2002 Ford F-350

2002 Ford F-350

Overview

The 2002 Ford F-350, a heavy-duty pickup truck, was designed for demanding work and towing. It offered robust powertrain options and a sturdy chassis, reflecting its purpose-built nature. While generally considered reliable for its class, like any vehicle of this age, specific components can experience issues. This analysis focuses on common mechanical and electrical concerns reported by owners, excluding routine maintenance. Understanding these potential problem areas can help owners anticipate and address repairs, ensuring the continued operational capability of their F-350.

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Engine

5.4L Triton V8

Spark Plug Blowout

• Symptoms: Loss of power, rough idling, misfires, audible popping sound from engine.
• Solution: Requires re-threading spark plug holes with inserts or replacing cylinder heads.
• Cost: $600 - $1200

Intake Manifold Gasket Leaks

• Symptoms: Coolant leaks, engine overheating, rough idle, check engine light.
• Solution: Replacement of intake manifold gaskets.
• Cost: $400 - $700

6.8L Triton V10

Spark Plug Blowout

• Symptoms: Loss of power, rough idling, misfires, audible popping sound from engine.
• Solution: Requires re-threading spark plug holes with inserts or replacing cylinder heads.
• Cost: $600 - $1200

Intake Manifold Gasket Leaks

• Symptoms: Coolant leaks, engine overheating, rough idle, check engine light.
• Solution: Replacement of intake manifold gaskets.
• Cost: $400 - $700

7.3L Power Stroke Diesel

Injector O-ring Leaks

• Symptoms: Hard starting, rough idle, diesel fuel smell in coolant, white smoke from exhaust.
• Solution: Replacement of injector O-rings and seals.
• Cost: $500 - $1000

Turbocharger Issues

• Symptoms: Loss of power, excessive smoke, whistling noises, turbo not spooling.
• Solution: Repair or replacement of the turbocharger assembly.
• Cost: $1000 - $2500

Transmission

4R100 Automatic (Gas & Diesel)

Torque Converter Clutch (TCC) Issues

• Symptoms: Shuddering at highway speeds, slipping, failure to engage or disengage.
• Solution: Rebuild or replacement of the torque converter and transmission.
• Cost: $1500 - $3000

Overheating

• Symptoms: Transmission slipping, delayed shifting, burning smell.
• Solution: Transmission cooler flush and replacement, potential transmission rebuild.
• Cost: $500 - $1500

5-Speed Manual (ZF S6-650)

No Major Issues

• Symptoms: No widespread issues reported.
• Solution: No widespread issues reported.
• Cost: No widespread issues reported.

Suspension

Standard Chassis

Leaf Spring Breakage

• Symptoms: Sagging rear end, uneven ride height, clunking noises over bumps.
• Solution: Replacement of broken leaf springs.
• Cost: $400 - $800

Ball Joint Wear

• Symptoms: Clunking noises, steering wander, uneven tire wear.
• Solution: Replacement of worn ball joints.
• Cost: $300 - $600

Electrical

General Electrical System

Alternator Failure

• Symptoms: Dimming headlights, battery warning light, electrical components malfunctioning.
• Solution: Replacement of the alternator.
• Cost: $400 - $700

Wiring Harness Issues

• Symptoms: Intermittent electrical problems, non-functioning accessories, short circuits.
• Solution: Diagnosis and repair/replacement of damaged wiring sections.
• Cost: $300 - $800

Exterior

Body and Trim

Rust and Corrosion

• Symptoms: Visible rust on body panels, frame, wheel wells, and undercarriage.
• Solution: Rust treatment, panel replacement, or undercoating.
• Cost: $200 - $1500+

Tailgate Latch Issues

• Symptoms: Difficulty opening or closing tailgate, spontaneous opening.
• Solution: Lubrication or replacement of tailgate latch mechanism.
• Cost: $100 - $300

Interior

Cabin Components

HVAC Blower Motor Failure

• Symptoms: No air conditioning or heat from vents, intermittent fan operation.
• Solution: Replacement of the blower motor or resistor.
• Cost: $200 - $400

Door Lock Actuator Failure

• Symptoms: Power locks not working on one or more doors, manual operation required.
• Solution: Replacement of faulty door lock actuators.
• Cost: $150 - $300

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Summary Verdict

The 2002 Ford F-350 is a capable heavy-duty truck, but owners should be aware of potential issues, particularly with the gasoline Triton V8 engines (spark plug blowout, intake manifold leaks) and the 4R100 automatic transmission (TCC issues, overheating). The robust 7.3L Power Stroke diesel is generally more reliable but can face injector O-ring or turbocharger problems. Suspension components like leaf springs and ball joints may require attention due to age and load. Electrical issues such as alternator failure are also noted. While rust can be a concern on older models, the core mechanicals, especially the diesel powertrain and manual transmission, are often durable with proper maintenance. Addressing these common issues proactively can ensure the longevity of the F-350.