2002 Ford F-150

The 2002 Ford F-150 is a popular full-size pickup truck known for its durability and capability. Engine options included the 4.2L Essex V6 (202 hp, 260 lb-ft torque), the 4.6L Triton V8 (231 hp, 293 lb-ft torque), and the 5.4L Triton V8 (260 hp, 350 lb-ft torque). Transmission options included a 4-speed automatic and a 5-speed manual, depending on the engine. Owners often praise the F-150 for its reliability, comfortable ride, and towing capacity. Common complaints include issues related to aging components, rust, and specific problems with certain engine configurations.

Engine

4.2L Essex V6

• Intake Manifold Gasket Leak
  • Description/Symptoms: Coolant leaks, overheating, rough idle, coolant smell.
  • Solution: Replace the intake manifold gasket.
  • Estimated Cost to Fix: $200 - $400+
  • Recalls: None Found

4.6L Triton V8

• Spark Plug Thread Failure
  • Description/Symptoms: Spark plug ejection, misfires, ticking noise.
  • Solution: Repair or replace cylinder head. Installation of spark plug thread inserts.
  • Estimated Cost to Fix: $300 - $1500+
  • Recalls: None Found
• Idle Air Control (IAC) Valve Failure
  • Description/Symptoms: Erratic idle, stalling.
  • Solution: Replace the IAC valve.
  • Estimated Cost to Fix: $100 - $200+
  • Recalls: None Found

5.4L Triton V8

• Spark Plug Thread Failure
  • Description/Symptoms: Spark plug ejection, misfires, ticking noise.
  • Solution: Repair or replace cylinder head. Installation of spark plug thread inserts.
  • Estimated Cost to Fix: $300 - $1500+
  • Recalls: None Found
• EGR Valve Failure
  • Description/Symptoms: Rough idle, poor performance, check engine light.
  • Solution: Replace the EGR valve.
  • Estimated Cost to Fix: $100 - $300+
  • Recalls: None Found

Transmission

4-Speed Automatic (4R70W/4R75E)

• Shift Flare/Slipping
  • Description/Symptoms: Delay or hesitation when shifting, slipping between gears, harsh shifting.
  • Solution: Transmission rebuild or replacement. In some cases, valve body replacement can resolve the issue.
  • Estimated Cost to Fix: $1500 - $3500+
  • Recalls: None Found

5-Speed Manual (Mazda M5OD-R2)

• Synchro Wear
  • Description/Symptoms: Grinding noise during shifts, difficulty shifting into certain gears (especially 2nd and 3rd).
  • Solution: Transmission rebuild or replacement. Replacing worn synchros.
  • Estimated Cost to Fix: $800 - $2500+
  • Recalls: None Found

Suspension

• Ball Joint Failure
  • Description/Symptoms: Clunking noise from the front suspension, loose steering, uneven tire wear.
  • Solution: Replace upper and/or lower ball joints.
  • Estimated Cost to Fix: $200 - $600+ per side
  • Recalls: None Found
• Leaf Spring Sag/Failure
  • Description/Symptoms: Rear of the truck sitting lower than the front, reduced load-carrying capacity, rough ride.
  • Solution: Replace leaf springs.
  • Estimated Cost to Fix: $300 - $800+ per side
  • Recalls: None Found

Electrical

• Window Motor Failure
  • Description/Symptoms: Window not going up or down, slow window movement, clicking noise.
  • Solution: Replace the window motor.
  • Estimated Cost to Fix: $150 - $300+ per window
  • Recalls: None Found
• Instrument Cluster Failure
  • Description/Symptoms: Gauges not working properly, flickering lights, complete cluster failure.
  • Solution: Repair or replace the instrument cluster.
  • Estimated Cost to Fix: $200 - $600+
  • Recalls: None Found

Exterior

• Rust (Body Panels)
  • Description/Symptoms: Rust on rocker panels, cab corners, wheel wells.
  • Solution: Rust repair, panel replacement, or patching.
  • Estimated Cost to Fix: Highly variable depending on severity $300 - $3000+
  • Recalls: None Found
• Door Handle Failure
  • Description/Symptoms: Door handle breaks or becomes loose, difficult or impossible to open the door.
  • Solution: Replace the door handle.
  • Estimated Cost to Fix: $50 - $200+ per handle
  • Recalls: None Found

Interior

• Blend Door Actuator Failure
  • Description/Symptoms: Inconsistent temperature from vents, clicking noise behind the dashboard.
  • Solution: Replace the blend door actuator.
  • Estimated Cost to Fix: $150 - $400+
  • Recalls: None Found

Summary:

The 2002 Ford F-150 can be a reliable truck, but common issues arise due to its age. Engine problems like spark plug thread failure in the Triton V8 engines and intake manifold gasket leaks in the V6 can be costly to repair. Transmission issues, especially shift flares in the automatic transmission, also represent significant expenses. Suspension components like ball joints and leaf springs are prone to wear and failure, impacting ride quality and safety. Electrical problems such as window motor and instrument cluster failures can also occur. Rust is a significant concern on the exterior, requiring extensive repairs. Overall, potential buyers should thoroughly inspect the truck, paying close attention to these common issues, and factor in the cost of potential repairs.