2003 Ford F650

The 2003 Ford F650 is a medium-duty truck known for its robust build and capability. Available engine options include the Caterpillar 3126 diesel engine, the Cummins ISB diesel engine, and the Ford 6.8L V10 gasoline engine. The Caterpillar 3126 produced around 300 horsepower and 860 lb-ft of torque. Common transmissions included Allison automatics and manual options. Owners often appreciate the F650’s immense towing capacity and durability, but dislike its fuel consumption and the challenges of maneuvering such a large vehicle.

Engine

Caterpillar 3126 Diesel

• Injector Failure
  • Description/Symptoms: Hard starting, excessive smoke, rough idling, loss of power, and poor fuel economy.
  • Solution: Replace faulty injectors with updated versions.
  • Estimated Cost to Fix: $400 - $800+ per injector, plus labor.
  • Recalls: None Found
• HEUI (Hydraulic Electronic Unit Injection) Pump Failure
  • Description/Symptoms: Engine stalling, poor performance, difficulty starting, and a loss of power.
  • Solution: Replace the HEUI pump.
  • Estimated Cost to Fix: $1,500 - $3,000+ including labor.
  • Recalls: None Found
• Turbocharger Failure
  • Description/Symptoms: Loss of power, excessive black smoke, whining noise from the turbocharger, and potentially high EGTs (Exhaust Gas Temperatures).
  • Solution: Replace the turbocharger. Consider upgrading to a newer, more reliable unit.
  • Estimated Cost to Fix: $1,000 - $2,500+ including labor.
  • Recalls: None Found

Cummins ISB Diesel

• Lift Pump Failure
  • Description/Symptoms: Hard starting, stalling, low power, and fuel starvation.
  • Solution: Replace the lift pump. Consider upgrading to a more reliable aftermarket pump.
  • Estimated Cost to Fix: $200 - $500+ including labor.
  • Recalls: None Found
• Injector Failure
  • Description/Symptoms: Hard starting, excessive smoke, rough idling, loss of power, and poor fuel economy.
  • Solution: Replace faulty injectors with updated versions.
  • Estimated Cost to Fix: $400 - $800+ per injector, plus labor.
  • Recalls: None Found

Ford 6.8L V10 Gasoline

• Spark Plug Ejection
  • Description/Symptoms: Sudden loud popping noise from the engine bay, followed by misfire and rough running. Caused by stripped threads in the cylinder head.
  • Solution: Repair the cylinder head threads with a thread repair kit (e.g., Time-Sert) or replace the cylinder head.
  • Estimated Cost to Fix: $500 - $2,000+ depending on the repair method and labor.
  • Recalls: None Found
• Exhaust Manifold Leaks
  • Description/Symptoms: Ticking noise, especially when cold, and a noticeable exhaust smell. Often caused by broken exhaust manifold bolts.
  • Solution: Replace the exhaust manifold and broken bolts.
  • Estimated Cost to Fix: $400 - $1,200+ including labor.
  • Recalls: None Found

Transmission

Allison Automatic Transmissions (Specific Model Noted If Applicable)

• Valve Body Issues
  • Description/Symptoms: Hard or erratic shifting, slipping between gears, delayed engagement, and potentially transmission failure.
  • Solution: Replace or rebuild the valve body.
  • Estimated Cost to Fix: $800 - $2,500+ including labor.
  • Recalls: None Found
• Torque Converter Failure
  • Description/Symptoms: Shuddering at certain speeds, slipping, and a complete loss of power transfer.
  • Solution: Replace the torque converter.
  • Estimated Cost to Fix: $700 - $2,000+ including labor.
  • Recalls: None Found

Suspension

• Leaf Spring Sagging/Failure
  • Description/Symptoms: Vehicle leaning to one side, rough ride, reduced load-carrying capacity, and potential breakage of the leaf springs.
  • Solution: Replace the leaf springs. Consider upgrading to heavier-duty springs if regularly hauling heavy loads.
  • Estimated Cost to Fix: $500 - $1,500+ per axle, including labor.
  • Recalls: None Found
• Air Suspension Issues (If Equipped)
  • Description/Symptoms: Air leaks, compressor failure, vehicle sagging, and ride height issues.
  • Solution: Replace the air springs, compressor, or associated lines and fittings.
  • Estimated Cost to Fix: $300 - $2,000+ depending on the component and labor.
  • Recalls: None Found

Electrical

• Wiring Harness Issues
  • Description/Symptoms: Intermittent electrical problems, such as lights flickering, gauges malfunctioning, and starting issues. Often caused by corrosion or damaged wiring.
  • Solution: Repair or replace the affected section of the wiring harness.
  • Estimated Cost to Fix: $200 - $1,500+ depending on the severity and location of the damage.
  • Recalls: None Found
• Alternator Failure
  • Description/Symptoms: Dimming lights, battery not charging, warning lights on the dashboard, and eventually a dead battery.
  • Solution: Replace the alternator.
  • Estimated Cost to Fix: $300 - $800+ including labor.
  • Recalls: None Found

Exterior

• Rust
  • Description/Symptoms: Rust forming on body panels, especially around wheel wells, rocker panels, and seams. Common in areas with harsh winters or salty roads.
  • Solution: Repair or replace rusted panels, apply rust prevention treatments.
  • Estimated Cost to Fix: $300 - $3,000+ depending on the extent of the rust and the repair method.
  • Recalls: None Found

Interior

• HVAC Blower Motor Failure
  • Description/Symptoms: Blower motor not working, weak airflow, or unusual noises coming from the HVAC system.
  • Solution: Replace the blower motor and resistor.
  • Estimated Cost to Fix: $200 - $500+ including labor.
  • Recalls: None Found

Summary

The 2003 Ford F650 is a capable truck, but owners should be aware of potential issues, particularly those related to the Caterpillar 3126 diesel engine (if equipped) and the Allison transmissions. Engine issues such as injector and HEUI pump failures can be costly. Suspension and electrical problems, like leaf spring issues and wiring harness damage, are also common. While some issues are relatively inexpensive to fix, others can be quite severe and costly, potentially running into the thousands of dollars. Regular maintenance and inspections are crucial for mitigating these risks.