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2002 Ford Expedition

Factory specifications, fluid capacities, torque values, EPA fuel economy and the federal safety record for the 2002 Expedition.

Body SUV

The 2002 Ford Expedition is an SUV with a 6.0-quart oil capacity and a 5W-20 API viscosity specification, figures that define its routine maintenance requirements. Owner data records 388 total complaints, with engine and engine cooling issues representing the top concern area alongside four manufacturer recalls. Within the model’s complaint history spanning 1991 through 2027, the 2002 model year registers significantly below the 1999 peak of 1,007 grievances, positioning it as a comparatively moderate year for reported problems despite its concentrated mechanical complaints.

Model year2025 2024 2023 2021 2020 2019 2018 2017 2002

Quick specs

Fluid capacities, tune-up values and fuel economy at a glance.

Engine oil capacity6.0 qtOEM · verified

Engine oil type5W-20 APIOEM · verified

Fitment & sizes

Replacement part sizes and factory part numbers — battery, bulbs, filters and belts.

From the factory this vehicle uses a BCI 65 · 650 CCA battery. Each part links to every other vehicle that shares it, so a part you already stock may fit more of your fleet than you'd expect.

Battery groupBCI 65 · 650 CCAOEM · verified

Tire sizeP255-70R16OEM · verified

Wheel / rim7.5-J inOEM · verified

OE service part numbers OEM · verified

Spark plug

AGSF32PM4

Full specifications

Engine, drivetrain, dimensions and economy.

Dimensions & weight NHTSA vPIC

Overall length	204.7 in
Overall width	78.7 in
Overall height	78.3 in
Wheelbase	118.9 in
Curb weight	5344 lb
Track (front / rear)	65.4 / 65.4 in
Weight distribution (front / rear)	52/48

Performance & power Independent road tests

0–60 mph, quarter-mile, horsepower and torque from independent road tests.

Independent road tests for the Expedition of this era, listed by trim and engine — this page spans more than one engine, so no single horsepower figure is shown.

9.5 sec0–60 mph (tested)quickest 9.50 sec — 2002 XLT

Year	Trim / engine	0–60	¼ mile	HP	Drivetrain
2002	XLT 5.4L V8	9.50 sec	17.10 sec	260 hp	4x4
2000	XLT 5.4L V8	9.90 sec	17.30 sec	260 hp	4x4
1997	Eddie Bauer 5.4L V8	9.90 sec	17.40 sec	230 hp	4x4
1997	XLT 5.4L V8	10.60 sec	18.00 sec	230 hp	4x4

Service quick specs OEM factory data

Capacities, torques and tune-up values from the factory service manual.

This engine holds 6.0 qt of 5W-20 API engine oil, SYNTHETIC · 75W-140 · GL-5 in the differential, DOT 3 brake fluid. Torque the oil drain plug to 10.0 ft-lbs. The firing order is 1-3-7-2-6-5-4-8. Note the cylinder-head bolts finish on a torque angle (torque-to-yield) — they stretch permanently and should be replaced, not reused, during any head service.

Lubricants & capacities

Brake Fluid	DOT 3
Differential Gear Oil	SYNTHETIC · 75W-140 · GL-5
Differential Gear Oil Capacity	5.7 Pints ( rear)
Engine Oil	5W-20 · API
Engine Oil Capacity	6.0 qt
Engine Oil	5W-20 · API
Engine Oil Capacity	6.0 qt
Power Steering Fluid	ATF

Engine torques

Camshaft Bearing/Carrier Cap Bolts or Studs	7.4 ft-lbs
Camshaft Bearing/Carrier Cap Bolts or Studs	6-9 ft-lbs
Engine Flywheel Bolts	59 ft-lbs
Engine Flywheel Bolts	55-64 ft-lbs
Exhaust Manifold to Cylinder Head Bolts	18 ft-lbs
Exhaust Manifold to Cylinder Head Bolts	18 ft-lbs
Engine Oil Pan Drain Plug	19.0 ft-lbs
Engine Oil Pan Drain Plug	10.0 ft-lbs

Chassis torques

Transfer Case Fill Plug	11.0 ft-lbs
Transfer Case Drain Plug	11.0 ft-lbs
Rear Wheel Hub	258 ft-lbs
Front Wheel Hub	221 ft-lbs

Ignition

Cylinder Firing Order	1-3-7-2-6-5-4-8
Curb Idle Speed (No Load)	755 rpm
Curb Idle Speed Variance (No Load)	75 rpm
Curb Idle Speed (No Load)	730 rpm
Curb Idle Speed Variance (No Load)	30 rpm
Spark Plug Manufacturer	Motorcraft
Spark Plug Gap	0.052-0.056 in
Spark Plug Torque	11.0 ft-lbs

Battery & A/C

Refrigerant	R134a
Refrigerant Capacity	Less auxiliary A/C, 2.31. With auxiliary A/C, 3.92. lbs
Oil Group	PAG
Oil Type	68
Oil Capacity	Less auxiliary A/C, 9.00. With auxiliary A/C, 11.00. oz
Standard BCI Group Number	65
Standard BCI Cranking Performance	650 cca
Standard BCI Group Number	65

Service checks

Key ON Engine OFF (KOEO)	30-45
Injector Primary Resistance	11-18 na ohms
Engine Oil Pressure	20-45 psi
Engine Oil Pressure RPM	1500 rpm
Intake Valve Lash	Hydraulic in
Exhaust Valve Lash	Hydraulic in

Brakes

Brake Application	WITH REAR DISC / WITH STANDARD
Torque Caliper to Bracket	20 ft-lbs / 21-26 ft-lbs
Torque to Knuckle	70 ft-lbs / 136 ft-lbs
Minimum Pad Thickness	Front: 0.039; Rear: 0.039 in
Brake Application	WITH REAR DISC / WITH STANDARD
Rotor Max Parallel Variation	0.0005 in
Rotor Runout Limit	0.002 in
Rotor Discard at or Under	0.4 in / 1.09 in

Multi-step torque procedures OEM · verified

Connecting Rod (Large End) Bearings — tightening sequence 1 stages

18 ft. lbs., Step 2: 33 degrees, Step 3: 90

18 ft. lbs

Connecting Rod (Large End) Bearings — tightening sequence 1 stages

33 ft. lbs., Step 2: 90 degrees, Step 3: 120

33 ft. lbs

Crankshaft Pulley and/or Damper Bolts — tightening sequence 1 stages

66 ft. lbs., Step 2: loosen one turn, step 3: 37 ft. lbs., step 4: 90

66 ft. lbs

Crankshaft Pulley and/or Damper Bolts — tightening sequence 1 stages

66 ft. lbs., step 2: Loosen one turn., step 3: 37 ft. lbs., step 4: 90

66 ft. lbs

Cylinder Head — tightening sequence 3 stages

1	30 ft. lbs.	30 ft. lbs
2	90 degrees	90 degrees
3	90

Cylinder Head — tightening sequence 3 stages

1	30 ft. lbs.	30 ft. lbs
2	90 degrees	90 degrees
3	90

Intake Manifold to Engine Bolts — tightening sequence 1 stages

3.7 ft. lbs., step 2: 18

3.7 ft. lbs

Intake Manifold to Engine Bolts — tightening sequence 1 stages

3 ft. lbs., step 2: 18

3 ft. lbs

Main Bearings — tightening sequence 1 stages

7.4 ft. lbs., Step 2: 18 ft. lbs., Step 3: 30 ft. lbs., Step 4: 90 degrees

7.4 ft. lbs

Factory maintenance schedule OEM · verified

Normal service, condensed from the factory interval matrix.

Under the factory schedule, replace the engine oil and filter every 5,000 mi; spark plugs every 100,000 mi; coolant every 50,000 mi. The big-interval services (every 50,000 mi for coolant, and the transmission fluid) are the ones owners most often skip — on a lower-mileage example, assume the original fluids are still in it and check them first.

Every 5,000 mi	Engine Oil (drain & refill) · Engine Oil Filter (replace) · Tire & Wheel Assembly (rotate)
Every 15,000 mi	Cabin Air Filter (replace) · Engine Coolant System Hoses (inspect)
Every 20,000 mi	Accessory Drive Belt (inspect)
Every 30,000 mi	Engine Air Filter Element (replace) · Fuel Filter (replace) · Transmission Assembly (drain & refill)
Every 50,000 mi	Engine Coolant System (drain, flush & refill)
Every 60,000 mi	Wheel Bearing (repack)
At 100,000 mi	Accessory Drive Belt (inspect) · Engine Coolant System (drain, flush & refill)
Every 100,000 mi	PCV Valve (replace) · Spark Plugs (replace)
At 150,000 mi	Drive Axle Assembly (drain & refill) · Transfer Case Assembly (drain & refill) · Transmission Filter (replace) · Transmission Fluid & Filter (replace)

Reliability & federal safety record

Owner-reported issues, recalls, investigations and service bulletins on record with NHTSA — an unfiltered look at what owners actually experience.

The first-generation Ford Expedition (1997–2002) shows a clear arc of declining federal activity as the platform matured, with complaints peaking at 1,007 in 1999 and recalls peaking at 11 in 2000 before tapering off. By 2002, complaints had fallen to 388, recalls to 4, and investigations to just 2 — the lowest figures across the entire generation — suggesting Ford had resolved many of the early-production issues that drove the 1997–2000 surge. However, the 2002 model still carries meaningful risk in its complaint profile: 73 fire complaints and 21 crash complaints are recorded, with Engine & Engine Cooling (88 complaints) and Vehicle Speed Control (45) as the top problem areas, pointing to persistent thermal and throttle-related concerns even in this final-year unit. The data does not specify root causes for these complaints, so buyers should treat the fire and speed-control figures as flags warranting mechanical inspection rather than confirmed defects. The following year (2003) sees complaints rebound to 655, likely reflecting a generational redesign with its own fresh issues. **Bottom line: 2002 is the best year of a problematic generation to buy, but it is not risk-free — prioritize a pre-purchase inspection focused on the engine cooling system and throttle mechanism, and verify that all four recalls have been completed.**

Open recalls

NHTSA campaigns

128

Service bulletins

Manufacturer communications

ODI investigations

Office of Defects Investigation

388

Owner complaints

21 involved a crash · 73 a fire

NHTSA crash-test rating federal NCAP · out of 5 stars

Rollover★★★★★

Owner complaints by model year NHTSA · this generation & adjacent

’91 ’93 ’94 ’95 ’96 ’97 ’98 ’99 ’00 ’01’02’03 ’04 ’05 ’06 ’07 ’08 ’09 ’10 ’11 ’12 ’13 ’14 ’15 ’16 ’17 ’18 ’19 ’20 ’21 ’22 ’23 ’24 ’25 ’26 ’27

Owner complaints filed with NHTSA, by component

All 388 complaints on record, top 8 components.

Engine & Engine Cooling88

Vehicle Speed Control45

Electrical System27

Tires24

Engine21

Power Train20

Seat Belts18

Suspension17

Source: NHTSA Office of Defects Investigation complaint database.

Recalls NHTSA · verified

Showing 2 of 4 campaigns on record for this vehicle.

06E056000Fuel System, GasolineReported 13/06/2006

CERTAIN AFTERMARKET FUEL FILTERS SOLD UNDER THE PUROLATOR BRAND NAME, P/N F65277, SHIPPED FROM JANUARY 16 THROUGH JUNE 2, 2006, FOR USE ON THE ABOVE LISTED PASSENGER VEHICLES. DUE TO INCORRECT DESIGN, THE QUICK… Remedy: UFI WILL NOTIFY OWNERS AND REPLACE THE FILTERS FREE OF CHARGE. THE RECALL BEGAN ON AUGUST 4, 2006. OWNERS MAY CONTACT UFI FILTERS USA AT 800-230-5876.

06E067000Exterior Lighting:HeadlightsReported 01/08/2006

CERTAIN MAXZONE HEADLIGHT ASSEMBLIES, DEPO BRAND, P/NOS. 331-1129L-ASN AND 331-1129R-ASN, SOLD FOR USE AS AFTERMARKET EQUIPMENT FOR THE ABOVE LISTED PASSENGER VEHICLES. THESE HEADLAMPS FAIL TO CONFORM TO THE PHOTOMETRIC… Remedy: MAXZONE WILL NOTIFY OWNERS AND OFFER REIMBURSEMENT FOR ANY NONCOMPLIANT HEADLIGHTS. THE RECALL BEGAN ON JULY 28, 2006. OWNERS MAY CONTACT MAXZONE AT 909-822-3288.

Technical service bulletins NHTSA · verified

Showing 5 of 128 bulletins on record with NHTSA.

Bulletin	Date	Component	Summary
TSB 20-2233	2020-07-13	Structure	This article supersedes TSB 19-2026 to update the vehicle model years affected. Some 2000…
TSB 19-2026	2019-02-07	Structure	Some 2000 and newer Ford, Lincoln and Mercury vehicles equipped with aluminum body panels…
TSB 19-2026	2019-02-07	Structure	Some 2000 and newer Ford, Lincoln and Mercury vehicles equipped with aluminum body panels…
07212	2007-10-01	Engine And Engine Cooling	SOME 1997-2008 VEHICLES EQUIPPED WITH A 4.6L 2V, 5.4L 2V, OR 6.8L 2V ENGINE--SPARK PLUG…
041601	2005-11-14	Engine And Engine Cooling	WDS COP KIT DIAGNOSTIC TIP - COIL ON PLUG (COP) IGNITION SYSTEMS - ENGINE MISFIRE OR…

Common OBD-II trouble codes

The most common OBD-II codes for this vehicle's emissions system. These are standardized SAE J2012 definitions, not vehicle-specific fault reports.

P0420

Catalyst system efficiency below threshold — Bank 1

P0300

Random / multiple cylinder misfire detected

P0171

System too lean — Bank 1

P0455

Evaporative emission system leak detected — large leak

P0128

Coolant thermostat below regulating temperature

P0442

Evaporative emission system leak detected — small leak

VIN tools

Decode factory build data for a specific vehicle by VIN.

VIN

Decode a VIN to confirm the transmission and build data for a specific Expedition. OEM

Build data

Plant, GVWR class, engine and body data for any 17-character VIN.

Recalls

Check open recall campaigns against a specific vehicle by VIN.

Vehicles with shared specs

Find every vehicle that shares this one's battery, bulbs, oil capacity, platform or parts.

Group 65 battery Vehicles taking 6.0 qt Spark plug AGSF32PM4

Reference guides

Cross-vehicle references for the kinds of data on this page.

Vehicle recalls & TSBs OBD-II trouble codes Torque specifications Maintenance schedules Fluid capacities & specs

Frequently asked

How much oil does the 2002 Expedition take?

6.0 qt of 5W-20 API MEETING FORD SPECIFICATION WSS-M2C945-A, per the factory manual.

Does the 2002 Expedition have open recalls?

NHTSA lists 4 recall campaign(s) for this model year. Check your specific vehicle by VIN.