Market Position:
The 2002 Ford F-250 Super Duty represented Ford's robust offering in the heavy-duty pickup truck segment, known for its towing and hauling capabilities, and robust construction.
Competitive Analysis:
Competed directly with the Chevrolet Silverado HD, GMC Sierra HD, and Dodge Ram Heavy Duty trucks of the same era.
Key Features:
Renowned for its strong chassis, powerful engine options (including the Power Stroke diesel), and significant towing and payload capacities. This era saw refinements in ride comfort and interior amenities compared to previous generations.
Manual Value Proposition:
This manual provides the exact same factory-level repair and diagnostic information used by dealership technicians, enabling owners to perform comprehensive maintenance and repairs efficiently and accurately.
Engine Systems:
Engine mechanical, control system, fuel service, emission control, intake/exhaust, cooling, lubrication, ignition, starting, charging
Drivetrain Systems:
Automatic transmission, clutch, manual transmission, transfer case, propeller shaft, drive shaft, differential, axle, suspension
Braking Steering Systems:
Brake control, brake systems (hydraulic and ABS), parking brake, steering column, power steering
Electrical Systems:
Wiring schematics, electrical components, multiplex/CAN communication, accessory systems, starter, alternator, battery, lighting
Body Interior Systems:
Air conditioning, supplemental restraint system (SRS), seat belts, engine immobilizer, cruise control, wiper/washer, door locks, meter/audio/visual, horn, windshield/glass/mirror, instrument panel, seats, engine hood/doors, exterior/interior trim
Diagnostic Procedures:
Troubleshooting guides, diagnostic procedures for all major systems
Repair Procedures:
Step-by-step repair instructions for all components and systems
Maintenance Procedures:
Scheduled maintenance, fluid changes, filter replacements
Rebuild Procedures:
Complete engine, transmission, and differential rebuild instructions
Technical Depth:
Comprehensive, factory-level detail covering diagnostics, repair, and overhaul
Print Quality:
High-resolution, printable pages with clear diagrams and illustrations
Binding Type:
N/A (Digital PDF)
Paper Type:
N/A (Digital PDF - user printable)
Searchability:
Searchable text within the PDF for quick information retrieval
Software Requirements:
Adobe PDF Reader, Winzip (free)
Operating Systems:
All versions of Windows and Mac
Gasoline Engine Options:
5.4L Triton V8 (SOHC 2-valve), 6.8L Triton V10 (SOHC 2-valve)
Diesel Engine Options:
7.3L Power Stroke V8 Turbodiesel (OHV, HEUI injection)
Engine Displacement 7.3L Power Stroke:
444 cu. in. (7.3 Liters)
Horsepower 7.3L Power Stroke 2002:
Approx. 250-275 hp (depending on specific calibration)
Torque 7.3L Power Stroke 2002:
Approx. 500-525 lb-ft (depending on specific calibration)
Fuel System Gasoline:
Electronic Fuel Injection (EFI)
Fuel System Diesel:
Hydraulically Actuated Electronically Controlled Unit Injector (HEUI) system
Cooling System Capacity Gas:
Approx. 20.4 US quarts (19.3 Liters)
Cooling System Capacity Diesel:
Approx. 24.7 US quarts (23.4 Liters)
Standard Transmission:
5-speed manual (for gas engines), 6-speed manual (for diesel)
Optional Transmission:
4-speed automatic (e.g., 4R100 for diesel, 5R110W for later 2002 models)
Transfer Case:
Manual or electronic shift-on-the-fly (ESOF) 4WD systems
Transmission Fluid Type 4R100:
Mercon V
Transmission Fluid Capacity 4R100:
Approx. 13.2 US quarts (12.5 Liters) dry fill
Wheelbase Options:
137" (standard), 152" (long bed), 172" (crew cab long bed)
Bed Length Options:
6.75 ft (standard), 8 ft (long bed)
Gvwr F250:
Starts around 8,800 lbs and can go up to 9,900 lbs depending on configuration
Curb Weight F250 Diesel 4X4 Crew Cab:
Est. 6,500-7,000 lbs
NHTSA Front Impact Rating 2002:
Not consistently rated for all configurations; generally performed well for its class but often did not receive full ratings like passenger cars.
Active Safety Features:
Anti-lock Braking System (ABS) standard on all wheels
Passive Safety Features:
Front airbags, available side-impact airbags, seat belts
Infotainment Features 2002:
Base audio systems typically included AM/FM radio, optional CD player. Higher trims could have premium audio. No integrated navigation or advanced infotainment systems were standard.
Driver Assistance Features:
Limited; primarily ABS. Features like traction control or stability control were not common or standard on this model/year.
Connectivity Features:
Basic connectivity for diagnostic tools via OBD-II port. No Bluetooth or USB connectivity.
Oil Change Interval Gas:
Typically 5,000 miles or 6 months (check manual for specific type/weight of oil)
Oil Change Interval Diesel:
Typically 5,000-7,500 miles or 6 months with conventional oil, potentially longer with synthetic (consult manual)
Coolant Flush Interval:
Every 30,000-50,000 miles or 2-3 years
Engine Oil Gas 5.4L 6.8L:
API SG, SH, or SJ; SAE 5W-30 (preferred), 5W-40, 10W-30, or 10W-40 depending on climate
Engine Oil Diesel 7.3L Power Stroke:
API CF-4, CG-4, or CH-4; SAE 15W-40 (preferred), 5W-40 synthetic for cold starts
Engine Coolant:
Ford Premium Engine Coolant (Green or Yellow, depending on original fill/spec); 50/50 mix with distilled water
Power Steering Fluid:
Mercon V or compatible ATF
Known Issues 7.3L Power Stroke:
Potential for UVCH (Under Valve Cover Gasket) oil leaks, injector seal issues, fuel pressure regulator issues, turbocharger soot buildup. The manual will detail diagnostics and repair for these.
Known Issues Gas Engines:
Spark plug blowouts (especially on early 2000s Triton engines), intake manifold gasket leaks, exhaust manifold cracks.
Known Issues Suspension Steering:
Worn ball joints, tie rod ends, and steering gearbox wear are common due to the heavy-duty nature and loads carried.
Brand Heritage:
Ford's F-Series has been a dominant force in the pickup truck market for decades, with a reputation for durability and utility.
Model Evolution 2002:
The 2002 model year is part of the third generation (2000-2007), which introduced a completely redesigned chassis and body, offering improved styling, interior comfort, and capability over its predecessor. Engine options like the 7.3L Power Stroke were highly regarded for their power and reliability in this generation.
Production Location:
United States (e.g., Louisville, Kentucky; Dearborn, Michigan)
