPS AND SENDING UNITS. TODAY 2 OF THE SAME UNITS BEGAN TO EXPERIENCE THE SAME DRIVABLE PROBLEM. THIS TIME WE FOUND RUST PARTICLES IN THE FUEL FILTER HOUSING AND THE FILTER PLUGGED WITH THESE RUST PARTICLES. AFTER REMOVING THE FUEL TANK WE FOUND THE BOTTOM HALF OF THE FUEL TANK COMPLETELY COVERED WITH RUST. THESE UNITS NEVER GET BELOW A HALF TANK OF FUEL. WE HAVE TESTED OUR DIESEL FUEL AND THE SAMPLES HAVE COME BACK FROM THE LAB NORMAL. WE ALSO REPLACED THE FILTERS ON THE OTHER 3 UNITS THAT HAD TANKS REPLACED LAST AUGUST AND FOUND THE FILTERS PLUGGED WITH RUST ALSO. WE HAVE A TOTAL ABOUT 40 DIESEL VEHICLES IN OUR FLEET AND THESE 5 VEHICLES AR

Mileage: 77,035

20070704FUEL SYSTEM, OTHER:DELIVERY:HOSES, LINES/PIPING, AND FITTINGS

7.3 DIESEL FUEL LINE, BETWEEN HOSE NEED STEERING BOX AND FUEL FILTER AT TOP FRONT OF ENGINE, RUSTED CAUSING A FUEL LEAK, MAY BE FUEL RETURN LINE

Mileage: 55,000

20041118VEHICLE SPEED CONTROL:ACCELERATOR PEDAL

WHEN STOPPING AT A LIGHT AND ATTEMPTING TO ACCELERATE VEHICLE HESITATED FOR ABOUT 4 SECONDS. *AK

Mileage: 9,600

20040903ENGINE AND ENGINE COOLING:EXHAUST SYSTEM:MANIFOLD/HEADER/MUFFLER/TAIL PIPE

FRONT PASENGER COMPARTMENT FLOORBOARD HEATS UP TO 160+ DEGREES WHEN IN HILLY OR MOUNTANIOUS AREA OF DRIVING. PASENGER UNABLE TO KEEP FEET ON FLOOR BOARD DUE TO HEAT. F450 10 CYL GASOLINE ENGINE MOTORHOME. FORD DEALER STATES "COMMON COMPLAINT FOR THIS ENGINE & VEHICHLE" NO REMEDY OFFERED.*AK

Mileage: 2,000

20040628SERVICE BRAKES, HYDRAULIC:ANTILOCK/TRACTION CONTROL/ELECTRONIC LIMITED SLIP

WHEN DEPRESSING THE BRAKES PEDAL WENT ALL THE WAY TO THE FLOOR BEFORE STOPPING. THE CONSUMER TOOK THE VEHICLE TO THE DEALER FOR INSPECTION. *AK THE BOOSTER WAS REPLACED, BUT NOTHING CHANGED. THE CONSUMER TRIED OTHER VEHICLES AT TWO DIFFERENT DEALERS AND THE VEHICLE DISPLAYED THE SAME PROBLEM. AS SOON AS ONE APPLIED THE BRAKES, THEY WOULD LOCK UP AND THERE WOULD BE NO FRICTION TO TURN THE WHEELS ON AND THE COMPUTER WOULD THINK THAT THE VEHICLE WAS STOPPED. *SC

20040226SEATS

HAVING BEEN A DRIVER OF LIMOUSINE COACHES FOR A NUMBER OF YEARS, I QUESTION THE SAFETY OF THE PERIMITER SEATING ARRANGEMENT IN THIS TYPE OF VEHICLE. I FEEL THAT IN THE EVENT OF AN EMERGENCY STOP OR A CRASH, NUMEROUS INJURIES COULD RESULT. THIS TYPE OF VEHICLE IS USED EXTENSIVLY WHERE ALCOHOL IS A FACTOR AND PEOPLE ARE RELAXED AN NOT TOO CONCERNED ABOUT PERSONAL SAFETY. IF FEEL THAT A FORWARD SEATING ARRANGEMENT IS MUCH SAFER AND THIS TYPE OF SEATING SHOULD BE MADE MANDATORY ON ALL LIMO COACHES.*AK

20040205ENGINE AND ENGINE COOLING

WHILE DRIVING THE VEHICLE AT AN UNDETERMINED SPEED THE VEHICLE STALLED. THE CONSUMER TOOK THE VEHICLE TO A MECHANIC. *NM

20030804POWER TRAIN:CLUTCH ASSEMBLY

FAILURE OF CLUTCH MASTER CYLINDER AND SLAVE CYLINDER. REPEATED PROBLEM. VEHICLE LOOSES ALL CLUTCH CONTROL, CAUSING UNCONTROLLED MOVEMENT WHILE ATTEMPTING TO GET THE ENGINE TO STALL. ALMOST CRASHED INTO INNOCENT VEHICLE.*AK

Mileage: 29,800

20021010FUEL SYSTEM, OTHER:STORAGE:TANK ASSEMBLY

CONSUMER STATES THAT GAS TANK IS FRACTURED CAUSING FUEL TO LEAK LARGE AMOUNTS ONTO THE GROUND. THE VEHICLE SHOWS NO WARNING. DEALER IS AWARE. PLEASE PROVIDE MORE INFORMATION. MR

Compare 2002FORDF-450 SD to Similar Vehicles

NHTSA Investigations 8 Open

View all investigations

Frequently Asked Questions

How many complaints does the 2002 FORD F-450 SD have?
The 2002 FORD F-450 SD has 15 NHTSA complaints, 0 crashes, 0 fires, 0 injuries, and 0 deaths reported.
Are there any recalls for the 2002 FORD F-450 SD?
Yes, the 2002 FORD F-450 SD has 6 recall(s). The most common affected component is EQUIPMENT:ELECTRICAL. Recalls are issued by NHTSA and manufacturers must provide a free remedy.
What are the most common problems with the 2002 FORD F-450 SD?
The most-complained component for the 2002 FORD F-450 SD is FUEL SYSTEM, DIESEL:STORAGE:TANK ASSEMBLY with 2 complaints. Other frequently reported areas include FUEL SYSTEM, GASOLINE and FUEL SYSTEM, OTHER:STORAGE:TANK ASSEMBLY.
Is the 2002 FORD F-450 SD safe to buy?
Review the complaint history, crash and fire reports, safety ratings, and recall status on this page to make an informed decision. No NHTSA crash test rating is available for this model year. Compare with other model years using the links above.
Where does this data come from?
All complaint, recall, and safety rating data is sourced from the National Highway Traffic Safety Administration (NHTSA). Complaints are filed by vehicle owners through NHTSA's Office of Defects Investigation.

Vehicle Safety Guides

Data as of 2025. Sources: NHTSA Office of Defects Investigation (ODI) complaints database, NHTSA recall campaign API, NHTSA NCAP crash-test ratings, and NHTSA FARS for fatality cross-reference.