Problems with 2002 Ford F-150 STRUCTURE

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?

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.

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?

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

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)

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.

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

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

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.

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.

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

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.

Vehicle cab rocker panels rusting off rear window leaking cruise control not working vehicle rusting and been in area with no salt on roads

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

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

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.

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

Paint coming off in large areas. *tr

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

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

I have a 2002 f150 harley davidson f150 kingcab truck, black in color and the paint on the hood is cracking something terrible. i have taken it to the local ford dealership here in pensacola and the service manager told me that it is a defect in the paint process but there is no recall for this. they quoted me over $500.00 to repaint just the hood and another body shop quoted me the same because it has to be completely stripped and repainted. i have noticed that several other ford hd trucks are doing the same thing also on other body part to. i'm afraid that this might get worse and possibly start on the fenders. is there ever going to be a recall on the paint on these trucks or does everyone drive around proudly in a beautiful truck with cracking paint displaying the ford emblem with the harley davidson reputation next to it? *tr

My vehicle has a water leak that is getting the gem module wet and this has resulted in the wipers failing, the power windows to fail, the heater fan stays on after the key is removed from the ignition, and the engine runs very rough and stalls resulting in me losing the power steering and putting the vehicle in a ditch, the wipers stopped working during a recent heavy rain and i had to pull onto the side of the interstate for over 30 minutes. ford customer service claims they never heard of the problem but i found out they issued a technical service bulletin 98-9-13 to the dealers about this and also ford special message #15773 for this problem. the dealer wants over $1,100.00 to fix .this problem is in 1997-2002 ford f150 and expeditions. i feel that the loss of wipers and sudden loss of power steering and power brakes is a bigger safety hazard than the current recall on the cruise control. *tr

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

We have been hearing a clicking or tapping sound from the 2002 f150 pickup for about a month. after two complete inspections of the suspension and steering we did not find any problem. today while rocking the pickup, we discovered the drivers side of the bed is loose. there is at least a 1/16" of vertical movement. at this point we check our 2003 f150 pickup, the passenger side of the bed is loose. i contacted the local ford dealership (hillard auto) regarding a recall. they indicate that there is no recall. they also indicate that they have never heard of this problem before, that i find hard to believe since i own two f150s and they both have the same problem. this is all fine until one of these trucks has the bed come loose while traveling at speed on the highway. was there a crash today? no, we caught the problem in time. to correct the problem, we will pull the plastic bed liner and tighten the bolts ourselves since i am opposed to paying someone to correct their mistakes and lack of quality control. *tr

Tl*the contact owns a 2002 ford f-150. the contact noticed smoke coming from the hood when he started the vehicle. the smoke disappeared on its own and burned a hole into the master cylinder. the insurance company was notified. the vehicle was towed to the dealer. the powertrain and failure mileage were unknown. the current mileage was 157,806.

Possible windshield leakage causing extreme random electrical failure. truck won't start if raining. truck shuts off during operation. particularly hazardous during highway operation. electrical operations occur without warning, with or without keys in ignition. *jb

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

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

Back window leaks and have been told ford knows about it. but yet no recalls are on it. *nm *ak

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

Vehicle was traveling at 15 mph and lost control due to a codder pin snapping in half causing the right front wheel to come entirely off of the vehicle. the disk brake stayed connected to the rim and was also removed entirely from the vehicle causing the brake lines to be severed which caused no pressure. with no pressure in the brake lines i was not able to stop the other wheels but was forced to let the vehicle come to a skidding stop, which happened by hitting a tree. the vehicle was taken to a local ford dealership where a year prior they had worked on the same wheel to pack the bearings and do other small maintenance. both the dealership and ford claimed no responsibility for the accident, which seems strange since a vehicles wheel should remain on when going 15 mph.

The plastic molding around the rear liftgate window has a crack in the plastic molding. the consumer believed this condition may lead to the glass falling out. the dealer was notified. *jb

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

The support cables that retained the tailgate corroded. the condition caused the tailgate to drop. *jb. on june 3, 2005 tom bowman (odi) contacted the owner to review the above report. the owner advised that his complaint was intended to address the spare tire support cable rather than the tailgate support cable reported above.

Passenger door would open while vehicle was moving. *ph the consumer also stated that the vehicle vibrated while driving. the consumer mother-in-law fell while trying to get into the front passengers side door of the truck. the brakes would lock up intermittently. *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

I bought my f150 extended cab in april 2002 and at 8,000 miles the passenger side rear door was hard to open. i took it in to the dealer and they repaired it and within a few days it was hard to open again. i took it back to the dealer and they fixed it again. again it became hard to open i just took it to a different dealer and they tried to fix it again with no luck. i feel that this is not safe in case of a wreck that i may not be able to open it to get my 9 year old son out if i had to in a hurry. *nlm

Vehicle has a gap on driver's side door over the top. the gap causes noise inside the cabin of the vehicle while driving. it makes it hard to keep the vehicle on the road. manufacturer was contacted with no results.*ak the dealer installed a rubber sealer around the gap but this seemed to cause more noise. the radio, cd player and tv in the rear of the van stopped working. the rotors warped and caused vibrations when braking. water had gotten into the left side park lamp. the seat belt warning chime and light failed intermittently, the dealer replaced the module. *nm

The automatic door lock feature activated and pinched my arm in the door lock. this has happened several time, howver this is the most serious instance. i received a bruice approximentley 1 1/2" inches in length and 2 small abrasions. this is at least my 4th ford vehicle with automatic locks and have never experienced this problem before. i believe there is a design problem with the door lock button. it is about 1" long and has an indentation with ridges. this is apparently what pinched my arm. there is no need for the ridges since the button is inside the door when locked and no way to use the indentation to pull up the door lock manually. it the lock button was made smooth and possible tapered toward the top i believe it would greatly remove the hazard. in addition this would not inpair the only use that i can see for the buttom, to push it down for a manual lock.*ak

Water was pouring into inside of the vehicle. structure is not lined up properly inside of vehicle. dealership is aware of the problem.*ak