2002 Ford Super duty problems

General information about Ford-Super duty
Overview of popular issues
Analysis of common problems
Сomplaints list

The Ford Super Duty (also known as the Ford F-Series Super Duty) is a series of heavy-duty pickup trucks produced by the Ford Motor Company since the 1999 model year. Slotted above the consumer-oriented Ford F-150, the Super Duty trucks are an expansion of the Ford F-Series range, from F-250 to the F-600. The F-250 through F-450 are offered as pickup trucks, while the F-350 through F-600 are offered as chassis cabs.

Rather than adapting the lighter-duty F-150 truck for heavier use, Super Duty trucks have been designed as a dedicated variant of the Ford F-Series. The heavier-duty chassis components allow for heavier payloads and towing capabilities. With a GVWR over 8,500 lb (3,900 kg), Super Duty pickups are Class 2 and 3 trucks, while chassis-cab trucks are offered in Classes 3, 4, 5, and 6. The model line also offers Ford Power Stroke V8 diesel engines as an option.

Ford also offers a medium-duty version of the F-Series (F-650 and F-750), which is sometimes branded as the Super Duty, but is another chassis variant. The Super Duty pickup truck also served as the basis for the Ford Excursion full-sized SUV.

The Super Duty trucks and chassis-cabs are assembled at the Kentucky Truck Plant in Louisville, Kentucky, and at Ohio Assembly in Avon Lake, Ohio. Prior to 2016, medium-duty trucks were assembled in Mexico under the Blue Diamond Truck joint venture with Navistar International.

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Common 2002 Ford Super duty problems

Based on the sources provided, here are the common problems with the Ford Super Duty 2002 based on complaints from owners:

Pitting or Cavitation in the Liner:
- Neglecting the cooling system can result in pitting in the Super Duty diesel engines' liners. This can lead to air bubbles or ice formation on the water pump, causing corrosion. Regularly adding antifreeze like Nalcool or Caterpillar ELC can prevent this issue, with antifreeze costing between $60 to $200.

Cylinder Head Ejection Spark Plug:
- Threads in the spark plug hole can get damaged, leading to spark plug ejection. This issue may necessitate cylinder head replacement, with a cylinder head costing around $400. Failure of cylinder heads can increase oil consumption and maintenance costs.

Shortage of Power from the Engine:
- A loose hose from the turbocharger to the intake manifold can result in a loss of engine boost pressure, causing a tapping sound from the engine. This issue can lead to a major internal engine breakdown if not addressed promptly.

Delamination in the Diesel Tank:
- Delamination occurs when metal and liner chips from the tank clog the diesel pump, causing engine shutdown. Repairing the tank can cost between $200 to $400, while replacing it may range from $1,200 to $2,400. Some repair shops install a thicker liner to address this problem.

Steering Wheel Vibrates When Braking:
- Vibrations in the steering wheel while braking can be attributed to bent rotors. Experts recommend gentle, smooth stops to prevent rough areas on the rotor's surface, potentially saving on rotor pad replacement costs.

These common problems with the Ford Super Duty 2002 highlight various issues that owners may encounter, emphasizing the importance of regular maintenance and prompt attention to any signs of trouble to ensure the longevity and reliability of the vehicle.

Is the 2002 7.3 Powerstroke a good engine?

Overall, the 7.3 Powerstroke is quite a reliable diesel engine, and even the issues listed here are generally easy to fix. As your engine gets older, it's always a good idea to replace stock parts with Powerstroke performance parts and upgrades for the best results.

What are the worst years for F-250 Super Duty?

The worst years for used Ford F-250 include:

2002 Ford F-250.
2006 Ford F-250.
2008 Ford F-250.
2011 Ford F-250.
2017 Ford F-250.

What is the recall on the 2002 Ford f250?

2002 Ford F-250 Recalls

A MULTI-FUNCTION SWITCH WITH A DEFORMED SLIDER MAY MALFUNCTION CAUSING THE TURN SIGNAL, TAIL LIGHTS, HAZARD WARNING SIGNAL FLASHERS AND/OR BRAKE LIGHTS NOT TO ACTIVATE.

Is Ford Super Duty a reliable Car?

Ford Super Duty Honored as America's Most Dependable Large Heavy-Duty Pickup by J.D. Power. DEARBORN, Mich., Feb. 8, 2024 – The 2021 Ford Super Duty is the most dependable large heavy-duty pickup in the J.D. Power 2024 U.S. Vehicle Dependability Study, based on feedback from drivers after three years of ownership.

Is the 2002 7.3 Powerstroke a good engine?

Is Ford Super Duty a reliable Car?

What is the most reliable Ford Super Duty year?

Reliability refers to how well the vehicle can handle heavy loads and rough terrains. The model years 2005, 2009, 2011, and 2020 were some of the stand-out models from the four generations of Ford F-250.

What years of F-250 to avoid?

In short, the 2003-2007 Ford F-250 are among those vehicles that you should avoid. Unless you're looking for a project truck or a parts' car these are best avoided, and here's a deeper dive into why.

2002 Ford Super duty car problems categorized by type of issue

After analyzing all complaints sent to the NHTSA and researching popular Ford Super duty problems, we found that the most common problems with these 2023 model year vehicles are:

Steering problems
Service brakes problems
Hydraulic problems
Electrical system problems
Equipment problems

The graph below shows statistics for all 2002 Ford Super duty vehicle components and the number of complaints received.

2002 Ford Super duty complaints

The NHTSA has received 1 complaints about various vehicle components related to the 2002 Ford Super duty.

2005-12-22

STEERING,SERVICE BRAKES, HYDRAULIC,ELECTRICAL SYSTEM,EQUIPMENT PROBLEM

Date Of Incident: 2005-12-20
VIN: 1FMSU41F82E
Components: STEERING,SERVICE BRAKES, HYDRAULIC,ELECTRICAL SYSTEM,EQUIPMENT
Summary: MARCH 2005 AN ALTERNATOR WAS REPLACED UNDER WARRANTY WITH A REMANUFACTURED ONE WHICH FAILED IN AUGUST 2005 LEAVING ME STRANDED 250 MILES FROM HOME. ON DECEMBER 09,2005 A POWER STEERING PUMP WAS REPLACED UNDER THE EXT. WARR. PROGRAM WITH YET AGAIN A REMAN. PUMP. ON DECEMBER 22 IT FAILED LEAVING ME WITH NO BRAKES AND NO STEERING. IT IS A DIESEL IN WHICH THE BRAKE SYSTEM USES THE POWER STEERING PUMP FOR BOOST POWER. I WAS NEARLY INJURED DUE TO THIS SINCE I WAS MAKING A U-TURN AND ENDED UP GOING HEAD-ON INTO THE TRAFFIC THAT WAS ORIGINALLY BEHIND ME. CAN SOMETHING BE DONE ABOUT THE USE OF REMANUFACTURED PARTS ON WARR. VEHICLES? I HAVE 44,000 MILES ON A TRUCK THAT IS BUILT TO LAST 300,000 PLUS MILES. I CAN'T UNDERSTAND WHY JAPANESE AND GERMAN VEHICLES THE I OWNED NEVER HAD ANY PROBLEMS. THANK YOU,JOE MARMORATO. *NM

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Additional sources

More sources of information about 2002 Ford Super duty problems:

2002 Ford F-250 Super Duty Problems and Complaints - 10 Issues

https://repairpal.com/2002-ford-f-250-super-duty/problems

Top 2002 Ford F-250 Super Duty Problems · Smoke From Tail Pipe Due to Failed EGR Valve · Hose From Turbo to Intake May Blow Off and Cause Pressure Loss · High ...

2002 7.3 powerstroke problems? - Ford Truck Enthusiasts Forums

https://www.ford-trucks.com/forums/1359276-2002-7-3-powerstroke-problems.html

Jan 30, 2015 ... Same motor, same stuff to check out. My 02 has been pretty trouble free for the last 498,000 miles. Not sure why your dad has had so many issues ...

I have 2002 F250 superduty that has been having issues with the ...

https://www.justanswer.com/ford/13kad-2002-f250-superduty-having-issues.html

Mar 3, 2008 ... The GEM modual is mounted to the back of the CJB (interior fuse panel). They dry out and everything work normal for a while till the next time ...

People with 7.3L over 200K miles?? - Ford Truck Enthusiasts Forums

https://www.ford-trucks.com/forums/1008884-people-with-7-3l-over-200k-miles.html

Nov 9, 2010 ... 2002 Ford F250 XL Super Duty Turbo Diesel...CHEAP!! Any input...yay's or nay's...and common problems would be nice to know before I get ...