Market Position:
Essential diagnostic and repair resource for owners and independent repair facilities of the 2002 Ford F-250 Super Duty.
Competitive Advantage:
Licensed OE materials from RepairSurge offer superior accuracy and breadth of information compared to generic aftermarket manuals. Digital format provides convenience and instant access.
Key Features:
Licensed OE data, comprehensive system coverage, step-by-step repair procedures, diagnostic information, online accessibility.
Engine:
All gasoline and diesel engines, including diagnostics, disassembly, assembly, and specifications.
Transmission:
Manual and automatic transmissions, including removal, installation, internal repairs, and fluid specifications.
Drivetrain:
Front and rear axles, driveshafts, differentials, transfer case (4WD models), and wheel bearings.
Brakes:
Front and rear brake systems (disc and drum), ABS, parking brake, hydraulic components, and bleeding procedures.
Suspension Steering:
Front and rear suspension components, steering gear, power steering system, alignment specifications, and wheel hub/bearing replacement.
Electrical System:
Battery, charging system, starting system, lighting, fuses, relays, wiring diagrams, power distribution, and accessory circuits.
Heating Air Conditioning:
HVAC system, refrigerant handling, climate control operation, blower motor, compressor, and diagnostic procedures.
Body Frame:
Body panel removal and installation, door mechanisms, interior trim, glass replacement, and structural repair basics.
Exhaust System:
Exhaust manifold, catalytic converter, mufflers, pipes, and mounting hardware.
Fuel System:
Fuel tank, fuel pump, fuel filter, fuel lines, fuel injectors, and vapor emission control system.
Maintenance:
Oil changes, filter replacements, fluid checks and top-offs, tire rotations, spark plug replacement, and belt inspections.
Troubleshooting:
Diagnostic flowcharts, symptom-based troubleshooting guides, and common problem identification.
Repair:
Step-by-step repair instructions for all major systems, including component removal, replacement, and reassembly.
Installation:
Guidance for installing new or replacement parts.
Diagnostics:
OBD-II diagnostic trouble code (DTC) interpretation and specific diagnostic procedures.
Depth:
Comprehensive, factory-level detail suitable for professional technicians and advanced DIY enthusiasts.
2002 F250 Engines:
5.4L Triton V8 (330 ci), 6.8L Triton V10 (415 ci), 7.3L Power Stroke V8 Turbo Diesel (444 ci).
5.4L Triton Hp Torque:
Approx. 230-260 HP / 325-350 lb-ft (varies by application and year nuances).
6.8L Triton V10 Hp Torque:
Approx. 275 HP / 410 lb-ft.
7.3L Power Stroke Hp Torque:
Approx. 235 HP / 500 lb-ft (early 2002 models), 250 HP / 525 lb-ft (late 2002 models).
Fuel Injection Type:
Port Fuel Injection (PFI) for 5.4L and 6.8L; Direct Injection (HEUI) for 7.3L Power Stroke.
Diesel Fuel Type:
ULSD (Ultra-Low Sulfur Diesel) required for 7.3L Power Stroke.
Standard Option:
5-speed manual transmission (M5OD-R2 for gas engines, ZF6-S650 for diesel).
Optional Option:
4-speed automatic transmission (4R100).
4R100 Features:
Electronic controls, torque converter lock-up, tow/haul mode.
Zf6 S650 Features:
Heavy-duty manual with dual-mass flywheel, robust construction for diesel torque.
Wheelbase Options:
137.1 inches (Standard Bed), 156.3 inches (Long Bed), 172.4 inches (Chassis Cab).
Bed Length Options:
6.75 ft (standard bed), 8.0 ft (long bed).
Gvwr Range:
8,800 lbs to 12,500 lbs (depending on configuration).
Curb Weight Range:
Approx. 6,000 - 7,500 lbs (depending on engine, cab, and drivetrain).
NHTSA Front Impact Rating:
Driver: 4 Stars, Passenger: 4 Stars (for specific configurations; consult NHTSA for exact model year ratings).
Active Safety Features:
Four-wheel Anti-lock Braking System (ABS).
Passive Safety Features:
Dual front airbags, height-adjustable shoulder belts, three-point rear seatbelts.
Oil Change Interval Gasoline:
Every 5,000 miles or 6 months, whichever comes first, using 5W-20 or 5W-30 synthetic blend oil.
Oil Change Interval Diesel:
Every 5,000 miles or 6 months, whichever comes first, using CJ-4 or CK-4 rated diesel engine oil.
Engine Coolant Flush Interval:
Initial flush at 100,000 miles, then every 50,000 miles or 24 months thereafter.
Transmission Fluid Change Automatic:
Inspect every 30,000 miles; change fluid and filter every 100,000 miles under normal use, or sooner under severe use (towing, heavy loads).
Transmission Fluid Change Manual:
Inspect every 30,000 miles; change fluid every 150,000 miles.
Engine Oil 5.4L 6.8L:
API Service Category SG, SH, or SJ; SAE 5W-20 or 5W-30.
Engine Oil 7.3L Power Stroke:
API Service Category CF-2, CG-4, CH-4; SAE 15W-40 (or 5W-40 synthetic for cold weather).
Automatic Transmission Fluid:
MERCON V.
Manual Transmission Fluid M5Od R2:
Meritor FNQ-M2C188-AA spec (often equivalent to Mercon V or equivalent manual trans fluid).
Manual Transmission Fluid Zf6 S650:
ZF TE-ML 01/07/08 specification (e.g., Mobilube HDLS 75W-90).
Coolant Type:
Ford Premium Gold Coolant (or equivalent meeting WSS-M97B51-A1 specification).
7.3L Power Stroke Injector O Rings:
Potential for leaks from injector seal O-rings, causing hard starting or rough running.
4R100 Transmission Hard Shifting:
Can develop hard shifting or solenoid issues, often addressed by updated valve bodies or solenoid packs.
Suspension Component Wear:
Common wear items include ball joints, tie rod ends, and leaf spring bushings due to heavy-duty use.
Ford Truck Heritage:
Ford has a long-standing legacy of producing durable and capable trucks, with the F-Series being a cornerstone of the brand for decades.
Super Duty Introduction:
The Super Duty line was introduced for the 1999 model year, representing a significant redesign and heavier-duty platform for Ford's heavy-duty trucks, separating them from the F-150.
Manufacturing Locations:
Kentucky Truck Plant (Louisville, KY) and Avon Lake, Ohio.
