Problems with 2002 Ford F-150 ELECTRICAL SYSTEM

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

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

Water intrusion from leaking windshield caused gem module /fuse block corrosion. windshield wipers inoperable and electric windows inoperable with no interior lights working. *jb

2002 ford f150 lightning, three blown spark plugs. two were repaired under warranty, one out of my pocket. ford did not acknowledge any problems with the triton cylinder head and did nothing about it. ford left me stranded three times, twice on the freeway. thanks ford. *nm

On thurs. 12-07, i was driving 40 mph when i heard a loud pop, the truck was running rough and loud. i pulled over, it blew a spark plug(#4). towed it to the dealership, was told the head would be replaced, then when i returned for the truck was told they would only repair the hole with a helicoil, which i found a service bulletin #0214 that states engine assemblies with aluminum cylinder heads repaired in vehicle have been found to leak coolant and/ or oil from the cylinder head gasket area. the dealership seems to think this is trivial, and refuses to replace the head under warranty. truck is an '02 f-150 lightning. 5.4 motor. *nm

The oil pressure gauge erratic at times, ok on start ups. but while in use it would drop to zero and the oil light would come on. if you shut vehicle off and restart oil gauge would go back to ok. until you start driving. *jb

Drove my 2002 f 150 approximately 25 miles home and parked it. the truck has never given me any problems and wasn't making any noise. about 30 minutes later i noticed a orange fire ball realizing it was my truck. the truck was fully involved within minutes. the entire front end of the truck melted away. the drivers side wheel, hood, and everything connected to the engine block is non existent. this is in addition to the cab which there is nothing left either. i am the second owner of this truck, never received a recall notice in the mail. im not sure what caused the fire. fire marshall said it started in the engine compartment. *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

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.

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

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.

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.

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.

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

Dt*: the consumer stated the windshield wipers and radio work intermittently. the dome light remained illuminated. the wipers and the radio come on for a few minutes and then stop working. the windshield wipers come on intermittently with the switch in the off position. the vehicle was not taken to the dealer for inspection. *jb

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

Electrical system failed due to water leaking from faulty windshield installation. *jb

After raining 4x4 indicator light flashes , windshield wipers and radio shut on and off while driving. *nm

Spark plug blown out/striped out of cylnider head

I receive storm damages to my vehicle. during the process of repairing the vehicle we sustain injuries from the windshield fibers and glass, in the vents which the repair shop said that the glass is impossible to remove. the truck has a defect in the heat control and the radio panel get extremely hot. we inhale the fiber from the glass , it got in our eyes, stinging and itching, etc. i was told that this may be a product problem. *nm

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: 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

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.

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

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

I purchased my 2002 ford f150 super crew in august of 2002. i have had ongoing problems since i purchased the vehicle, and have had no responses or assistance from any ford dealerships. the problems started out with my radio going on and off all on its own. i took my vehicle to the dealership at least 10 times alone for this problem. never any assistance. the problems escalated around 40,000 miles and my whole electrical system seemed to be shorting out. i have had fire under the dash, the headlights not work, the wipers would only work when the vehicle was in park, same thing with the heater, it would not turn off after you shut the vehicle off. now this week i had another fire which i was able to put out on my own. i took it to a different dealer and they identified the problem with the gem module and central junction box. apparently the vehicle was not put together correctly and these modules keep shorting out causing my vehicles problems. i have to wonder everyday whether or not my vehicle is going to catch fire and burn up. on a daily basis i can smell smoke coming from under the dash almost like burning plastic or wiring. none of the problems have been addressed and seem to be escalating. to me this is a safety issue. i would hate to think that i would be traveling with my family and the car catch fire while we are driving. the electrical system needs to be investigated and repaired. none of which has been done by the dealer i purchased the vehicle from. i even filed a complaint with the ford motor company and received no real concern.*ak

While driving approximately 60 mph consumer heard a loud pop coming from the engine. took vehicle to dealer for service, and it was determined that a spark plug blew out. *ak

While parked in a work yard vehicle caught on fire. the cause has yet to be determined. *ak

(1) truck's bed spreading apart and ignition/wiring shortage (2) the bed of my truck has spread apart for no reason at all. i cannot even shut my tailgate. my truck's battery continues to run down. when i turn on my truck, the starter doesn't want to stop. a light displays, "door opened!" the windshield wipers stopped working. the music goes on and off. (3) i took my truck to the dealer to get the bed fixed. they set me an appointment. i made another trip over an hour one way to get fixed and then they didn't fix. my warranty has just recently ran out. i am having several problems and don't know what is the matter. i haven't had no luck with talking with a ford mechanic. the wires in the steering column looks too tight or loose. there is a constant buzzing sound. my clock and mileage readings erases. my windows stop working. this only happens when i place the truck in drive. most of the time everything starts working once placed in park. i only have close to 70,000 miles. this has been going on for months.*ak

Vehicle blew out a spark plug, resulting in fuel going into the cylinder unburned. then it washes down, pass the rings into the crank case, which could cause a fire or an explosion . provide further details. *ak

My 2002 f150 supercrew [xxx] is getting the 3rd ignition coil replaced. 1st time @ 26,000 miles, 2nd @ 46,000 miles, and now @ 59,000. each time tomball ford has repaired the vehicle and the last two times i have had to pay for the repairs. i would like ford to recall the ignition coil on this model and pay for my repairs. *jb updated 07/24/2012 *js information redacted pursuant to the freedom of information act (foia), 5 u.s.c. 552(b)(6)

While driving vehicle stalled. consumer was unable to restart vehicle, and had it towed to the dealer for inspection. mechanic determined that the battery an battery cable needed to be replaced. *ak

While driving vehicle stalled. consumer noticed that all the electrically compliences failed. to come on its own. consumer had the vehicle towed to the dealer for inspection, and mechanic stated that the problem could not duplicated. *ak

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

Spark plug blew out of the head. i hear this has happened to many times to mention. i have a 2002 hd - f-150 with 45,000 miles on it.*ak

Windshield seal leaked (rain) along roofline causing multiple electrical problems. vehicle has multiple system warning lights visible on dash. short circuit sounds coming from behind dashboard. warning lights, blower motor and head lights operate without key in the ignition causing battery to be drained. wipers cut off without warning. door windows stop working without warning. vehicle shifts into four-wheel drive without warning. engine races while parked (revs to 4000 rpm and returns to normal). sales man informed that ford will not cover the problem because the truck is out of warranty and to bring truck to dealer (5/3/04). truck would not start until 5/8/04. seal to windshield separated from vehicle on left side while driving to dealership (5/10/04). the truck now has excessive wind noise. truck will no longer start (5/11/04). i called ford_x0019_s customer and requested that a representative from ford inspect the truck. customer service asked that the truck be towed to a ford dealer. truck was towed to local dealer. dealer did not want to help me contact ford after i informed them that the truck has a defective windshield seal. dealership informs me on 5/13/04 that the zone supervisor from ford said that there was nothing that could be done about the problem. in addition, dealer refuses to put statement in writing. the dealer also informed me that for a fee, they could seal the windshield and diagnosis the problem but the dealership where the truck was purchased from should do the repairs. *ak

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

Sparkplugs blew out of the head at 65 mph on svt lightning. service manager indicated ford is aware of this happening but they are not issuing a recall. he stated they put out a "what to do" if a vehicle comes in with this problem. unfortunately, that does not help us consumers who have to fork the bill.*ak

Dt: the contact stated windshield leaked in the lower passenger side. the fuse box was damaged due to the leaking, and replaced. the windshield was replaced at contact's expense. the manufacturer was notified. they did not offer any free remedy. *ak

Ignition coil misfiring, vehicle exhibited occasional miss fire. upon cold start after sitting for several days plume of blue smoke from tail pipe was noticed. dealer could not duplicate event but determined #1 ignition coil was firing at reduced capacity. unit was replaced and incident of blue smoke at cold start has been reduced. *la

Ignition coils had to be replaced 5 times within the last year. when taken to get serviced, they could not determine the problem. *nm

Electrical: at 306 miles the solenoids had to be replaced. upon shutting the vehicle off; the dash board would still illuminate. also, upon shutting the vehicle off it would continue to run. this has happened a total of four times. the transmission completely failed with no warning. the consumer took the vehicle to the dealer, and was told the windshield had a leak which corroded the electrical system. the electrical problems started at 44000 miles. the gasket had to be replaced, and the harness wiring had to be replaced also. upon trying to start the vehicle again the battery would be completely dead. please provide any further information. *jb

Hello, i'm writing to complain about my friends 2002 ford lightning which launched a spark plug through the head. i've heard that this problem has been happening to many of these trucks, and i think the problem needs to be resolved. how about a recall. *nlm

Electrical system fails intermittently, causing headlights and other electronic components to blink. *ak

Spark plug self launching from ford f150 5.4 l engine

While driving the vehicle noticed a problem in the instrumental cluster dash board, dealer and manufacturer has been notified. (see odi#0814163). nlm

The ignition coil went out continuously, which caused the vehicle to loose power. the dealer has replaced the ignition coil four times and the vehicle is being repaired again for the coil. *jb