Segment:
Full-size pickup truck
Target Audience:
Professionals, contractors, fleet managers, and individuals seeking a robust and versatile workhorse vehicle.
Key Competitors:
Chevrolet Silverado, GMC Sierra, Dodge Ram, Toyota Tundra.
Vehicle Strengths:
Renowned for its durability, towing and hauling capabilities, wide range of engine options, and comfortable ride for its class. Third generation (2004-2008) brought significant updates, but the 2002-2003 models were still highly competitive.
Engines Covered:
4.2L V6, 4.6L V8, 5.4L V8 (2-valve and 3-valve Triton)
Transmissions Covered:
4R70W (4-speed automatic), 4R75W (4-speed automatic), NV3550 (5-speed manual), ZF S6-650 (6-speed manual)
Trim Levels Covered:
XL, XLT, Lariat, King Ranch, Harley-Davidson Edition
Type:
Factory Service Manual (FSM)
Powertrain:
Engine mechanical, fuel system, cooling system, ignition system, exhaust system, engine control systems (PCM/ECM), manual and automatic transmissions, transfer case (4x4 models), drive shafts, axles, differentials.
Chassis:
Frame and body, suspension (front and rear), steering system, brake system (ABS, parking brake), wheels and tires.
Electrical:
Battery, charging system, starting system, lighting system (headlights, taillights, interior), gauges and instruments, power accessories (windows, locks, mirrors), climate control system, entertainment system, body control module (BCM), Powertrain Control Module (PCM) diagnostic procedures, fuse and relay locations.
HVAC:
Air conditioning system (refrigerant, components, diagnostics), heating system, blower motor, climate control modules.
Body And Trim:
Exterior body panels, doors, hood, tailgate, bumpers, interior trim, seats, airbags, seat belts.
Maintenance:
Oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, belt inspection and replacement, brake pad and rotor replacement, tire rotation and inspection.
Repair:
Engine overhaul, transmission rebuild/replacement, suspension component replacement (shocks, struts, ball joints), steering component replacement (tie rods, steering rack/gearbox), brake system repair, electrical component diagnosis and replacement, body panel repair and alignment, HVAC system repair.
Diagnostics:
Systematic troubleshooting procedures, diagnostic trouble codes (DTCs), wiring diagrams, component testing, scan tool usage, common fault identification.
Specifications:
Torque specifications for all fasteners, engine specifications (bore, stroke, compression ratio), electrical specifications (voltage, resistance), fluid capacities and types, emission control information.
Depth:
Comprehensive, covering from routine maintenance to full engine and transmission rebuilds, detailed diagnostic procedures, and wiring schematics for all electrical systems.
Base Engine:
4.2L Triton V6
Optional Engines:
4.6L Triton V8, 5.4L Triton V8 (2-valve), 5.4L Triton V8 (3-valve, introduced later in the generation)
Horsepower:
232 hp @ 4,750 rpm
Torque:
291 lb-ft @ 3,500 rpm
Horsepower:
260 hp @ 4,500 rpm
Torque:
350 lb-ft @ 3,000 rpm
Horsepower:
300 hp @ 5,000 rpm
Torque:
365 lb-ft @ 3,750 rpm
Injection Type:
Sequential Electronic Fuel Injection (SEFI)
Recommended Fuel:
Regular Unleaded (87 Octane)
Systems:
Catalytic converter, EGR (Exhaust Gas Recirculation), PCV (Positive Crankcase Ventilation).
Availability:
Optional on most configurations, manual transmission often paired with smaller engines.
Automatic 4R70W:
4-speed automatic, widely used across V6 and 4.6L V8 engines.
Automatic 4R75W:
Upgraded 4-speed automatic, often paired with 5.4L V8 engines, offering improved torque handling.
Manual Nv3550:
5-speed manual, typically found in 4.2L V6 and some 4.6L V8 models.
Manual Zf S6 650:
6-speed manual, often available with the 5.4L V8, known for robust construction.
Automatic Transmission Fluid:
Mercon V
Manual Transmission Fluid:
Refer to manual for specific gearbox type (e.g., Mercon V, GL-4 gear oil).
Transfer Case:
Electronic Shift-On-The-Fly (ESOF) for 4x4 models, featuring 2H, 4H, 4L modes.
Exterior Wheelbase Reg Cab
Wheelbase:
125.9 inches (3,198 mm)
Wheelbase:
144.7 inches (3,675 mm)
Bed Lengths Offered:
Short (6.5 ft), Long (8.0 ft)
Curb Weight Range:
Approx. 4,200 - 5,200 lbs (1,905 - 2,359 kg) depending on configuration.
Towing Capacity:
Up to 8,800 lbs (3,992 kg) for properly equipped configurations (5.4L V8 with towing package).
Payload Capacity:
Up to 2,020 lbs (916 kg) for properly equipped configurations.
Front Impact Driver:
4 Stars (for 2002)
Front Impact Passenger:
4 Stars (for 2002)
Frontal Offset:
Good (for 2002-2003, specific sub-models may vary)
ABS:
Standard Anti-lock Braking System (ABS) on all wheels.
Traction Control:
Optional Traction Assist System (4x2 models) or Electronic Traction Control (4x4 models).
Airbags:
Driver and front passenger airbags, optional side-impact airbags.
Seatbelts:
Three-point seatbelts with pretensioners.
Rollover Protection:
Built into the frame and cab structure, enhanced by seat belts and airbags.
Audio Systems:
Standard AM/FM radio with CD player, optional premium audio systems, cassette player available on base models.
Navigation:
Optional factory-installed navigation system available on higher trim levels.
Cruise Control:
Standard cruise control.
Parking Sensors:
Optional rear parking sensors (Reverse Sensing System) on certain trims.
Power Outlets:
12V power outlets for accessory charging.
Remote Keyless Entry:
Available on XLT and higher trims.
Service Intervals Oil Change
Recommended Interval:
Every 5,000 miles or 6 months, whichever comes first (or per Ford's 'Intelligent Oil Life Monitor' if equipped and active).
Service Intervals Air Filter
Recommended Interval:
Inspect every 15,000 miles, replace as needed.
Service Intervals Spark Plugs
Recommended Interval:
4.6L/5.4L V8 (2V): 100,000 miles; 4.2L V6: 60,000 miles (use specific plug types).
Engine Oil:
SAE 5W-20 (preferred for fuel economy and emissions), SAE 5W-30 (also acceptable, especially for heavy-duty use or towing). Check owner's manual for specific recommendations based on ambient temperature.
Coolant:
Ford Premium Engine Coolant (Green) or equivalent meeting Ford specification WSS-M97B51-A1.
Spark Plugs 5.4L 3V:
Early 5.4L 3V engines (not standard in these years but notable for subsequent models) experienced spark plug ejection or breakage due to a design flaw. This manual would cover proper removal and replacement procedures. For 2002-2003, this is less of an issue.
Rear Main Seal Leaks:
Some reported leaks from the rear main crankshaft seal, particularly on higher mileage vehicles.
Door Lock Actuators:
Failure of power door lock actuators can be a common electrical issue.
Transmission Hard Shifting:
Occasional reports of hard shifting in automatic transmissions, often related to fluid condition or solenoids.
Ford Trucks:
Ford has a long-standing legacy in the truck market, with the F-Series being America's best-selling vehicle for decades.
Tenth Generation:
The 2002-2003 models represent the latter part of the tenth generation (1997-2003), characterized by its rounded styling and improved interior comfort compared to previous generations.
Manufacturing Plants:
Dearborn Truck Plant (Michigan), Kansas City Assembly Plant (Missouri).
Sales Figures Trend:
Consistently strong sales, maintaining leadership in the full-size pickup segment.
Motor Trend Truck Of The Year:
The F-Series platform has won MotorTrend's Truck of the Year award multiple times historically, though not specifically for the 2002 or 2003 model years as distinct iterations.
Kelley Blue Book Best Resale Value:
The F-150 consistently ranks high in resale value within its segment, a testament to its durability and market demand.
Emissions Compliance:
Meets U.S. EPA and California Air Resources Board (CARB) emission standards for the respective model years.
