Segment:
Heavy-Duty Pickup Truck (Class 4)
Target User:
DIY enthusiasts, professional mechanics, fleet owners
Competitors 2002:
Chevrolet Silverado 4500/5500, Dodge Ram 4500/5500, GMC Sierra 4500/5500
Manual Advantage:
Single-year specific for precise information, OEM quality, comprehensive coverage beyond owner's manuals.
Vehicle Advantage:
Robust construction, powerful engine options, and towing/hauling capability.
Primary Focus:
Repair and Service Procedures
Breadth:
Comprehensive; covers all major repair and maintenance aspects
Estimated Pages:
Varies by specific model/engine configuration, but substantial for a workshop manual (typically 1500+ pages for this era Ford Super Duty)
Type:
Workshop Repair Manual (OEM Level)
Powertrain:
Engine mechanical, fuel system, ignition system, cooling system, lubrication system, exhaust system, transmission (manual & automatic), driveline, differentials
Chassis:
Suspension (front & rear), steering, brakes (hydraulic, ABS), wheels, tires
Electrical:
Starting system, charging system, lighting, instruments, power accessories, body electrical, wiring diagrams, electrical schematics
Body And Interior:
Body construction, doors, glass, interior trim, HVAC, safety systems (airbags), security systems
Maintenance:
Fluid changes (oil, coolant, brake fluid, transmission fluid, power steering fluid), filter replacements, lubrication, inspections
Repair:
Engine tune-up, component diagnostics and replacement (alternator, starter, fuel pump, etc.), transmission overhaul, brake system repair, suspension component replacement, exhaust system repair, body panel repair
Diagnostics:
Troubleshooting guides, diagnostic trouble codes (DTCs), power balance testing, circuit testing, diagnostic flowcharts
Depth:
Advanced; includes complete engine and transmission rebuild procedures, detailed electrical system troubleshooting, and diagnostic code interpretations.
Engine Option 1:
7.3L Power Stroke V8 Turbo Diesel (OHV, 16V)
Displacement 7 3L:
444 cu in (7.3 L)
Horsepower 7 3L:
Approximately 250-275 hp (depending on exact tune and intercooler)
Torque 7 3L:
Approximately 505-525 lb-ft (depending on exact tune)
Engine Option 2:
5.4L Triton V8 (SOHC, 24V)
Displacement 5 4L:
330 cu in (5.4 L)
Horsepower 5 4L:
Approximately 235 hp
Torque 5 4L:
Approximately 330 lb-ft
Fuel Type Gasoline:
Unleaded Gasoline
Diesel Injection:
Electronic HEUI (Hydraulically Actuated Electronically Controlled Unit Injector)
Gasoline Injection:
Sequential Electronic Fuel Injection (SEFI)
Transmission Diesel Std:
5-speed manual (e.g., ZF 5S-4700)
Transmission Gas Std:
5-speed manual (e.g., M5R2-HD)
Transmission Diesel Opt:
4-speed automatic (e.g., 4R100)
Transmission Gas Opt:
4-speed automatic (e.g., 4R70W or 4R100 for heavier duty applications)
Drivetrain:
RWD or 4WD (Part-Time with Transfer Case)
Wheelbase:
Varies by configuration, typically 137.1" (Regular Cab, Long Bed) up to 177.1" (Crew Cab, Long Bed) for F-450 Chassis Cab.
Overall Length:
Varies significantly by cab and bed configuration.
Gvwr:
14,500 lbs (typical for F-450)
Curb Weight:
Varies by configuration, but significantly higher for diesel models.
Payload Capacity:
Substantial, designed for heavy loads (typically 4,000-7,000+ lbs depending on configuration).
Towing Capacity:
Designed for heavy towing, often exceeding 10,000 lbs, up to 12,500 lbs (conventional) and higher with gooseneck/5th wheel.
Audio System:
Factory AM/FM/CD or Cassette player, optional premium sound systems.
Cruise Control:
Standard cruise control on most models.
Trailer Brake Controller:
Factory integrated trailer brake controller available as an option on some trims.
Auxiliary Inputs:
Limited; typically no standard auxiliary audio inputs or USB ports.
Oil Change Gas:
Every 5,000 - 7,500 miles or 6 months (refer to manual for specific conditions)
Oil Change Diesel:
Every 5,000 - 10,000 miles or 6 months (depending on usage and oil quality, consult manual)
Transmission Fluid Change Auto:
Every 30,000 - 60,000 miles (depending on towing and load conditions)
Coolant Flush:
Every 30,000 - 50,000 miles or 2-4 years
Engine Oil Gas Spec:
API SG or SH, SAE 5W-30 (or 10W-30 for warmer climates)
Engine Oil Diesel Spec:
API CH-4 or CI-4, SAE 15W-40 (preferred for Power Stroke)
Transmission Fluid Auto Spec:
Mercon V (for 4R100, 4R70W)
Coolant Spec:
Ford Premium Engine Coolant (Yellow) or equivalent, 50/50 mix with distilled water
Diesel Injectors:
7.3L Power Stroke: Potential issues with UVCH (Under Valve Cover Harness) chafing, injector seal leaks, and occasional FICM (Fuel Injection Control Module) failures.
Transmission Overheating:
4R100 Automatic: Can overheat under heavy towing; upgrading the transmission cooler is recommended.
Front Suspension:
Common wear items include ball joints, tie rod ends, and steering components, especially with heavy use or off-road conditions.
Rust:
Frame rust, particularly in areas with road salt, can be a concern for trucks of this vintage.
Ford Trucks:
Ford has a long and storied history in the pickup truck market, dating back to the Model T Runabout with the pickup body.
F Series Legacy:
The F-Series is the best-selling truck line in the United States and has been a dominant force for decades. The Super Duty line was introduced in 1999 to differentiate from the lighter-duty F-150.
Manufacturing Location:
United States (e.g., Kentucky Truck Plant, Louisville, KY)
