2002 Ford F650

The 2002 Ford F650 is a medium-duty truck known for its robust capabilities and commercial applications. It was available with several engine options including the Caterpillar 3126 diesel, the Cummins ISB diesel, and the Ford 6.8L V10 gasoline engine. The horsepower and torque varied depending on the specific engine and tuning, but the Caterpillar 3126 commonly produced between 175-330 horsepower and 420-860 lb-ft of torque. Transmission options included manual and automatic transmissions such as the Allison 2000 series. Owners appreciate the F650’s towing capacity and durability, but common complaints often revolve around the cost of maintenance, fuel economy, and the truck’s large size making it difficult to maneuver in tight spaces.

Engine

Caterpillar 3126

• Injector Failure
  • Description/Symptoms: Rough running, excessive black smoke, decreased fuel economy, engine misfires, and possible complete engine shutdown.
  • Solution: Replace faulty injectors. Consider replacing all injectors at once to ensure balanced performance.
  • Estimated Cost to Fix: $400-$800+ per injector.
  • Recalls: None Found
• Turbocharger Issues
  • Description/Symptoms: Whining or screeching noises from the turbo, loss of power, excessive black smoke, and potential oil leaks.
  • Solution: Inspect the turbocharger for damage or wear. Replace the turbocharger if necessary.
  • Estimated Cost to Fix: $1,500 - $3,000+ depending on the turbocharger model and labor.
  • Recalls: None Found
• HEUI (Hydraulic Electronic Unit Injector) Pump Failure
  • Description/Symptoms: Hard starting, rough idle, loss of power, and potential engine stalling. This pump provides the high-pressure oil needed to operate the fuel injectors.
  • Solution: Replace the HEUI pump.
  • Estimated Cost to Fix: $1,000 - $2,500+
  • Recalls: None Found

Cummins ISB

• Lift Pump Failure
  • Description/Symptoms: Hard starting, loss of power, and engine stalling.
  • Solution: Replace the lift pump.
  • Estimated Cost to Fix: $200 - $500
  • Recalls: None Found
• ECM Failure
  • Description/Symptoms: Intermittent engine problems, random error codes, engine stalling.
  • Solution: Replace ECM, reprogramming may be required.
  • Estimated Cost to Fix: $1,000 - $3,000
  • Recalls: None Found

Ford 6.8L V10

• Spark Plug Thread Failure
  • Description/Symptoms: Ticking noise, loss of power, potential for spark plug to be ejected from the cylinder head.
  • Solution: Repair or replace the cylinder head. Time-Sert kits can be used to repair the threads.
  • Estimated Cost to Fix: $500 - $2,500+ depending on the repair method and the number of affected cylinders.
  • Recalls: None Found
• Exhaust Manifold Leaks
  • Description/Symptoms: Ticking noise, especially when the engine is cold, decreased fuel economy.
  • Solution: Replace the exhaust manifold and gaskets.
  • Estimated Cost to Fix: $400 - $1,000+
  • Recalls: None Found

Transmission

Allison 2000 Series

• Shift Solenoid Failure
  • Description/Symptoms: Erratic shifting, failure to shift into certain gears, transmission slipping.
  • Solution: Replace the faulty shift solenoids.
  • Estimated Cost to Fix: $500 - $1,500+
  • Recalls: None Found
• Torque Converter Failure
  • Description/Symptoms: Transmission slipping, shuddering, overheating, and decreased fuel economy.
  • Solution: Replace the torque converter.
  • Estimated Cost to Fix: $1,000 - $3,000+
  • Recalls: None Found
• Internal Clutch Wear
  • Description/Symptoms: Transmission slipping, delayed engagement, and overheating.
  • Solution: Transmission rebuild or replacement.
  • Estimated Cost to Fix: $3,000 - $7,000+
  • Recalls: None Found

Suspension

• Leaf Spring Sagging/Cracking
  • Description/Symptoms: Vehicle sitting lower on one side, poor ride quality, and clunking noises from the suspension.
  • Solution: Replace the worn or damaged leaf springs.
  • Estimated Cost to Fix: $500 - $2,000+ per spring depending on the type of spring and labor.
  • Recalls: None Found
• Worn Shocks/Struts
  • Description/Symptoms: Bouncy ride, excessive body roll, and poor handling.
  • Solution: Replace the worn shocks/struts.
  • Estimated Cost to Fix: $200 - $800+ per axle depending on the type of shocks/struts and labor.
  • Recalls: None Found

Electrical

• Wiring Harness Issues
  • Description/Symptoms: Intermittent electrical problems, such as lights flickering, gauges not working, and engine starting problems.
  • Solution: Inspect the wiring harness for damage or corrosion. Repair or replace the damaged sections of the harness.
  • Estimated Cost to Fix: $200 - $1,000+ depending on the extent of the damage.
  • Recalls: None Found
• Alternator Failure
  • Description/Symptoms: Dimming lights, slow engine cranking, and a dead battery.
  • Solution: Replace the alternator.
  • Estimated Cost to Fix: $300 - $800+
  • Recalls: None Found

Exterior

• Rust
  • Description/Symptoms: Rust on the body panels, frame, and undercarriage.
  • Solution: Repair or replace the rusted panels. Apply rust prevention coatings.
  • Estimated Cost to Fix: Varies greatly depending on the extent of the rust damage. $500 - $5,000+
  • Recalls: None Found

Interior

• Seat Upholstery Damage
  • Description/Symptoms: Tears or rips in the fabric.
  • Solution: Replace the upholstery.
  • Estimated Cost to Fix: $200 - $1,500+
  • Recalls: None Found

Summary:

The 2002 Ford F650, while a capable truck, can suffer from issues across its engine, transmission, suspension, electrical, exterior, and interior systems. Engine problems with the Caterpillar, Cummins, and Ford V10 engines can be costly, especially injector or turbocharger replacements. Transmission issues, particularly with the Allison 2000 series, are also potentially expensive. Suspension and electrical issues can be moderate in cost, but rust and interior repairs can vary significantly based on severity. Overall, potential buyers should thoroughly inspect the vehicle and budget for potential repairs.