2002 Ford F-350 Super Duty

The 2002 Ford F-350 Super Duty is a robust workhorse known for its towing and hauling capabilities. Available engine options include the 5.4L Triton V8 (260 hp and 350 lb-ft of torque), the 6.8L Triton V10 (310 hp and 425 lb-ft of torque), and the legendary 7.3L Power Stroke Turbo Diesel V8 (275 hp and 525 lb-ft of torque, depending on the build date). Transmission choices consist of a 5-speed manual and a 4-speed automatic. Owners often praise the truck’s ruggedness and towing capacity, but common complaints revolve around fuel economy, particularly with the gasoline engines, and some model-year-specific reliability issues.

Engine

5.4L Triton V8

• Spark Plug Blowout
  • Description/Symptoms: Spark plugs can eject from the cylinder head due to weak aluminum threads. This can cause a loud popping noise, misfires, and loss of power.
  • Solution: Repairing the cylinder head threads with thread inserts (e.g., Time-Sert or Helicoil) or replacing the cylinder head.
  • Estimated Cost to Fix: $500 - $1500+ depending on the severity and repair method.
  • Recalls: None Found
• Exhaust Manifold Bolts Breaking
  • Description/Symptoms: Exhaust manifold bolts can break, causing exhaust leaks. This is often accompanied by a hissing sound and a decrease in fuel economy.
  • Solution: Replacing the broken bolts. May require drilling out broken bolts.
  • Estimated Cost to Fix: $300 - $800+ depending on the number of broken bolts and ease of access.
  • Recalls: None Found

6.8L Triton V10

• Spark Plug Blowout
  • Description/Symptoms: Similar to the 5.4L, spark plugs can eject from the cylinder head due to weak aluminum threads.
  • Solution: Repairing the cylinder head threads with thread inserts (e.g., Time-Sert or Helicoil) or replacing the cylinder head.
  • Estimated Cost to Fix: $500 - $1500+ depending on the severity and repair method.
  • Recalls: None Found
• Exhaust Manifold Bolts Breaking
  • Description/Symptoms: Similar to the 5.4L, exhaust manifold bolts can break, causing exhaust leaks.
  • Solution: Replacing the broken bolts. May require drilling out broken bolts.
  • Estimated Cost to Fix: $300 - $800+ depending on the number of broken bolts and ease of access.
  • Recalls: None Found

7.3L Power Stroke Turbo Diesel V8

• Cam Position Sensor Failure
  • Description/Symptoms: Stalling, rough running, and difficulty starting.
  • Solution: Replace the Cam Position Sensor.
  • Estimated Cost to Fix: $100 - $200+
  • Recalls: None Found
• ICP Sensor Failure
  • Description/Symptoms: Stalling, no start, and poor performance.
  • Solution: Replace the ICP (Injection Control Pressure) sensor.
  • Estimated Cost to Fix: $150 - $300+
  • Recalls: None Found
• Under Valve Cover Harness (UVCH) Issues
  • Description/Symptoms: Misfires, rough running, and injector problems. This is due to the clips that hold the wiring harness to the injectors coming loose.
  • Solution: Replace the UVCH, ensuring a secure connection.
  • Estimated Cost to Fix: $200 - $500+
  • Recalls: None Found

Transmission

4R100 4-Speed Automatic Transmission

• Torque Converter Failure
  • Description/Symptoms: Shuddering, slipping, and complete transmission failure.
  • Solution: Replace the torque converter. Often best to rebuild the entire transmission.
  • Estimated Cost to Fix: $500 - $2500+ depending on the extent of the damage and repairs.
  • Recalls: None Found
• Shift Solenoid Failure
  • Description/Symptoms: Erratic shifting, failure to shift, or getting stuck in a particular gear.
  • Solution: Replace the faulty shift solenoid(s).
  • Estimated Cost to Fix: $200 - $600+
  • Recalls: None Found

ZF5 5-Speed Manual Transmission

• No Issues Found

Suspension

• Leaf Spring Sagging/Failure
  • Description/Symptoms: Rear end sag, poor ride quality, reduced towing capacity.
  • Solution: Replace the leaf springs.
  • Estimated Cost to Fix: $500 - $1500+ depending on the quality of the replacement springs and if you replace all of the leaf springs.
  • Recalls: None Found
• Ball Joint Wear
  • Description/Symptoms: Clunking noises, steering wander, and uneven tire wear.
  • Solution: Replace the worn ball joints.
  • Estimated Cost to Fix: $300 - $1000+ depending on whether upper and lower ball joints need replacing.
  • Recalls: None Found

Electrical

• Instrument Cluster Issues
  • Description/Symptoms: Gauges malfunctioning (speedometer, fuel gauge, etc.), lights flickering, or complete cluster failure.
  • Solution: Repair or replace the instrument cluster.
  • Estimated Cost to Fix: $200 - $800+
  • Recalls: None Found
• GEM (Generic Electronic Module) Failure
  • Description/Symptoms: Intermittent electrical problems such as power windows not working, door locks malfunctioning, or alarm system issues.
  • Solution: Replace the GEM.
  • Estimated Cost to Fix: $300 - $800+
  • Recalls: None Found

Exterior

• Rust on Rocker Panels and Cab Corners
  • Description/Symptoms: Visible rust developing on rocker panels and cab corners, especially in areas with road salt use.
  • Solution: Cutting out the rusted metal, welding in new panels, and painting.
  • Estimated Cost to Fix: $500 - $2000+ depending on the extent of the rust.
  • Recalls: None Found

Interior

• Cracked Dash Pad
  • Description/Symptoms: Cracking on the dashboard pad, especially in sunny climates.
  • Solution: Dash pad replacement or using a dash cover.
  • Estimated Cost to Fix: $100 - $600+ depending on the method.
  • Recalls: None Found

Summary

The 2002 Ford F-350 Super Duty is a capable truck, but it’s essential to be aware of its potential issues. The spark plug blowout issue on the gasoline engines can be costly, while the diesel engine’s sensor and harness problems can lead to drivability concerns. Suspension and electrical issues are also common. Overall, while some issues are relatively minor, others can be expensive to repair, so a thorough inspection is recommended before purchasing.