Three problems related to dash wiring have been reported for the 2002 Ford Expedition. The most recently reported issues are listed below. Please also check out the statistics and reliability analysis of the 2002 Ford Expedition based on all problems reported for the 2002 Expedition.
While driving to work, heard "pop" under dashboard (fuse panel) and radio went off. Replacement fuse blew immediately upon replacement. Removed radio and replacement fuse immediately blew again. Suspected ground in power circuit to factory stereo, verified with test light. Shorted circuit, 797 in this vehicle, is hot at all times (not switched through ignition). Subsequent investigation by owner shows that main wiring harness behind dashboard was not correctly installed when the vehicle was assembled at factory. The mounting points installed in the harness were never installed in the corresponding holes in the body, allowing the harness to sag approximately 2 inches below its correct position (and presumably rub against metal parts behind the dashboard). Due to the faulty factory installation, the harness can not be raised far enough to be properly installed without removing at least part of the dashboard and passenger side airbag (dealer says entire dashboard must be removed, a significant cost item). Dealer mechanic has viewed harness and agrees harness was not correctly installed. Subject harness also contains wiring for airbags, instrument panel, transmission control, rear lighting, trailer controls; basically every circuit in the vehicle which is controlled from or has indication in the dashboard. Owner is still troubleshooting and attempting to repair.
Every time it rains hard my vehicle won't start and if it does the wipers and radio will not operate when I put in reverse or drive. I took it to the dealership and they told me that it was the right side windshield seal. I asked them if this was a manufacture defect and they said no that it was the shifting of the glass when I run over bumps. The same thing was happening to a f-250 p/u when I took my vehicle in. They told me that they would have to replace the fuse box, gear module, rear wiper motor. I don't believe bumps would cause this to happen and from the sound of it, it appears to have been happening for a good while because they told me at the service department that there was mold in the gear module. I am afraid that if it rains and I am on the road that my truck might just turn off or my wipers might short out. The estimated cost for all repairs is about $1000. 00.
Complete fire distructin of veh. Fire appears to have started under dash in wiring harness and spread to engine compartment as well as interior of unit. Forensic analysis indicates above. Forensic report available on request. Fire started while unit parked in garage and damaged dwelling as well.