FORD F SERIES (LIGHT) · model year

2002 FORD F SERIES (LIGHT)

17 NHTSA complaints for this specific cohort.

NHTSA overall rating

Not crash-tested

New Car Assessment Program

The 2002FORDF SERIES (LIGHT) carries 17 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 SERIES (LIGHT) is engine and engine cooling:cooling system:radiator assembly with 4 filings, followed by engine (4) and suspension:rear:axle:spindle (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.

NHTSA currently has 177 investigation files overlapping the 2002 F SERIES (LIGHT), 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.

17
Complaints
0
Crashes
0
Fires
0
Injuries
0
Deaths

Total Complaints

17 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
ENGINE AND ENGINE COOLING:COOLING SYSTEM:RADIATOR ASSEMBLY4
ENGINE4
SUSPENSION:REAR:AXLE:SPINDLE1
ENGINE AND ENGINE COOLING:ENGINE1
FUEL SYSTEM, GASOLINE1
ELECTRICAL SYSTEM1
ENGINE AND ENGINE COOLING1
FUEL/PROPULSION SYSTEM1
POWER TRAIN1
SERVICE BRAKES1
STRUCTURE1

Recent Complaints

20180706ENGINE

WE PURCHASED A CAR FROM NAB AUTOS IN FREDERICKSBURG, VA. AFTER THE 7TH DAY OF DRIVING IT, THE MOTOR BLEW UP. WRONG SPARK PLUGS WERE INSTALLED BY DEALER. ALSO THE TRUCK HAD BEEN RACED WITH NITROUS WHICH WE WERE UNAWARE OF UNTIL WE TRIED TO FIND OUT WHAT HAPPENED TO MOTOR. I HAVE DOCUMENTATION FROM THE REPAIR SHOP. MY 18 YEAR OLD SON DRIVES THIS VEHICLE WHICH BEGAN LOSING POWER AND SHAKING BEFORE HE WAS ABLE TO PULL OFF TO THE SIDE OF THE HIGHWAY.

Mileage: 90,000

20140728POWER TRAIN

CROSS FRAME MEMBER WHICH CONTAINS THE TRANSMISSION MOUNT WAS EXTREMELY RUSTED OUT AND CRACKED. STATE SAFETY INSPECTION REP INDICATED IT WOULD NOT PASS INSPECTION IN THE NEAR FUTURE. FORD NO LONGER MANUFACTURES THE FRAME MEMBER. I WAS LUCKY AFTER A LONG SEARCH TO FIND A DEALER WHICH STILL HAD THE PART AVAILABLE. PART # IS: XL3Z6A023CA. THE VEHICLE HAS BEEN OPERATED IN WARWICK NY SINCE NEW AND IN NORTHEASTERN PA SINCE 2007. I BELIEVE IF THE FRAME MEMBER WOULD FAIL THE TRANSMISSION WOULD DROP DOWN. I HAVE PHOTOS OF THE RUSTED UNIT. IF YOU CARE TO SEE THEM PLEASE SEND AN E-MAIL ADDRESS AND I'LL ATTACH THEM TO A E-MAIL. SOMETHING MUST BE DONE TO REQUIRE MANUFACTURES TO USE BETTER MATERIAL FOR PICKUP TRUCK FRAMES AND BRAKE LINES. I HAVE ALSO REPORTED PROBLEMS WITH BRAKE LINES ON THIS TRUCK RUSTING OUT. ONE INCIDENT, I REPORTED, OCCURRED AFTER BACKING UP A RV IN A CAMPSITE AFTER JUST DRIVING OVER 150 MILES ON THE INTERSTATE HIGHWAY. PROVIDENCE PROTECTED ME AS I COULD HA

Mileage: 76,000

20140728SERVICE BRAKES

CROSS FRAME MEMBER WHICH CONTAINS THE TRANSMISSION MOUNT WAS EXTREMELY RUSTED OUT AND CRACKED. STATE SAFETY INSPECTION REP INDICATED IT WOULD NOT PASS INSPECTION IN THE NEAR FUTURE. FORD NO LONGER MANUFACTURES THE FRAME MEMBER. I WAS LUCKY AFTER A LONG SEARCH TO FIND A DEALER WHICH STILL HAD THE PART AVAILABLE. PART # IS: XL3Z6A023CA. THE VEHICLE HAS BEEN OPERATED IN WARWICK NY SINCE NEW AND IN NORTHEASTERN PA SINCE 2007. I BELIEVE IF THE FRAME MEMBER WOULD FAIL THE TRANSMISSION WOULD DROP DOWN. I HAVE PHOTOS OF THE RUSTED UNIT. IF YOU CARE TO SEE THEM PLEASE SEND AN E-MAIL ADDRESS AND I'LL ATTACH THEM TO A E-MAIL. SOMETHING MUST BE DONE TO REQUIRE MANUFACTURES TO USE BETTER MATERIAL FOR PICKUP TRUCK FRAMES AND BRAKE LINES. I HAVE ALSO REPORTED PROBLEMS WITH BRAKE LINES ON THIS TRUCK RUSTING OUT. ONE INCIDENT, I REPORTED, OCCURRED AFTER BACKING UP A RV IN A CAMPSITE AFTER JUST DRIVING OVER 150 MILES ON THE INTERSTATE HIGHWAY. PROVIDENCE PROTECTED ME AS I COULD HA

Mileage: 76,000

20140728STRUCTURE

CROSS FRAME MEMBER WHICH CONTAINS THE TRANSMISSION MOUNT WAS EXTREMELY RUSTED OUT AND CRACKED. STATE SAFETY INSPECTION REP INDICATED IT WOULD NOT PASS INSPECTION IN THE NEAR FUTURE. FORD NO LONGER MANUFACTURES THE FRAME MEMBER. I WAS LUCKY AFTER A LONG SEARCH TO FIND A DEALER WHICH STILL HAD THE PART AVAILABLE. PART # IS: XL3Z6A023CA. THE VEHICLE HAS BEEN OPERATED IN WARWICK NY SINCE NEW AND IN NORTHEASTERN PA SINCE 2007. I BELIEVE IF THE FRAME MEMBER WOULD FAIL THE TRANSMISSION WOULD DROP DOWN. I HAVE PHOTOS OF THE RUSTED UNIT. IF YOU CARE TO SEE THEM PLEASE SEND AN E-MAIL ADDRESS AND I'LL ATTACH THEM TO A E-MAIL. SOMETHING MUST BE DONE TO REQUIRE MANUFACTURES TO USE BETTER MATERIAL FOR PICKUP TRUCK FRAMES AND BRAKE LINES. I HAVE ALSO REPORTED PROBLEMS WITH BRAKE LINES ON THIS TRUCK RUSTING OUT. ONE INCIDENT, I REPORTED, OCCURRED AFTER BACKING UP A RV IN A CAMPSITE AFTER JUST DRIVING OVER 150 MILES ON THE INTERSTATE HIGHWAY. PROVIDENCE PROTECTED ME AS I COULD HA

Mileage: 76,000

20140715ENGINE

SPARK PLUG FAILURE AS ACCELERATING FROM A STOP LIGHT, AND ENGINE PROBLEM RESULTING FROM 7 CYLINDER OPERATION. GOT IT TO A MECHANIC AND HE WAS ABLE TO SLEEVE THE SPARK PLUG THREAD AND INSTALL A NEW PLUG. NOW THE SAME IS STARTING AGAIN. I AM TAKING THE VEHICLE TO THE MECHANIC TO MAKE PERMANENT REPAIRS FOR ALL THE SPARK PLUG. THIS MAY END UP WITH THE ENGINE HEADS BEING REMOVED IN ORDER TO MAKE COMPLETE REPAIRS, AND THE COST FOR THAT WILL BE THOUSANDS OF DOLLARS. THIS IS A FORD ENGINE DESIGN PROBLEM THAT FORD HAS BEEN AWARE OF, YET THEY CONTINUE TO DENY ANY RESPONSIBILITY. *TR

Mileage: 150,000

20130722ENGINE

OIL LEAKING PASSENGER SIDE REAR ON TO THE STARTER AND EXHAUST SYSTEM. *TR

Mileage: 66,000

20120908ENGINE

A SPARK PLUG WORKED LOOSE FROM THE HEAD AND BLEW OUT CAUSING DAMAGE TO THE HEAD AND THE IGNITION COIL. ALL 8 PLUGS HAD TO BE REPLACED, TWO DAMAGED SPARK PLUG HOLES REPAIRED AND TWO IGNITION COILS REPLACED. *TR

Mileage: 200,500

20120908FUEL/PROPULSION SYSTEM

A SPARK PLUG WORKED LOOSE FROM THE HEAD AND BLEW OUT CAUSING DAMAGE TO THE HEAD AND THE IGNITION COIL. ALL 8 PLUGS HAD TO BE REPLACED, TWO DAMAGED SPARK PLUG HOLES REPAIRED AND TWO IGNITION COILS REPLACED. *TR

Mileage: 200,500

20120514ENGINE AND ENGINE COOLING:COOLING SYSTEM:RADIATOR ASSEMBLY

TRUCK STARTED MAKING NOISE EVERY TIME THERE WAS A BUMP. HANDLING FELT LOOSE. DISCOVERED THAT THE RADIATOR CORE SUPPORT HAD RUSTED COMPLETELY AWAY ON THE PASSENGER SIDE. THE MECHANIC REFERRED TO THE CONDITION AS "ROT". THIS SUPPORTS THE RADIATOR, A/C AND PROVIDES AN ATTACHMENT FOR THE FRONT FENDERS. I BOUGHT 4 VEHICLES THE SAME YEAR. CHECKED THE OTHER 3 AND THEY HAVE THE SAME ISSUE. I WILL BE FILING REPORTS ON THEM TOO. *JS

Mileage: 120,000

20120514ENGINE AND ENGINE COOLING:COOLING SYSTEM:RADIATOR ASSEMBLY

CHECKED THE CONDITION OF THIS TRUCKS RADIATOR CORE SUPPORT AFTER ANOTHER TRUCK BOUGHT THE SAME YEAR HAD ONE THAT ROTTED AWAY AND FAILED. THIS PART SUPPORTS THE RADIATOR, A/C AND PROVIDES AN ATTACHMENT FOR THE FRONT FENDERS. THIS VEHICLE'S RADIATOR CORE SUPPORT IS RUSTED COMPLETELY THROUGH IN SPOTS AND LARGE FLAKES OF RUST FALL OFF WHEN IT IS DISTURBED. IT WILL NEED TO BE REPAIRED AND 3 OTHERS BOUGHT THE SAME YEAR HAVE THE SAME ISSUE. *JS

Mileage: 210,000

20120514ENGINE AND ENGINE COOLING:COOLING SYSTEM:RADIATOR ASSEMBLY

CHECKED THE CONDITION OF THIS TRUCKS RADIATOR CORE SUPPORT AFTER ANOTHER TRUCK BOUGHT THE SAME YEAR HAD ONE THAT ROTTED AWAY AND FAILED. THIS PART SUPPORTS THE RADIATOR, A/C AND PROVIDES AN ATTACHMENT FOR THE FRONT FENDERS. THIS VEHICLE'S RADIATOR CORE SUPPORT IS RUSTED COMPLETELY THROUGH IN SPOTS AND LARGE FLAKES OF RUST FALL OFF WHEN IT IS DISTURBED. IT WILL NEED TO BE REPAIRED AND 3 OTHERS BOUGHT THE SAME YEAR HAVE THE SAME ISSUE. *JS

Mileage: 181,000

20120514ENGINE AND ENGINE COOLING:COOLING SYSTEM:RADIATOR ASSEMBLY

CHECKED THE CONDITION OF THIS TRUCKS RADIATOR CORE SUPPORT AFTER ANOTHER TRUCK BOUGHT THE SAME YEAR HAD ONE THAT ROTTED AWAY AND FAILED. THIS PART SUPPORTS THE RADIATOR, A/C AND PROVIDES AN ATTACHMENT FOR THE FRONT FENDERS. THIS VEHICLE'S RADIATOR CORE SUPPORT IS RUSTED COMPLETELY THROUGH IN SPOTS AND LARGE FLAKES OF RUST FALL OFF WHEN IT IS DISTURBED. IT WILL NEED REPAIRED AND 3 OTHERS BOUGHT THE SAME YEAR HAVE THE SAME ISSUE. *JS

Mileage: 180,000

20111117ELECTRICAL SYSTEM

SPARK PLUG BLEW OUT OF PLUG HOLE, STRIPPING THREADS OF INTAKE CYLINDER HEAD. PLUG WAS FOUND LAYING BETWEEN VALVE COVER AND INTAKE MANIFOLD. *TR

Mileage: 107,590

20111117ENGINE AND ENGINE COOLING

SPARK PLUG BLEW OUT OF PLUG HOLE, STRIPPING THREADS OF INTAKE CYLINDER HEAD. PLUG WAS FOUND LAYING BETWEEN VALVE COVER AND INTAKE MANIFOLD. *TR

Mileage: 107,590

20100915FUEL SYSTEM, GASOLINE

GAS TANK LEAK AT STRAP HOLDING TANK IN PLACE. 2002 FORD F-150 4X4 4.6 LITER. AT THIS TIME I CAN NOT FILL THE VEHICLES TANK TO FULL. THE PROBLEM WILL ONLY GET WORSE WITH TIME. AT THIS TIME THE VEHICLE IS ONLY FILLED TO 1/2 FULL. *TR

Mileage: 170,000

20050524ENGINE AND ENGINE COOLING:ENGINE

DRIVING ON HIGHWAY.. HEAR A LARGE NOISE FROMN THE ENGINE BAY. TRUCK BREAKS DOWN AND I HAVE IT TOWED. 2002 FORD F-150 LIGTHNING. 3RD TIME ITS BEEN TO THE DEALERSHIP FOR THE SAME PROBLEM.. BLOWING A SPARK PLUG IN THE ENGINE BAY.. THIS TIME... WORSE THEN EVER... READ IT WAS A VERY BAD PROBLEM WITH OTHER TRUCK MADE THIS YEAR ETC.. ONLINE SO I'AM PUTTING A COMPLAINT IN..

Mileage: 28,000

20030205SUSPENSION:REAR:AXLE:SPINDLE

REAR WHEELS HAVE ENOUGH PLAY IN THEM THAT THERE IS A NOTICEABLE CLUNK WHEN TURNING. TOOK THE TRUCK TO THE DEALER AND THE END PLAY OF THE AXLES ARE .020. FORD MANUFACTURER SAID UP TO .030 IS TOLERABLE AND I WILL HAVE TO LIVE WITH THE CLUNKING SOUND. I DID NOT PAY $30,000 FOR A TRUCK TO LISTEN TO A CLUNKING SOUND!

Mileage: 6,500

Compare 2002FORDF SERIES (LIGHT) to Similar Vehicles

NHTSA Investigations 8 Open

View all investigations

Frequently Asked Questions

How many complaints does the 2002 FORD F SERIES (LIGHT) have?
The 2002 FORD F SERIES (LIGHT) has 17 NHTSA complaints, 0 crashes, 0 fires, 0 injuries, and 0 deaths reported.
What are the most common problems with the 2002 FORD F SERIES (LIGHT)?
The most-complained component for the 2002 FORD F SERIES (LIGHT) is ENGINE AND ENGINE COOLING:COOLING SYSTEM:RADIATOR ASSEMBLY with 4 complaints. Other frequently reported areas include ENGINE and SUSPENSION:REAR:AXLE:SPINDLE.
Is the 2002 FORD F SERIES (LIGHT) 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.