2003 Ford F-350 Super Duty

The 2003 Ford F-350 Super Duty is a heavy-duty pickup truck known for its robust capabilities and workhorse nature. Engine options for this year included the 5.4L Triton V8, the 6.8L Triton V10, and the formidable 7.3L Power Stroke Turbo Diesel (early 2003) or the 6.0L Power Stroke Turbo Diesel (late 2003). The 7.3L produced around 275 horsepower and 525 lb-ft of torque. Transmission options consisted of a 5-speed manual and a 4-speed automatic. Owners often praise the truck’s towing capacity and durability, especially those equipped with the 7.3L diesel. Common complaints revolve around the reliability of certain components, particularly in later model 6.0L diesels, and the age-related issues that come with owning a 20+ year old vehicle.

Engine

7.3L Power Stroke Turbo Diesel

• Cam Position Sensor Failure
  • Description/Symptoms: Stalling, rough running, or complete failure to start.
  • Solution: Replace the cam position sensor.
  • Estimated Cost to Fix: $50 - $150
  • Recalls: None Found
• Injector Issues
  • Description/Symptoms: Rough idle, poor fuel economy, excessive smoke, and lack of power. Can sometimes be heard in the form of a “cackle” from the engine.
  • Solution: Replace faulty injectors.
  • Estimated Cost to Fix: $200 - $400 per injector (parts and labor).
  • Recalls: None Found
• ICP Sensor Failure
  • Description/Symptoms: Intermittent Stalling, Poor fuel economy, Lack of power.
  • Solution: Replace the ICP sensor.
  • Estimated Cost to Fix: $100 - $250
  • Recalls: None Found

6.0L Power Stroke Turbo Diesel

• EGR Valve Problems
  • Description/Symptoms: Rough idling, poor performance, excessive black smoke, possible engine stalling.
  • Solution: Replace or clean the EGR valve.
  • Estimated Cost to Fix: $200 - $500
  • Recalls: None Found
• Oil Cooler Failure
  • Description/Symptoms: Overheating, coolant loss, oil contamination.
  • Solution: Replace the oil cooler.
  • Estimated Cost to Fix: $800 - $1500+ (due to labor involved)
  • Recalls: None Found
• Head Gasket Failure
  • Description/Symptoms: Overheating, coolant loss, white smoke from exhaust, bubbling in coolant reservoir. This is a very common and serious issue.
  • Solution: Replace head gaskets, consider head studs for increased reliability.
  • Estimated Cost to Fix: $3000 - $6000+
  • Recalls: None Found
• Injector Stiction
  • Description/Symptoms: Hard starting when cold, rough idle when cold, white smoke from exhaust when cold.
  • Solution: Replace injectors, or use a stiction removing oil additive
  • Estimated Cost to Fix: $200 - $400 per injector (parts and labor).
  • Recalls: None Found

5.4L Triton V8

• Spark Plug Ejection
  • Description/Symptoms: Loud popping noise, engine misfire, loss of power. This issue is more prevalent in early 5.4L Triton engines due to insufficient threads in the cylinder head.
  • Solution: Repair or replace the cylinder head, install thread inserts.
  • Estimated Cost to Fix: $500 - $2000+ depending on the extent of the damage.
  • Recalls: None Found
• Manifold Leaks
  • Description/Symptoms: Ticking noise from engine, especially when cold; exhaust smell.
  • Solution: Replace Exhaust Manifold and hardware
  • Estimated Cost to Fix: $300 - $800
  • Recalls: None Found

6.8L Triton V10

• Spark Plug Ejection
  • Description/Symptoms: Loud popping noise, engine misfire, loss of power. This issue is more prevalent in early Triton engines due to insufficient threads in the cylinder head.
  • Solution: Repair or replace the cylinder head, install thread inserts.
  • Estimated Cost to Fix: $500 - $2000+ depending on the extent of the damage.
  • Recalls: None Found

Transmission

4R100 4-Speed Automatic

• Torque Converter Failure
  • Description/Symptoms: Slipping, shuddering, poor acceleration, overheating.
  • Solution: Replace the torque converter.
  • Estimated Cost to Fix: $500 - $1500
  • Recalls: None Found
• Valve Body Issues
  • Description/Symptoms: Harsh or delayed shifting, slipping between gears.
  • Solution: Rebuild or replace the valve body.
  • Estimated Cost to Fix: $400 - $1000
  • Recalls: None Found

ZF5 5-Speed Manual

No Issues Found

Suspension

• Ball Joint Wear
  • Description/Symptoms: Clunking or popping noises from the front end, uneven tire wear, loose steering.
  • Solution: Replace worn ball joints.
  • Estimated Cost to Fix: $200 - $600 per side
  • Recalls: None Found
• Leaf Spring Sag/Failure
  • Description/Symptoms: Rear end sagging, poor ride quality, reduced load capacity.
  • Solution: Replace leaf springs.
  • Estimated Cost to Fix: $300 - $800 per side
  • Recalls: None Found

Electrical

• GEM (Generic Electronic Module) Failure
  • Description/Symptoms: Issues with power windows, door locks, interior lights, wipers, and other electrical components.
  • Solution: Replace or repair the GEM.
  • Estimated Cost to Fix: $300 - $1000+ depending on the extent of the damage.
  • Recalls: None Found
• Alternator Failure
  • Description/Symptoms: Dimming lights, battery not charging, stalling.
  • Solution: Replace the alternator.
  • Estimated Cost to Fix: $200 - $500
  • Recalls: None Found

Exterior

• Rust
  • Description/Symptoms: Rust formation on the body panels, especially around wheel wells, rocker panels, and cab corners. This is accelerated in areas that experience road salt.
  • Solution: Repair or replace rusted panels, apply rust inhibitor.
  • Estimated Cost to Fix: Varies greatly depending on the extent of the rust. $200+ per area.
  • Recalls: None Found
• Door Handle Failure
  • Description/Symptoms: Door handle breaking or becoming difficult to use.
  • Solution: Replace door handle.
  • Estimated Cost to Fix: $50 - $200
  • Recalls: None Found

Interior

• Instrument Cluster Issues
  • Description/Symptoms: Gauges not working properly, flickering lights, complete cluster failure.
  • Solution: Repair or replace the instrument cluster.
  • Estimated Cost to Fix: $200 - $600
  • Recalls: None Found
• HVAC Blend Door Actuator Failure
  • Description/Symptoms: Inability to control temperature, only hot or cold air blowing.
  • Solution: Replace the blend door actuator.
  • Estimated Cost to Fix: $100 - $400
  • Recalls: None Found

Summary:

The 2003 Ford F-350 Super Duty, while a capable truck, suffers from several common issues that potential buyers should be aware of. The 6.0L Power Stroke diesel engine is particularly prone to expensive problems like head gasket and oil cooler failures. The 7.3L diesel, while generally more reliable, can still experience injector and sensor issues due to its age. Other common problems include suspension wear, electrical component failures, and rust. The severity and cost of these issues vary, but major engine or transmission repairs can easily exceed several thousand dollars. It is essential to thoroughly inspect any prospective purchase and consider a pre-purchase inspection by a qualified mechanic.