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2002 Ford F750

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By Research the Car 4 min read

The 2002 Ford F750 is a medium-duty truck designed for commercial applications, known for its robust build and versatility. Engine options for this model year include the Caterpillar 3126 diesel engine, which produces approximately 300-330 horsepower and 860 lb-ft of torque, and the Cummins ISB engine. Transmission options include various manual and automatic transmissions. Owners often appreciate the truck’s durability and workhorse capabilities, but some dislike its fuel consumption and maintenance costs associated with commercial vehicles. The information below highlights common issues reported by owners and mechanics for the 2002 Ford F750.

Engine

Caterpillar 3126 Diesel Engine

  • Injector Failure
    • Description/Symptoms: Rough idling, black smoke, reduced power, and potential misfires. Can lead to engine damage if not addressed promptly.
    • Solution: Replace faulty injectors with new or remanufactured units. Recalibrate the ECM (Engine Control Module) after injector replacement.
    • Estimated Cost to Fix: $400 - $800+ per injector, plus labor.
    • Recalls: None Found
  • HEUI (Hydraulic Electronic Unit Injector) Pump Failure
    • Description/Symptoms: Hard starting, poor engine performance, stalling, and potential complete engine shutdown. Loss of power and decreased fuel efficiency.
    • Solution: Replace the HEUI pump with a new or remanufactured unit. Verify proper oil pressure and quality after replacement.
    • Estimated Cost to Fix: $1200 - $2500+, plus labor.
    • Recalls: None Found
  • Turbocharger Issues
    • Description/Symptoms: Whining noise from the turbo, loss of power, excessive black smoke, and potential oil leaks.
    • Solution: Inspect the turbocharger for damaged vanes or bearings. Replace the turbocharger if necessary.
    • Estimated Cost to Fix: $800 - $2000+, plus labor.
    • Recalls: None Found

Cummins ISB Engine

  • Lift Pump Failure
    • Description/Symptoms: Hard starting, stalling, loss of power, and potentially complete engine shutdown.
    • Solution: Replace the lift pump with an updated unit. Ensure proper fuel filtration to prevent future issues.
    • Estimated Cost to Fix: $200 - $500+, plus labor.
    • Recalls: None Found
  • Fuel Injector Issues
    • Description/Symptoms: Rough idling, black smoke, reduced power, misfires. Can lead to engine damage if not addressed.
    • Solution: Replace the faulty injectors with new or remanufactured units. Recalibrate the ECM after injector replacement.
    • Estimated Cost to Fix: $300 - $700+ per injector, plus labor.
    • Recalls: None Found

Transmission

Automatic Transmission (Allison)

  • Shift Flare/Slippage
    • Description/Symptoms: Delayed or erratic shifting, RPM flare between gears, and eventual transmission failure.
    • Solution: Diagnose and repair valve body issues. Replace worn clutches and seals. Complete transmission rebuild or replacement may be necessary.
    • Estimated Cost to Fix: $500 (valve body repair) - $4000+ (rebuild/replacement).
    • Recalls: None Found
  • Torque Converter Issues
    • Description/Symptoms: Shuddering at low speeds, poor acceleration, overheating, and potential transmission failure.
    • Solution: Replace the torque converter. Inspect transmission for damage.
    • Estimated Cost to Fix: $800 - $2000+, plus labor.
    • Recalls: None Found

Manual Transmission

  • Clutch Failure
    • Description/Symptoms: Slipping clutch, difficulty shifting, unusual noises, and inability to engage gears properly.
    • Solution: Replace the clutch disc, pressure plate, and throw-out bearing. Resurface or replace the flywheel.
    • Estimated Cost to Fix: $800 - $2000+, plus labor.
    • Recalls: None Found

Suspension

  • Leaf Spring Sagging/Breakage
    • Description/Symptoms: Vehicle leaning to one side, rough ride, reduced load capacity, and potential safety hazard.
    • Solution: Replace the leaf springs with new or heavy-duty units. Inspect and replace worn shackles and bushings.
    • Estimated Cost to Fix: $500 - $1500+ per spring, plus labor.
    • Recalls: None Found
  • Worn Shocks/Struts
    • Description/Symptoms: Excessive bouncing, poor handling, reduced stability, and increased tire wear.
    • Solution: Replace the shocks/struts with new or heavy-duty units.
    • Estimated Cost to Fix: $200 - $600+ per axle, plus labor.
    • Recalls: None Found

Electrical

  • Wiring Harness Issues
    • Description/Symptoms: Intermittent electrical problems, such as lights flickering, gauges malfunctioning, and starting problems. Corrosion and frayed wires are common.
    • Solution: Inspect and repair damaged wiring. Replace sections of the wiring harness if necessary. Clean and protect electrical connections.
    • Estimated Cost to Fix: $100 - $1000+, depending on the severity and location of the damage.
    • Recalls: None Found
  • Alternator Failure
    • Description/Symptoms: Dimming lights, dead battery, and charging system warning light.
    • Solution: Replace the alternator with a new or remanufactured unit. Check the battery and charging system for other potential issues.
    • Estimated Cost to Fix: $300 - $800+, plus labor.
    • Recalls: None Found

Exterior

  • Rust
    • Description/Symptoms: Rust forming on the undercarriage, body panels, and around the wheel wells.
    • Solution: Remove rust, repair damaged metal, and apply rust preventative coatings.
    • Estimated Cost to Fix: $100 - $3000+ depending on the severity.
    • Recalls: None Found

Interior

  • HVAC Issues
    • Description/Symptoms: Blower motor failure, weak airflow, and temperature control problems.
    • Solution: Replace the blower motor, resistor, or control module. Repair or replace damaged vacuum lines.
    • Estimated Cost to Fix: $100 - $500+, plus labor.
    • Recalls: None Found

Summary

The 2002 Ford F750, while a robust and capable truck, does have some common issues to be aware of. Engine-related problems, particularly with the Caterpillar 3126 (injector/HEUI pump failure) and Cummins ISB (lift pump) engines, can be costly to repair. Transmission issues, such as shift flare in automatic transmissions, also contribute to potential expenses. Suspension issues are also not uncommon in these work vehicles. Electrical problems, especially related to wiring, and rust can also arise. Overall, potential buyers should thoroughly inspect the vehicle, particularly the engine, transmission, and suspension, and consider the potential costs of repairs when making a purchase decision.

Ford, F750
Ford F750 2002
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