2002 Ford F-150 Body & structure Problems

Left rear passenger door will not open. Door is jammed. This will not allow rear passengers to quickly exit vehicle if pinned in due to crash or fire.

NHTSA ID

11467942

Incident

Jun 7, 2022

I WAS DRIVING ON FREEWAY WHEN A CAR THAT WAS TRAVELING IN AN EXCESS OF 80+ MILES AND REAR-ENDED MY 2002 FORD F 150. MY TRUCK WAS TOTALED AND MY DRIVERS SEAT BACK FRAME BROKE FROM RIGHT SIDE AND NONE OF MY AIRBAGS DEPLOYED. I ENDED UP IN THE HOSPITAL FOR 3 DAYS. I HAD A CONCUSSION, NECK INJURY, KNEES AND RE-INJURED MY BACK. I WAS LUCKY TO BE ALIVE.

NHTSA ID

11361288

Incident

Aug 15, 2020

Mileage

300,000 mi

FRAME HAS RUSTED TO THE EXTENT THAT THE BED HAS DROPPED AND IS ABOUT TO FALL OFF. WHEN I WAS REPLACING THE FUEL TANK, WHICH HAD RUSTED THROUGH, I DISCOVERED THAT THE ENTIRE FRAME HAS HOLES AND CRACKS FROM RUST.I HAVE NOW BEEN HEARING THAT THIS PROBLEM HAS BEEN REPORTED BY MANY, BUT NO ANSWER OR RECALLS FROM FORD. WHY DO THESE TRUCKS RUST SO BADLY. IS THERE NO RECOURSE FOR THOSE OF US WHO HAVE A TRUCK THAT FALLS APART?

NHTSA ID

11065950

Incident

Jan 29, 2018

TWO ISSUES: 1] BOTH REAR DOORS IN THE EXTENDED CAB (SWING COUNTERCLOCKWISE) DOOR LATCHES JAMMED PREVENTING EXITING OR ENTRY. IF EGRESS WAS NEEDED QUICKLY, IT WAS NOT THERE. THE COST TO REPAIR EACH WAS ABOUT $450. (LOCKED UP WHILE DRIVING) 2]SPEED CONTROL DOES NOT WORK - FORD SAYS IT IS A MALFUNCTIONING CONTROL THAT COST ABOUT $500 TO REPLACE. (WHEN VEHICLE IS IN OPERATION)

NHTSA ID

11047739

Incident

May 7, 2015

Mileage

68,000 mi

MY TRUCK FRAME HAS RUSTED THROUGH JUST BEHIND THE RIGHT REAR WHEEL! THIS IS A 2002 FORD F150 SUPERCAB THAT HAS ONLY 75500 MILES ON IT. THE FRAME BROKE JUST AFTER I LEFT THE INTERSTATE AND DROVE TO MY SON'S HOUSE. I INSPECTED THE TRUCK AND SAW THE BREAK IN THE FRAME AS I DESCRIBED. A PICTURE IS ATTACHED. I WAS LUCKY NOT TO HAVE WRECKED ON THE INTERSTATE! WHAT IS GOING ON WITH FORD THAT THE CHASSIS RUSTS THROUGH LIKE THIS!!! WHAT IS GOING ON WITH FORD?

NHTSA ID

11031617

Incident

Sep 26, 2017

Mileage

75,500 mi

MY FIANCE AND I HAD TO PLACE ARE FULL SIZE SPARE ON THAT CAME WITH TRUCK IT WAS BRAND NEW WE HAD NO CHOICE BC THIS WAS FRIDAY EVENING AND OUT LOCAL TIRE SHOP WAS CLOSED TELL TODAY (MONDAY) YESTERDAY WE DROVE 7 MILE TO COLLINSVILE TO CHANGE BRAKES AFTER WE FINISH WE LOAD OUR 3 KIDS AND BEFAN TO HIDE HOME ANOTHER 3 MILES FROM HOME WE NOTICE THE TRUCK SHAKING THEN WE HEARD LOAD POP AND TAIL OF THE TRUCK LOST CONTROL FOR ABOUT 2 SECOND ONCE WE GOT CONTROL BACK WE PULLED TO SAFETY TO ONLY SEE THE DRIVER SIDE OF THE BED CRACKED TORE AND SHATTERED. EVEN THE HOSE WHERE U FUEL U TRUCK UP AT HAD BEEN DAMAGETTING WHEN WE CONTINUED TO EXAMINE THE TIRE IT WASN'T BLOWN AND IT'S STILL HOLDING AIR. BUT PLZ EXPLAIN TO ME HOW THE ENTIRE CENTER SECTION OF TREAD RIPPED OFF FOR NO REASON AND NOT ONLY PUT MY CHILDREN IN DANGER BUT DAMAGED MY TRUCK TO A SEVERE EXTENT ? IT'S A FULL SIE HERCULES TERRAIN TRAC SIZE 16 HAD NOTHING WRONG WITH IT TELL NOW.

NHTSA ID

11030768

Incident

Oct 1, 2017

Mileage

141,513 mi

TL* THE CONTACT OWNS A 2002 FORD F-150. WHILE DRIVING APPROXIMATELY 5 MPH, THE CABLE THAT HELD THE SPARE TIRE UNDERNEATH THE VEHICLE RUSTED AND DETACHED, CAUSING THE SPARE TIRE TO DROP FROM THE VEHICLE. THE CONTACT STOPPED THE VEHICLE AND PICKED UP THE TIRE. THE DEALER WAS NOT CONTACTED. THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 100,000. ......UPDATED 11/21/17 *BF

NHTSA ID

11022187

Incident

Sep 6, 2017

Mileage

100,000 mi

VEHICLE CAB ROCKER PANELS RUSTING OFF REAR WINDOW LEAKING CRUISE CONTROL NOT WORKING VEHICLE RUSTING AND BEEN IN AREA WITH NO SALT ON ROADS

NHTSA ID

10862917

Incident

Jan 1, 2011

Mileage

85,000 mi

I OWN TWO FORD SUPER CABS AND BOTH TRUCKS THE BACK PASSENGER DOORS FROZE SHUT. ON ONE I PAID OVER $500 FOR THE PARTS AND THEN HAD A MECHANIC REPAIR THE DOORS AND I WAS TOLD THAT THIS WOULD LAST FOR APPROXIMATELY FIVE YEARS. ON THE ONE I LISTED ABOVE I WENT ON YOU TUBE AND THEY HAVE VIDEOS HOW TO FIX THE PROBLEM. THEY SAY THAT ALL FORD TRUCK SUPER CABS, I.E. F150, F250, AND F350 THE REAR DOORS WILL EVENTUALLY FREEZE UP. THIS IS A VERY SERIOUS SAFETY HAZARD FOR THE BACK SEAT PASSENGER. THE PROBLEM IS THAT THEY USED A PLASTIC CONNECTOR FOR THE TERMINAL OF THE RELEASE CABLE INSTEAD OF ONE MADE OF METAL. THE PLASTIC DETERIORATES IN THE HEAT WHICH DOES NOT ALLOW THE CABLE TO PULL THE RELEASE MECHANISM FAR ENOUGH.

NHTSA ID

10690903

Incident

Nov 20, 2014

Mileage

180,000 mi

I HAVE A 2002 F 150 AND THE BED SUPPORT RAILS AND BED FLOOR ARE COMPLETELY RUSTED AWAY AS WELL AS THE FRAME RAILS. I AM AFRAID THE BED WILL COME OFF AT HIGHWAY SPEED AND CAUSE A WRECK. FORD HAS GOT TO KNOW THERE IS A PROBLEM WHY ARE THEY NOT ADDRESSING IT? I KNOW SEVERAL PEOPLE WITH THE SAME STYLE TRUCK WITH THE SAME PROBLEM, I BOUGHT A PICKUP TRUCK TO USE AS A TRUCK AND NOW I AM AFRAID TO BECAUSE WHO KNOWS WHAT WILL FALL OFF THE TRUCK DUE TO ALL OF THE RUST. TOYOTA HAD A MAJOR RECALL BECAUSE OF THIS SAME ISSUE, WHY DOES THE GOVERNMENT NOT MAKE FORD DO THE SAME THING??? I HAVE HAD PICKUPS IN THE PAST THAT WERE A LOT OLDER THAT DID NOT RUST LIKE THIS. MAKE FORD FIX THE PROBLEM BEFORE A BED FLIES OFF AND CAUSES AT MINIMUM A WRECK AT WORST A DEATH. *JS

NHTSA ID

10545242

Incident

Sep 24, 2013

Mileage

82,000 mi

THE REAR PORTION OF THE FRAME IS ROTTEN TO THE POINT THAT THE LET SPRINGS HANGERS ARE READY TO BREAK OFF THE FRAME AND THE SPARE TIRE HOLDER IS ALSO READY TO FALL OFF. I JUST REPLACED THE REAR SPRING SHACKLES DUE TO THE WERE ALSO ROTTEN AND BROKE. THE GAS TANK STRAPS WERE ALSO A PROBLEM DUE TO RUST BUT FORD THOUGH ENOUGH OF THE PROBLEM THERE WAS A RECALL ON THAT, TOYOTA HAD A PROBLEM WITH RUSTED FRAMES AND DID A MASSIVE RECALL ON THAT ISSUE. WHY HASN'T FORD DONE THE SAME THING? THE FRAME SHOULD BE THE LAST THING ONE NEEDS TO WORRY ABOUT WITH ANY VEHICLE. THE TRUCK CURRENTLY HAS 146000 MILES AND NOW WE NEED TO FIGURE OUT WHAT THE NEXT MOVE WILL BE WITH THIS VEHICLE. REPAIR IT, JUNK IT OR TRADE IT ????? *TR

NHTSA ID

10510898

Incident

May 7, 2013

Mileage

146,000 mi

TL* THE CONTACT OWNS A 2002 FORD F-150. WHILE TRAVELING 5 MPH, THE CONTACT NOTICED A CRACKING SOUND COMING FROM THE REAR OF THE VEHICLE. AFTER EXAMINING THE VEHICLE, THE CONTACT NOTICED THAT THE REAR FRAME ON THE DRIVER'S SIDE HAD CRACKED. THE VEHICLE WAS TAKEN TO THE DEALER, WHERE THE CONTACT WAS INFORMED THAT THE FRAME NEEDED TO BE REPLACED. THE VEHICLE HAD NOT BEEN REPAIRED. THE FAILURE AND CURRENT MILEAGES WERE 95,000. THE VIN WAS UNAVAILABLE.

NHTSA ID

10457793

Incident

Mar 29, 2012

Mileage

95,000 mi

TL* THE CONTACT OWNS A 2002 FORD F-150. WHILE DRIVING APPROXIMATELY 5 MPH, THE CONTACT NOTICED THAT THE SPARE TIRE DETACHED FROM UNDER THE VEHICLE. AFTER INSPECTING THE VEHICLE THE CONTACT NOTICED THAT THE SPARE TIRE CABLE WAS FRACTURED. THE VEHICLE WAS NOT TAKEN TO THE DEALER FOR DIAGNOSTICS OR REPAIRS. THE APPROXIMATE FAILURE MILEAGE WAS 75,500.

NHTSA ID

10451236

Incident

Mar 2, 2012

Mileage

75,500 mi

ON AUGUST 20, 2011 ON MY WAY HOME, MY SPARE TIRE THAT WAS MOUNTED UNDER TRUCK FELL ONTO ROADWAY. I RECOVERED THE TIRE AND PARTS FROM ROAD AND LOOKED UNDER TRUCK FOR CAUSE. THE CABLE AND CLAMP THAT HOLDS THE SPARE TIRE HAD CORRODED AND BROKEN CAUSING THE TIRE TO FALL TO ROADWAY. *TR

NHTSA ID

10428070

Incident

Aug 20, 2011

Mileage

140,000 mi

TL* THE CONTACT OWNS A 2002 FORD F-150. THE CONTACT STATED WHILE DRIVING THERE WAS A LOUD NOISE IN THE REAR OF THE VEHICLE AND FOUND THAT THE SPARE TIRE SEPARATED FROM THE VEHICLE DUE TO CORRODED CABLE AND CLIP HOLDER. THE VEHICLE WAS NOT REPAIRED. THE FAILURE AND CURRENT MILES WAS 140,000.

NHTSA ID

10427990

Incident

Aug 20, 2011

Mileage

140,000 mi

NUMEROUS FORD PICK-UP TRUCKS TO INCLUDE F SERIES AND RANGER HAVE AN ISSUE WITH THE CROSS BEAMS THAT HOLD THE PICK-UP BED TO THE TRUCK RUSTING OUT. THE POTENTIAL IS THERE THAT THE BED COULD COME LOOSE FROM THE TRUCK AND POSE A SERIOUS SAFETY HAZARD. I HAVE CONTACTED FORD ABOUT IT BUT AS YOU CAN GUESS THEY WERE UNRESPONSIVE. SEVERAL WORKERS AT THE LOCAL FORD DEALER ALSO HAVE THE SAME PROBLEM BUT HAVE BEEN UNABLE TO GET A SATISFACTORY RESPONSE FROM FORD. MY VEHICLE IS A 2002 MODEL BUT I HAVE BEEN TOLD THAT IT OCCURS IN OLDER AS WELL AS NEWER MODELS. I AM GOING TO HAVE TO HAVE THE BED REMOVED AND NEW CROSS BEAMS WELDED ON TO REPLACE THE DEFECTIVE ONES AT MY EXPENSE. I HAVE ONLY 77,000MILES. THE TRUCK IS OPERATED IN NC WITH SOME SALT USED IN THE WINTER. *TR

NHTSA ID

10353689

Incident

Sep 3, 2010

FORD MOTOR COMPANYMAIN TOPIC: VEHICLE SERVICE ISSUES YOUR INQUIRY: I HAVE A 02 FORD F150 SUPERCREW WITH A MAJOR PROBLEM THE WINDSHIELD LEAKS ON THE DRIVERSIDE WHEN IT RANS INTO THE GEM MODULE CAUSE THE TRUCK TO BE HARD TO START AND THE GAUGES AND SERVICES LIGHTS TO STAY ON THE SEATBELT BELL TO RING ALL THE TIME > I CONTACTED DICK MASHETER FORD AND TOLD THEM WHAT WAS GOING ON WITH THE TRUCK ANDTHEY TOLD ME IT IS COMMON WITH THAT YEAR TRUCK FORF THE WINDSHIELD TO LEAK ONTO THE GEM MODULE OWNER: YESVEHICLE IDENTIFICATION NUMBER: [XXX] MILEAGE: 94000VEHICLE LOCATION: INPOSSESSIONIF CONTACTED DEALER: YESDEALER NAME: DICK MASHETER FORD OWNER FIRST NAME: [XXX] OWNER LAST NAME: [XXX] OWNER EMAIL ADDRESS: [XXX] OWNER ADDRESS1: 2761 GOSLING WAY CITY: COLUMBUSSTATE: OHZIPPOSTAL: [XXX]: UNITED STATESDAY PHONE: [XXX] CLIENT > THIS HAS BEEN GOING ON SINCE I BOUGHT THE TRUCK 03/19/10 I HAVE BEEN ONT HE FORD FORUM AND HAVE SEEN ALOT OF OTHER CUSTOMERS HAVING THE SAME PROBLEM WITH THE GEM MODULE GETTING WET WHEN IT RAINS > > I FEEL THAT FORD SHOULD DO A RECALL ON THIS ISSUE TO TAKE CARE OF THE PROBLEM I HAVE ALSO TALKED TO DICK MASHETER FORD ON HAMILTON RD IN COLUMBUS, OH AND THEY HAVE TOLD ME THAT IT IS THE GEM MODULE CAUSING THE PROBLEMS WHEN IT RAINS AND IT HAS BEEN HAPPENING WITH FORD F150 TRUCKS FROM THE YEAR '97 ON UP. IT SEEMS THAT FORD IS DOING RECALLS FOR EVERYTHING ELSE WHY NOT THE PROBLEM WITH THE WINDSHIELD LEAKING HTTP://WWW.TOPIX.COM/FORUM/AUTOS/FORD-F-150/TAA9DVMDG7RO706EI/P3#LASTPOST THIS IS THE WEBSITE THAT I FOUND THAT OTHER FORD TRUCK OWNERS ARE HAVING THE SAME PROBLEM AND IT IS COSTING THEM ALOT OF MONEY TO GET THE PROBLEM REPAIRED AT THEIR EXPENSE. > > FROM: [XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6). *TR

NHTSA ID

10334347

Incident

Mar 24, 2010

Mileage

92,250 mi

TL*THE CONTACT OWNS A 2002 FORD F-150 CREW CAB. WHILE DRIVING APPROXIMATELY 3 TO 5 MPH THE SPARE TIRE FELL FROM UNDERNEATH THE BED OF THE VEHICLE. THE CONTACT COULD SEE FROM THE REAR VIEW MIRROR THAT THE BRACKET THAT HOLDS THE SPARE TIRE IN PLACE HAD BROKEN. THE DEALER INFORMED THE CONTACT THAT THE SPARE TIRE BRACKET WAS NOT A PART OF THE WARRANTY AND HE WOULD BE RESPONSIBLE FOR THE REPAIR COST. THE CONTACT IS CONCERNED THAT THE SAFETY RISK COULD HAVE CAUSED A CRASH. THE FAILURE MILEAGE WAS 160,000.

NHTSA ID

10298995

Incident

Jan 6, 2010

Mileage

160,000 mi

I OWN A 2002 FORD F150 SUPER CREW PICKUP TRUCK. SHORTLY AFTER PURCHASING THIS TRUCK IT DEVELOPED A LEAK IN THE WINDSHIELD. THE WINDSHIELD WAS REPLACED UNDER WARRANTY AND WAS LEAK FREE FOR ABOUT 2 YEARS. THE LEAK RETURNED AND DURING SOME HEAVY RAIN STORMS I HAVE HAD CHRONIC ELECTRICAL PROBLEMS DUE TO WATER LEAKING IN THE WINDSHIELD AND RUNNING DOWN BEHIND THE DASHBOARD AND GETTING INTO THE ELECTRICAL COMPONENTS. I HAVE HAD THE INTERIOR LIGHTS COME ON WITH NO ONE IN OR NEAR THE TRUCK. AT THE SAME TIME, SOME OF THE DASH INDICATOR LIGHTS WERE ON VERY DIM. I HAD TO DISCONNECT THE BATTERY TO GET THE LIGHTS TO TURN OFF. I RAN THE HEAT IN THE TRUCK FOR A FEW HOURS TO DRY IT OUT AND IT SEEMED TO TEMPORARILY CURE THE LIGHTING PROBLEM. I ALSO HAD A PROBLEM STARTING THE TRUCK IN THE RAIN. I TURNED THE KEY TO THE START POSITION AND NOTHING HAPPENED. I GOT IN THE TRUCK THE NEXT DAY AFTER THE RAIN STOPPED AND IT STARTED WITHOUT A PROBLEM. I TOOK THE TRUCK TO A LOCAL GLASS SHOP AND HAD SOME SEALER PUT ON THE TOP RIM OF THE WINDSHIELD TO TRY AND STOP THE LEAK. IT DID NOT WORK. I WAS TOLD BY THE GLASS SHOP THAT THE ONLY WAY TO SEAL THE WINDSHIELD PROPERLY WAS TO REPLACE IT DUE TO THE FACT THAT THE WINDSHIELDS NOW ARE GLUED IN AND THE GLUE IS WHAT SEALS THEM. I AM RELUCTANT TO REPLACE THE WINDSHIELD AGAIN BECAUSE THE FIRST REPLACEMENT WINDSHIELD DID NOT SOLVE THE PROBLEM. I MAY SPEND SEVERAL HUNDRED DOLLARS ON A NEW WINDSHIELD AND STILL HAVE THE SAME PROBLEM. *TR

NHTSA ID

10295710

Incident

Oct 20, 2004

I HAVE A 2002 FORD F-150. IT STARTED TO LEAK WHEN IT RAINS. THE PROBLEM IS THE BEZEL COVERING THE PLACES WHERE THE GLASS IS ATTACHED TO THE TRUCK - THE BRACKETS WHERE THE SCREWS GO HAVE CRACKED AND THE GROMMETS AROUND THE BOLTS HAVE FAILED. I WANT TO FIX THE ITEM, BUT I HAVE LEARNED THAT THE NECESSARY PART (THE PLASTIC BEZEL FOR THE BACK WINDOW) IS ON NATIONAL BACKORDER, BECAUSE SO MANY OF THEM HAVE FAILED THERE ARE NO MORE AVAILABLE. IT SEEMS TO ME THAT IF SOMETHING IS BREAKING SO MUCH THAT NO ONE HAS THE REPAIR PARTS, THEN THIS SHOULD BE AN ITEM FOR RECALL. *TR

NHTSA ID

10285236

Incident

Jun 1, 2009

Mileage

104,000 mi

THE FACTORY PAINT ALREADY HAS TO BE REPAINTED THE WHOLE PAINT JOB IS CRACKED ALL OVER THE TRUCK SO BAD THAT IT WILL HAVE TO BE SANDED TO THE METAL AND COST OVER 4000 TO REPAINT. *TR

NHTSA ID

10261112

Incident

Mar 6, 2008

PAINT PEELING IN SMALL SHEETS AROUND EDGES OF HOOD. SEVERAL COMPLAINTS FOUND ONLINE BUT, CAN FIND NO RECALL ON VEHICLE. HAS ALUMINUM HOOD ALSO. ONLY PAINT PEELING AS PRIMER STILL SHOWING. *TR

NHTSA ID

10261094

Incident

Aug 15, 2008

Mileage

84,000 mi

PAINT COMING OFF IN LARGE AREAS. *TR

NHTSA ID

10258368

Incident

Feb 6, 2009

Mileage

85,000 mi

THE WINDSHIELD OF MY F150 FORD KING RANCH LEAKS AND HAS DONE DAMAGE TO THE FUSE BOX AND RUST IS OCCURRING IN LOCATIONS NOT EASILY ACCESSED BY WATER. *TR

NHTSA ID

10255558

Incident

Jul 5, 2007

Mileage

80,000 mi

I HAVE A 2002 FORD F150 DURING THE LAST RAIN WE HAD WATER LEAKED IN FROM THE FRONT WINDSHIELD AND GOT INTO THE FUSE BOX AND SHORTED OUT THE BATTERY, FUSE BOX AND A MODULE TOTAL COST WAS OVER $1,000.00. INSURANCE SAID THEY COULD NOT COVER IT BECAUSE THE SERVICE MANAGER SAID THIS IS A COMMON PROBLEM WITH FORD TRUCKS SO THE ADJUSTER SAID IT SOUNDED LIKE A DEFECT AND FORD SHOULD CORRECT THE PROBLEM. I TALKED TO FORD AND THEY SAID NO RECALL HAS BEEN ISSUED AND NO REIMBURSE MENT COULD BE MADE, BUT IF THIS IS A COMMON PROBLEM WITH FORD TRUCKS WHY HASN'T A RECALL BEEN ISSUED. *TR

NHTSA ID

10252207

Incident

Dec 10, 2008

Mileage

160,000 mi