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2002 Ford F-450 Super Duty

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By Research the Car 6 min read

Here’s a breakdown of common issues and complaints for the 2002 Ford F-450 Super Duty, formatted for your website.

The 2002 Ford F-450 Super Duty is a heavy-duty work truck known for its towing and hauling capabilities. Engine options included the 7.3L Power Stroke Turbo Diesel V8 (275 hp, 525 lb-ft torque), the 6.8L Triton V10 (310 hp, 425 lb-ft torque), and the 5.4L Triton V8 (260 hp, 350 lb-ft torque). Transmission options were generally a 4-speed automatic or a 5-speed manual, depending on the engine. Owners often praise the truck’s robust build and ability to handle tough jobs, but complaints often center around fuel economy (especially with the V10), ride quality, and the age-related maintenance issues common to older vehicles.

Engine

7.3L Power Stroke Turbo Diesel V8

  • Injector Problems
    • Description/Symptoms: Hard starting, rough idling, excessive black smoke, loss of power, poor fuel economy. Can be caused by worn injectors or a faulty Injection Control Pressure (ICP) sensor.
    • Solution: Replace faulty injectors (individually or as a set) or replace the ICP sensor.
    • Estimated Cost to Fix: $200 - $400+ per injector (parts and labor), $100-$200 for the ICP sensor (parts and labor).
    • Recalls: None Found
  • Cam Position Sensor (CPS) Failure
    • Description/Symptoms: Stalling, rough running, no-start condition. The CPS provides critical timing information to the engine control module.
    • Solution: Replace the CPS.
    • Estimated Cost to Fix: $50 - $150 (parts and labor).
    • Recalls: None Found
  • Turbocharger Issues
    • Description/Symptoms: Lack of power, excessive black smoke, whistling noises from the turbo, possible oil leaks. Could indicate a failing turbocharger, boost leaks, or issues with the wastegate actuator.
    • Solution: Inspect the turbocharger and related components (hoses, clamps, wastegate). Replace or rebuild the turbocharger if necessary.
    • Estimated Cost to Fix: $100 (hose replacement), $200-$400 (wastegate actuator), $800-$2000+ (turbocharger replacement).
    • Recalls: None Found

6.8L Triton V10

  • Spark Plug Issues
    • Description/Symptoms: Misfires, rough idling, poor acceleration, check engine light. The 2-valve V10s, in particular, were prone to spark plugs breaking upon removal due to seizing in the cylinder head.
    • Solution: Careful removal of spark plugs (using penetrating oil and proper technique). Replacement with new plugs. Thread repair may be necessary if damage occurs.
    • Estimated Cost to Fix: $200 - $500+ (depending on the number of plugs that need to be replaced or if thread repair is needed).
    • Recalls: None Found
  • Exhaust Manifold Leaks
    • Description/Symptoms: Ticking or hissing noise from the engine, especially when cold. Reduced fuel economy. Broken exhaust manifold studs are common.
    • Solution: Replace the exhaust manifold and broken studs.
    • Estimated Cost to Fix: $400 - $800+ (parts and labor).
    • Recalls: None Found

5.4L Triton V8

  • Spark Plug Issues
    • Description/Symptoms: Misfires, rough idling, poor acceleration, check engine light. The 2-valve V8s, in particular, were prone to spark plugs breaking upon removal due to seizing in the cylinder head.
    • Solution: Careful removal of spark plugs (using penetrating oil and proper technique). Replacement with new plugs. Thread repair may be necessary if damage occurs.
    • Estimated Cost to Fix: $200 - $500+ (depending on the number of plugs that need to be replaced or if thread repair is needed).
    • Recalls: None Found
  • Exhaust Manifold Leaks
    • Description/Symptoms: Ticking or hissing noise from the engine, especially when cold. Reduced fuel economy. Broken exhaust manifold studs are common.
    • Solution: Replace the exhaust manifold and broken studs.
    • Estimated Cost to Fix: $400 - $800+ (parts and labor).
    • Recalls: None Found

Transmission

4R100 4-Speed Automatic Transmission

  • Harsh Shifting/Slipping
    • Description/Symptoms: Erratic or delayed shifts, slipping between gears, particularly when towing or under heavy load. Can be caused by worn clutches, valve body issues, or low fluid level.
    • Solution: Check and adjust fluid level, replace valve body, or rebuild the transmission.
    • Estimated Cost to Fix: $50-$100 (fluid), $300 - $600 (valve body), $2000-$4000+ (transmission rebuild).
    • Recalls: None Found
  • Torque Converter Problems
    • Description/Symptoms: Shuddering at low speeds, especially when accelerating. Can also cause poor fuel economy.
    • Solution: Replace the torque converter.
    • Estimated Cost to Fix: $500 - $1000+ (parts and labor).
    • Recalls: None Found

ZF5 5-Speed Manual Transmission

  • Hard Shifting/Grinding
    • Description/Symptoms: Difficulty shifting into gear, grinding noises during shifts, especially in higher gears. This can be caused by worn synchronizers.
    • Solution: Replace synchronizers or rebuild the transmission.
    • Estimated Cost to Fix: $1000-$3000+ (transmission rebuild).
    • Recalls: None Found
  • Clutch Failure
    • Description/Symptoms: Slipping clutch, difficulty engaging or disengaging gears, unusual noises.
    • Solution: Replace the clutch disc, pressure plate, and throw-out bearing.
    • Estimated Cost to Fix: $500 - $1200+ (parts and labor).
    • Recalls: None Found

Suspension

  • Worn Ball Joints/Tie Rod Ends
    • Description/Symptoms: Loose steering, wandering on the road, clunking noises from the front end, uneven tire wear.
    • Solution: Replace worn ball joints and/or tie rod ends.
    • Estimated Cost to Fix: $200 - $500+ per side (parts and labor).
    • Recalls: None Found
  • Leaf Spring Sagging/Broken Leaves
    • Description/Symptoms: Reduced load-carrying capacity, rough ride, vehicle leaning to one side.
    • Solution: Replace leaf springs (individually or as a set).
    • Estimated Cost to Fix: $300 - $800+ per spring (parts and labor).
    • Recalls: None Found

Electrical

  • Alternator Failure
    • Description/Symptoms: Dimming lights, slow cranking, dead battery, check engine light.
    • Solution: Replace the alternator.
    • Estimated Cost to Fix: $200 - $400+ (parts and labor).
    • Recalls: None Found
  • Glow Plug Issues (Diesel Engines)
    • Description/Symptoms: Hard starting in cold weather, excessive white smoke on startup, rough idling. Faulty glow plugs or a glow plug control module can be the cause.
    • Solution: Replace faulty glow plugs or the glow plug control module.
    • Estimated Cost to Fix: $50 - $150 per glow plug (parts and labor), $100-$300 for the glow plug control module (parts and labor).
    • Recalls: None Found

Exterior

  • Rust
    • Description/Symptoms: Rust on the frame, body panels, and undercarriage. Common areas include wheel wells, rocker panels, and the bottom of doors.
    • Solution: Rust repair, including sanding, patching, and painting.
    • Estimated Cost to Fix: Highly variable depending on severity. Can range from a few hundred dollars for minor repairs to several thousand for extensive rust remediation.
    • Recalls: None Found

Interior

  • Cracked Dashboard
    • Description/Symptoms: Cracking and splitting of the dashboard plastic, especially in hot climates.
    • Solution: Dash cover, dashboard replacement.
    • Estimated Cost to Fix: $50-$150 (dash cover), $500-$1000+ (dashboard replacement).
    • Recalls: None Found
  • Power Window/Door Lock Issues
    • Description/Symptoms: Intermittent or non-functional power windows or door locks. This can be caused by faulty switches, wiring problems, or failing window regulators.
    • Solution: Replace faulty switches, repair wiring, or replace window regulators.
    • Estimated Cost to Fix: $50 - $200 per switch, $100-$300+ for wiring repairs, $200 - $500+ per window regulator.
    • Recalls: None Found

Summary

The 2002 Ford F-450 Super Duty is a capable truck, but due to its age, it’s prone to certain issues. Engine problems, especially related to the diesel injectors, spark plugs, and exhaust manifolds, can be costly. Transmission issues, particularly in the automatic models, are also common. Suspension wear is typical for a truck of this age. Rust can be a significant concern, depending on the vehicle’s history and location. Overall, potential buyers should carefully inspect the truck and be prepared for potential maintenance and repair costs. While some fixes are relatively inexpensive, major repairs like engine or transmission overhauls can be significant investments.

Ford, F-450 Super Duty
Ford F-450 Super Duty 2002
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