One problem related to transfer case has 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.
Rear differential control links rusted thru and broke. This allowed the differential to move toward the rear. When it moved far enough the rear drive shaft fell out of the transfer case and broke off at the rear yoke. Considering the number of Expeditions and navigators on the road. . . Someone is going to get killed.