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2002 Ford F-250

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By Research the Car 5 min read

The 2002 Ford F-250 Super Duty is a heavy-duty pickup truck known for its ruggedness and workhorse capabilities. Engine options included the 5.4L Triton V8, the 6.8L Triton V10, and the 7.3L Power Stroke Turbo Diesel V8. The 5.4L V8 produced around 260 horsepower and 350 lb-ft of torque. The available transmissions were generally a 4-speed automatic or a 5-speed manual, depending on the engine and trim. Owners often appreciate the F-250’s towing capacity and robust build. Common complaints revolve around fuel economy, especially with the larger engines, and the age-related issues that naturally arise in a vehicle of this vintage.

Engine

5.4L Triton V8

  • Spark Plug Ejection
    • Description/Symptoms: Spark plugs can eject from the cylinder heads, often due to stripped threads in the aluminum head. This results in a sudden loss of power, loud popping noises, and potential damage to surrounding components.
    • Solution: Repairing the threads with a thread insert kit (e.g., Time-Sert) or replacing the cylinder head.
    • Estimated Cost to Fix: $500 - $1500+
    • Recalls: None Found
  • Manifold Cracks
    • Description/Symptoms: Cracks in the exhaust manifold, leading to exhaust leaks. This results in a ticking noise, reduced fuel efficiency, and potential exhaust fumes entering the cabin.
    • Solution: Replacement of the exhaust manifold.
    • Estimated Cost to Fix: $300 - $800
    • Recalls: None Found

6.8L Triton V10

  • Spark Plug Ejection
    • Description/Symptoms: Similar to the 5.4L, spark plugs can eject from the cylinder heads due to stripped threads.
    • Solution: Thread repair or cylinder head replacement.
    • Estimated Cost to Fix: $500 - $1500+
    • Recalls: None Found
  • Exhaust Manifold Leaks
    • Description/Symptoms: Leaks from cracked or warped exhaust manifolds, causing a loud ticking noise and reduced performance.
    • Solution: Manifold replacement.
    • Estimated Cost to Fix: $400 - $900
    • Recalls: None Found

7.3L Power Stroke Turbo Diesel V8

  • Cam Position Sensor Failure
    • Description/Symptoms: Rough running, stalling, or difficulty starting. Diagnostic trouble codes (DTCs) related to the cam position sensor are often present.
    • Solution: Replacement of the cam position sensor.
    • Estimated Cost to Fix: $100 - $300
    • Recalls: None Found
  • Injector Issues
    • Description/Symptoms: Rough idle, white smoke, reduced power, and poor fuel economy. Can be caused by worn or leaking injectors.
    • Solution: Injector replacement or cleaning (depending on the severity).
    • Estimated Cost to Fix: $200 - $2000+ (depending on the number of injectors replaced)
    • Recalls: None Found
  • ICP Sensor Failure
    • Description/Symptoms: The engine may exhibit symptoms such as rough running, stalling, or no-start conditions. The truck may also show a lack of power, poor fuel economy, and diagnostic trouble codes (DTCs) related to the ICP sensor.
    • Solution: The ICP sensor must be replaced
    • Estimated Cost to Fix: $150 - $400
    • Recalls: None Found

Transmission

4R100 4-Speed Automatic Transmission

  • Torque Converter Failure
    • Description/Symptoms: Slipping, shuddering, or complete loss of drive. Often accompanied by unusual noises.
    • Solution: Torque converter replacement.
    • Estimated Cost to Fix: $800 - $2000+ (can include transmission rebuild)
    • Recalls: None Found
  • Shifting Problems
    • Description/Symptoms: Harsh or delayed shifts, slipping between gears, or failure to shift. Can be caused by worn solenoids, valve body issues, or internal wear.
    • Solution: Valve body repair or replacement, solenoid replacement, or transmission rebuild.
    • Estimated Cost to Fix: $500 - $3000+ (depending on the extent of the repair)
    • Recalls: None Found

ZF5 5-Speed Manual Transmission

  • Clutch Failure
    • Description/Symptoms: Slipping clutch, difficulty shifting, or complete failure to engage/disengage.
    • Solution: Clutch replacement.
    • Estimated Cost to Fix: $400 - $1200
    • Recalls: None Found
  • Synchro Wear
    • Description/Symptoms: Grinding or difficulty shifting into specific gears, especially when cold.
    • Solution: Transmission rebuild or replacement with new synchros.
    • Estimated Cost to Fix: $800 - $2500+
    • Recalls: None Found

Suspension

  • Ball Joint Failure
    • Description/Symptoms: Clunking or popping noises from the front end, uneven tire wear, and loose steering.
    • Solution: Ball joint replacement.
    • Estimated Cost to Fix: $200 - $600 per side
    • Recalls: None Found
  • Leaf Spring Sag/Breakage
    • Description/Symptoms: Rear of the truck sitting lower than normal, reduced load-carrying capacity, and potential cracking or breakage of the leaf springs.
    • Solution: Leaf spring replacement.
    • Estimated Cost to Fix: $300 - $1000 per side
    • Recalls: None Found

Electrical

  • Instrument Cluster Issues
    • Description/Symptoms: Gauges malfunctioning (e.g., speedometer, fuel gauge), erratic readings, or complete failure of the instrument cluster.
    • Solution: Instrument cluster repair or replacement.
    • Estimated Cost to Fix: $200 - $800
    • Recalls: None Found
  • Alternator Failure
    • Description/Symptoms: Dimming headlights, battery light on, and difficulty starting the vehicle.
    • Solution: Alternator replacement.
    • Estimated Cost to Fix: $200 - $500
    • Recalls: None Found

Exterior

  • Rust on Frame/Body Panels
    • Description/Symptoms: Rust forming on the frame, especially in areas exposed to road salt, and on body panels, particularly around wheel wells and rocker panels.
    • Solution: Rust repair, panel replacement, or frame repair/replacement (depending on the severity).
    • Estimated Cost to Fix: $300 - $5000+ (depending on the extent of the damage)
    • Recalls: None Found

Interior

  • Dashboard Cracking
    • Description/Symptoms: Cracking and warping of the dashboard, especially in areas exposed to direct sunlight.
    • Solution: Dashboard replacement or installation of a dashboard cover.
    • Estimated Cost to Fix: $200 - $1000+
    • Recalls: None Found
  • Power Window Motor Failure
    • Description/Symptoms: Window moving slowly or not at all, clicking noises when attempting to operate the window.
    • Solution: Power window motor replacement.
    • Estimated Cost to Fix: $150 - $400 per window
    • Recalls: None Found

Summary

The 2002 Ford F-250, while a robust and capable truck, is subject to age-related issues. Common engine problems include spark plug ejection (especially in the 5.4L and 6.8L engines), injector issues in the 7.3L Diesel, and exhaust manifold leaks. Transmission issues range from torque converter problems in the automatic to clutch and synchro wear in the manual. Suspension components like ball joints and leaf springs are also prone to wear. Electrical problems, such as instrument cluster malfunctions and alternator failures, can occur. Frame and body rust are also concerns, particularly in regions with harsh winters. Repair costs can vary significantly depending on the specific issue and the extent of the damage, ranging from a few hundred dollars to several thousand for major repairs like engine or transmission rebuilds. The severity of these issues can range from minor inconveniences to significant drivability problems, so a thorough inspection is recommended before purchasing a used 2002 F-250.

Ford, F-250
Ford F-250 2002
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