2002 Ford F-350
The 2002 Ford F-350 is a heavy-duty pickup truck known for its robust capabilities and workhorse reputation. Engine options included the 5.4L Triton V8, the 6.8L Triton V10, and the highly regarded 7.3L Power Stroke Turbo Diesel V8. The 7.3L Power Stroke produced around 275 horsepower and 525 lb-ft of torque, and it is known for its reliability and longevity, making it a highly desirable engine. The 2002 F-350 was offered with either a 5-speed manual or a 4-speed automatic transmission, depending on the engine. Owners often praise the truck’s towing capacity and durability, while common complaints include issues related to age, such as rust, worn suspension components, and general maintenance items associated with older vehicles. This list of issues is not exhaustive and may not apply to every 2002 Ford F-350.
Engine
7.3L Power Stroke Turbo Diesel V8
- Injector Issues
- Description/Symptoms: Rough running engine, misfires, black smoke, reduced power. Injectors may fail due to age and wear, especially with poor fuel quality.
- Solution: Replace faulty injectors. It is recommended to replace all injectors at the same time if one fails.
- Estimated Cost to Fix: $200 - $400+ per injector installed
- Cam Position Sensor Failure
- Description/Symptoms: Stalling, rough running, no-start condition.
- Solution: Replace the cam position sensor.
- Estimated Cost to Fix: $50 - $150+
- Fuel Bowl Leaks
- Description/Symptoms: Fuel smell, fuel leaking from under the hood, especially near the fuel filter housing.
- Solution: Replace the fuel bowl seals or the entire fuel bowl assembly.
- Estimated Cost to Fix: $50 - $300+
- ICP (Injection Control Pressure) Sensor Failure
- Description/Symptoms: Rough idle, stalling, poor performance, no-start condition.
- Solution: Replace the ICP sensor.
Estimated Cost to Fix: $100 - $250+
- Recalls: None Found
5.4L Triton V8
- Spark Plug Blowout
- Description/Symptoms: Loud popping noise, sudden loss of power, spark plug ejected from the cylinder head. This is due to insufficient threads in the cylinder head for the spark plugs, a common issue for early 5.4L engines.
- Solution: Repair the cylinder head threads with a thread repair kit (Time-Sert is a popular brand) or replace the cylinder head.
- Estimated Cost to Fix: $300 - $1500+
- Oil Leaks (Valve Cover Gaskets, Oil Pan Gasket)
- Description/Symptoms: Visible oil leaks, oil consumption, burning oil smell.
- Solution: Replace the leaking gaskets.
Estimated Cost to Fix: $150 - $500+
- Recalls: None Found
6.8L Triton V10
- Exhaust Manifold Leaks/Cracks
- Description/Symptoms: Ticking noise, especially when the engine is cold, exhaust smell, reduced fuel economy.
- Solution: Replace the exhaust manifold and gaskets. Broken exhaust manifold studs are also common and may need to be extracted.
- Estimated Cost to Fix: $300 - $800+
- Spark Plug Blowout
- Description/Symptoms: Loud popping noise, sudden loss of power, spark plug ejected from the cylinder head. This is due to insufficient threads in the cylinder head for the spark plugs, a common issue for early Triton engines.
- Solution: Repair the cylinder head threads with a thread repair kit (Time-Sert is a popular brand) or replace the cylinder head.
Estimated Cost to Fix: $300 - $1500+
- Recalls: None Found
Transmission
4R100 4-Speed Automatic (Typically paired with 7.3L Diesel)
- Torque Converter Failure
- Description/Symptoms: Shuddering, slipping, difficulty shifting, complete loss of drive.
- Solution: Replace the torque converter. It’s recommended to flush the transmission cooler lines and replace the transmission fluid and filter.
- Estimated Cost to Fix: $800 - $2000+
- Valve Body Issues
- Description/Symptoms: Hard shifting, delayed engagement, slipping between gears.
- Solution: Replace or rebuild the valve body.
Estimated Cost to Fix: $500 - $1200+
- Recalls: None Found
ZF5 5-Speed Manual (Typically paired with 7.3L Diesel)
- Clutch Failure
- Description/Symptoms: Clutch slippage, difficulty shifting, grinding gears, clutch pedal issues.
- Solution: Replace the clutch disc, pressure plate, and throwout bearing. Consider replacing the flywheel as well.
- Estimated Cost to Fix: $500 - $1500+
- Synchro Wear
- Description/Symptoms: Grinding when shifting into specific gears, especially 2nd or 3rd.
- Solution: Rebuild or replace the transmission.
Estimated Cost to Fix: $1500 - $4000+
- Recalls: None Found
4R70W/4R75W 4-Speed Automatic (Typically paired with 5.4L & 6.8L Gasoline Engines)
- Slipping between gears
- Description/Symptoms: Engine revving high before gears change, difficulty maintaining speed, delayed engagement
- Solution: Replace valve body or replace transmission.
Estimated Cost to Fix: $500 - $2500+
- Recalls: None Found
Suspension
- Leaf Spring Sagging/Broken Leaves
- Description/Symptoms: Vehicle sitting lower than normal, especially in the rear, rough ride, clunking noises.
- Solution: Replace the leaf spring pack.
- Estimated Cost to Fix: $300 - $800+ per side
- Ball Joint Wear/Failure
- Description/Symptoms: Loose steering, wandering, clunking noises when going over bumps, uneven tire wear.
- Solution: Replace the ball joints.
- Estimated Cost to Fix: $200 - $600+ per side
- Tie Rod End Wear/Failure
- Description/Symptoms: Loose steering, wandering, uneven tire wear.
- Solution: Replace the tie rod ends.
Estimated Cost to Fix: $100 - $400+ per side
- Recalls: None Found
Electrical
- GEM (Generic Electronic Module) Failure
- Description/Symptoms: Intermittent issues with power windows, power door locks, wipers, interior lights.
- Solution: Replace the GEM. Programming may be required.
- Estimated Cost to Fix: $300 - $800+
- Alternator Failure
- Description/Symptoms: Dimming lights, battery not charging, battery light on, stalling.
- Solution: Replace the alternator.
- Estimated Cost to Fix: $150 - $400+
- Window Motor Failure
- Description/Symptoms: Window will not go up or down.
- Solution: Replace the window motor.
Estimated Cost to Fix: $150 - $300+
- Recalls: None Found
Exterior
- Rust (Cab Corners, Rocker Panels, Wheel Wells)
- Description/Symptoms: Visible rust, especially in areas prone to moisture and road salt exposure.
- Solution: Rust repair, body panel replacement.
- Estimated Cost to Fix: $200 - $2000+ depending on the severity.
- Door Handle Breakage
- Description/Symptoms: Door handle breaks when attempting to open the door.
- Solution: Replace the door handle.
Estimated Cost to Fix: $50 - $200+
- Recalls: None Found
Interior
- Dashboard Cracks
- Description/Symptoms: Cracks forming in the dashboard due to sun exposure and age.
- Solution: Replace the dashboard or install a dash cover.
- Estimated Cost to Fix: $100 - $800+
- Headliner Sagging
- Description/Symptoms: The headliner fabric detaches from the backing and sags.
- Solution: Replace the headliner.
Estimated Cost to Fix: $200 - $500+
- Recalls: None Found
Summary
The 2002 Ford F-350, while a robust and capable truck, is subject to age-related issues. Engine problems, particularly with the 7.3L Power Stroke, often revolve around fuel delivery and sensor failures. The Triton engines can suffer from spark plug issues and exhaust leaks. Transmission problems vary depending on the model, with torque converter and valve body issues being common in the automatics, and clutch/synchro wear being issues with the manuals. Suspension components wear out over time, requiring replacement of springs, ball joints, and tie rod ends. Electrical glitches can arise from the GEM, alternator, or window motors. Exterior rust is a significant concern, and interior components like dashboards and headliners can deteriorate. The severity and cost of these issues can range from minor repairs to major overhauls, so a thorough inspection is recommended before purchasing a 2002 F-350.