Target Audience:
Owners and independent repair shops seeking detailed, factory-accurate information for the 2002 Ford F-550 Super Duty.
Value Proposition:
Provides the same level of detail as dealership-used manuals, enabling complex repairs and maintenance at a fraction of dealer costs.
Uniqueness:
Specific to the 2002 F-550, not generic. Includes wiring schematics, step-by-step instructions, and detailed illustrations.
Completeness:
Complete step-by-step instructions, diagrams, illustrations, wiring schematics, and specifications.
Format Advantage:
Digital PDF allows for targeted printing of necessary pages, easy searching, and avoids physical wear and tear.
Primary Coverage:
Service, Maintenance, Diagnosis, and Repair
Scope:
All Models and All Repairs A-Z
Estimated Pages:
Extensive (typical factory service manuals are 2000+ pages)
Type:
Factory Service Manual / Repair Manual
Compatibility:
All Versions of Windows and Mac
Software Requirements:
Adobe PDF Reader and Winzip (free online)
Download Speed:
Speed Download
Powertrain:
Engine, Fuel Service, Emission Control, Intake/Exhaust/Cooling, Lube, Ignition, Starting, Charging, Automatic Transmission, Clutch, Manual Transmission, Transfer Case, Propeller Shaft, Drive Shaft, Differential, Axle
Chassis:
Suspension, Tire & Wheel, Brake Control, Brakes, Parking Brake, Steering Column, Power Steering
Electrical Electronics:
Electrical, Multiplex/CAN Communication, Supplemental Restraint System (SRS), Seat Belt, Engine Immobilizer, Cruise Control, Wiper & Washer, Door Lock, Meter/Audio/Visual, Horn, Air Conditioning
Body Interior:
Windshield/Glass/Mirror, Instrument Panel, Seat, Engine Hood/Door, Exterior & Interior Trim
HVAC:
Air Conditioning system service and repair.
Maintenance:
Scheduled Maintenance, Fluid Changes, Filter Replacements, Inspections
Diagnosis:
Troubleshooting Guides, Diagnostic Trouble Codes (DTCs), Electrical Schematics for Fault Finding
Repair:
Step-by-step repair procedures for all major components and systems
Technical Data:
Specifications, Tolerances, Torque Values, Wiring Diagrams, Component Locations
Component Overhaul:
Detailed procedures for engine rebuilds, transmission overhauls, differential rebuilds, and brake system overhauls.
Component Replacement:
Detailed instructions for replacing major components such as alternators, starters, water pumps, fuel injectors, etc.
Depth:
Factory-level detail, suitable for professional technicians and advanced DIYers
Wiring Schematics:
Comprehensive, model-specific wiring diagrams for all electrical systems, including lighting, power distribution, and sensor circuits.
Diagnostic Tools:
While not listing specific tools, the depth of diagnostic procedures implies the use of advanced diagnostic equipment (e.g., Ford's NGS or WDS).
Engine Options:
Likely includes the 7.3L Power Stroke V8 Turbo Diesel and potentially gasoline V8 options (e.g., 5.4L Triton V8, 6.8L Triton V10).
7.3L Power Stroke Torque:
Approximately 525 lb-ft @ 1600 RPM (for 2002 models)
7.3L Power Stroke Horsepower:
Approximately 250 HP @ 2600 RPM (for 2002 models)
Fuel Type:
Diesel (for Power Stroke), Gasoline (for Triton engines)
Injection System:
Direct Injection (HEUI) for 7.3L Power Stroke
Diesel Engine:
7.3L Power Stroke V8 Turbo Diesel
Gasoline Engines:
5.4L Triton V8, 6.8L Triton V10
Transmission Type:
Likely the 6-speed manual transmission (e.g., ZF S6-650) or the 4-speed automatic transmission (e.g., 4R100).
Manual Transmission Model:
ZF S6-650 (6-speed)
Automatic Transmission Model:
4R100 (4-speed)
Optional Transmission:
The 4R100 automatic was a common option for the F550.
Transmission Fluid:
Specific MERCON® V or MERCON® specified for automatic transmissions, and appropriate manual transmission fluid (e.g., GL-4/GL-5).
Chassis Configuration:
Class 4/5 Chassis Cab, designed for upfitting with various body types (e.g., service bodies, dump beds, van bodies).
F550 Class:
Class 5 Commercial Truck
Gvwr:
Gross Vehicle Weight Rating typically starts around 17,500 lbs for F550 models, with variations based on configuration.
Curb Weight:
Varies significantly based on chassis, engine, and cab configuration. Typically starts around 7,000-8,000 lbs.
Oil Change:
Diesel: 5,000-7,500 miles or 6 months. Gasoline: 3,000-5,000 miles or 6 months (refer to manual for specific intervals based on usage).
Fuel Filter Diesel:
Scheduled replacement typically between 15,000 - 30,000 miles for the 7.3L Power Stroke, depending on fuel quality and operating conditions.
Engine Oil Diesel:
API CJ-4 or CI-4 PLUS, SAE 15W-40 (e.g., Motorcraft® Super Duty Diesel Engine Oil).
Engine Oil Gasoline:
API SN or higher, SAE 5W-20 or 5W-30 (e.g., Motorcraft® SAE 5W-20 Synthetic Blend).
Coolant:
Ford Gold Coolant (VC-13-G) or equivalent. Capacity approx. 23 quarts (21.8 liters) for diesel.
Brake Fluid:
DOT 3 Motor Vehicle Brake Fluid.
Power Steering Fluid:
Mercon® V Automatic Transmission Fluid or equivalent power steering fluid.
7.3L Power Stroke Ides:
Injectors (sticking or failure), UVCH (Under Valve Cover Harness), Fuel Injection Control Module (FICM) issues, Exhaust Gas Recirculation (EGR) valve issues.
General Wear Items:
Ball joints, U-joints, brake components, and exhaust systems are common wear items on heavy-duty trucks.
Ford Trucks:
Ford has a long and dominant history in the truck market, with the F-Series being a perennial best-seller.
Super Duty Line:
The Super Duty line, introduced in 1998, represented a significant redesign and strengthening of Ford's heavy-duty truck offerings to compete with GM and Dodge.
Manufacturing Location:
Typically assembled in Louisville, Kentucky, and Ontario, Canada.
