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I have a 02 and have had very little problems. I read this board almost daily and try to find what others have had problems with but rarely ever find mention of the 02.
Get an '04 if you have a choice in the matter. The new generation is a better overall truck and most of the bugs from '03 were addressed. I too have an '03 with zero problems at 60k miles, but maybe I'm just lucky.
I think the reason you don't hear too much about the 02's is that they didn't sell many of them due to the pending redesign in '03. Which may also be why you hear about a lot of problems with the '03's simply because there are a lot more of them out on the road.
The new-generation is a very popular vehicle, and it seems that the first year after a redesign of an already very popular truck would be the biggest sales year.
This is all strictly assumption on my part, as I am way too lazy to go look up sales data for 2002-2005, but it makes a lot of sense to me.
Maybe someone has the sales data readily available and can prove/disprove my theory.
My 04EB with the 4.6L and 2wd has been very reliable. Only problem has been a failed starter motor. All the gadgets work well (heat/cooled front seats, sunroof, power 3rd row) and I have racked up about 26k miles so far mostly in the city. I added a K&N FIPK and that has helped to improve the acceleration and economy a little bit. Main complaint is that the ride is very stiff. Good Luck!
I had an 03'. Wife loved it. Even with the fit/finish issures we had, all covered under warranty. rattling doors-new seals & faded running boards-new boards.
I think the 04' has the 3V 5.4L (305 HP), while the 02-03 had the 2V (265 HP). The 02' doesn;t have the all wheel independent suspension. Super Comfy ride.
The 03' is nice with the fold flat power 3rd row. The thing was super comfy going down the road. The XLT came in leather. The wife won't let me live down the trade to an Excursion (only for added towing ability). I liked the 02' body style, but the fold flat was definatley worth the TSBs I dealt with. Try and get an 03' (if TSBs taken care of) or an 04' both will have better ride than the 02'. I would look for an 04' (issues taken care of) because of the 3V motor.
Both the '03 and '04 have the old 2 valve motor like the '02. However they do use a different type of program and/or computer to control it. The 3 valve wasn't put into the Expy until '05, even though it was in the F-150 in '04.
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