Post
Research the Car Logo

2002 Ford F-250 Super Duty

Posted
By Research the Car 5 min read

The 2002 Ford F-250 Super Duty is a heavy-duty pickup truck known for its robust capabilities and workhorse reputation. Available engine options included the 5.4L Triton V8, the 6.8L Triton V10, and the venerable 7.3L Power Stroke Turbo Diesel V8. A 4-speed automatic transmission (4R100) was the most common transmission option. The 7.3L Power Stroke, producing 275 horsepower and 525 lb-ft of torque, was a popular choice for its reliability and power. Owners often praise the truck’s towing capacity and ruggedness, while common complaints include fuel economy (especially with the gas engines) and rust issues, particularly in areas with road salt.

Engine

5.4L Triton V8

  • Spark Plug Blowout
    • Description/Symptoms: Spark plugs ejecting from the cylinder heads, resulting in a loud popping noise, misfires, and potential damage to the cylinder head threads.
    • Solution: Repairing the damaged cylinder head threads with thread inserts (e.g., Time-Sert or Heli-Coil) or replacing the cylinder head.
    • Estimated Cost to Fix: $500 - $1500+ (depending on repair method and whether the head needs to be replaced).
    • Recalls: None Found

6.8L Triton V10

  • Spark Plug Blowout
    • Description/Symptoms: Similar to the 5.4L, spark plugs ejecting from the cylinder heads, resulting in a loud popping noise, misfires, and potential damage to the cylinder head threads.
    • Solution: Repairing the damaged cylinder head threads with thread inserts (e.g., Time-Sert or Heli-Coil) or replacing the cylinder head.
    • Estimated Cost to Fix: $500 - $1500+ (depending on repair method and whether the head needs to be replaced).
    • Recalls: None Found
  • Exhaust Manifold Leaks/Cracks
    • Description/Symptoms: Exhaust leaks, often noticeable as a ticking noise that increases with engine speed, reduced fuel economy, and potentially a smell of exhaust fumes in the cabin.
    • Solution: Replacing the cracked or leaking exhaust manifold and gaskets.
    • Estimated Cost to Fix: $300 - $800+
    • Recalls: None Found

7.3L Power Stroke Turbo Diesel V8

  • Cam Position Sensor (CPS) Failure
    • Description/Symptoms: Stalling, rough running, or difficulty starting. The engine may cut out intermittently.
    • Solution: Replacing the Cam Position Sensor (CPS).
    • Estimated Cost to Fix: $50 - $200+
    • Recalls: None Found
  • Injector Issues
    • Description/Symptoms: Rough idle, white smoke, reduced power, and poor fuel economy. Can lead to cylinder misfires.
    • Solution: Replacing faulty injectors. It is often recommended to replace all injectors at the same time for balanced performance.
    • Estimated Cost to Fix: $200 - $400+ per injector, $1600-$3200 for all 8
    • Recalls: None Found
  • Fuel Bowl Drain Valve Leaks
    • Description/Symptoms: Diesel fuel leaking from the fuel bowl area, often noticeable after the engine is shut off.
    • Solution: Replacing the fuel bowl drain valve or the entire fuel bowl assembly.
    • Estimated Cost to Fix: $50 - $300+
    • Recalls: None Found

Transmission

4R100 4-Speed Automatic

  • Loss of 3rd and 4th Gear
    • Description/Symptoms: Transmission slipping, failure to shift into 3rd or 4th gear, or complete loss of forward movement.
    • Solution: Rebuilding or replacing the transmission. This often involves replacing worn clutches, bands, and potentially the valve body.
    • Estimated Cost to Fix: $1500 - $4000+
    • Recalls: None Found
  • Torque Converter Failure
    • Description/Symptoms: Shuddering, slipping, or complete transmission failure. Often accompanied by a burnt smell.
    • Solution: Replacing the torque converter. It’s usually recommended to also flush the transmission cooler lines and replace the transmission fluid and filter.
    • Estimated Cost to Fix: $500 - $1500+
    • Recalls: None Found
  • Shift Flare
    • Description/Symptoms: A momentary increase in engine RPM between shifts, particularly between 2nd and 3rd gear, before the next gear engages.
    • Solution: Can be caused by worn clutches, valve body issues, or low transmission fluid. A transmission flush and filter change may help, but a valve body rebuild or replacement may be necessary.
    • Estimated Cost to Fix: $100 (flush) - $1000+ (valve body)
    • Recalls: None Found

Suspension

  • Leaf Spring Sagging/Cracking
    • Description/Symptoms: Rear end sagging, reduced load capacity, rough ride, and visible cracks in the leaf springs.
    • Solution: Replacing the leaf springs, potentially with upgraded or heavy-duty options.
    • Estimated Cost to Fix: $400 - $1000+ per side
    • Recalls: None Found
  • Ball Joint Wear
    • Description/Symptoms: Clicking, popping, or squeaking noises from the front suspension, loose steering, and uneven tire wear.
    • Solution: Replacing worn ball joints.
    • Estimated Cost to Fix: $200 - $600+ per side
    • Recalls: None Found

Electrical

  • Alternator Failure
    • Description/Symptoms: Dimming headlights, warning lights on the dashboard, battery not charging, and potential stalling.
    • Solution: Replacing the alternator.
    • Estimated Cost to Fix: $200 - $500+
    • Recalls: None Found
  • Window Motor Failure
    • Description/Symptoms: Window not going up or down, slow or erratic window movement, or clicking noises from the door panel.
    • Solution: Replacing the window motor.
    • Estimated Cost to Fix: $150 - $400+
    • Recalls: None Found

Exterior

  • Rust (Body Panels, Frame)
    • Description/Symptoms: Rust forming on body panels (especially around wheel wells, rocker panels, and cab corners), as well as on the frame. Severe rust can compromise structural integrity.
    • Solution: Repairing or replacing rusted body panels, and treating the frame to prevent further rust. Frame replacement may be necessary in extreme cases.
    • Estimated Cost to Fix: $200 - $10,000+ (depending on severity and extent of rust).
    • Recalls: None Found

Interior

  • Dashboard Cracking
    • Description/Symptoms: Cracking and splitting of the dashboard, often due to sun exposure and temperature changes.
    • Solution: Replacing the dashboard or using a dashboard cover.
    • Estimated Cost to Fix: $200 - $1000+
    • Recalls: None Found

Summary

The 2002 Ford F-250 Super Duty, while a capable and popular truck, is prone to certain issues due to its age. Engine problems, particularly spark plug issues in the gasoline engines and injector problems in the 7.3L Power Stroke, can be costly. Transmission issues, such as loss of gears, require extensive repairs or replacements. Rust is a significant concern, especially in regions with harsh winters. Overall, potential buyers should carefully inspect the vehicle for these common issues and factor in potential repair costs. The severity and cost of these issues can range from relatively minor repairs (e.g., replacing a cam position sensor) to major overhauls (e.g., rebuilding the transmission or repairing significant rust damage).

Ford, F-250 Super Duty
Ford F-250 Super Duty 2002
This post is licensed under CC BY 4.0 by the author.