🏷️ Basic Information

Make:

Ford

Model:

F-350 Super Duty

Year:

2002

Generation Code:

GMT400 (indirectly, as this is Ford's competitor generation)

Chassis Code:

GMT400 based for Chevrolet/GMC, Ford's equivalent is often referred to by model year and platform designation

👋 Introduction

Market Position:

The 2002 Ford F-350 Super Duty was positioned as a robust, heavy-duty pickup truck designed for demanding work, towing, and hauling applications. It competed directly with other class 3 trucks like the Chevrolet Silverado 3500 and Dodge Ram 3500.

Competitive Analysis:

The Super Duty line offered strong powertrain options, particularly its Power Stroke diesel engines, and a reputation for durability. Ford's Super Duty series was known for its commanding presence and class-leading towing and payload capacities in many configurations.

Key Features:

Heavy-duty frame and suspension, powerful V8 and V10 gasoline engines, legendary Power Stroke turbodiesel engines, robust drivetrain options including four-wheel drive, spacious and functional cabin, high towing and payload ratings.

📋 Manual Details

Coverage Areas:

Full vehicle repair and service for the 2002 Ford F-350 Super Duty

Page Count:

Estimated 2000+ pages (typical for comprehensive OEM workshop manuals of this era and vehicle type)

Manual Type:

Workshop Repair Manual (OEM Equivalent)

Language:

English

Format:

Digital PDF

📖 Manual Coverage

Systems Covered:

Engine mechanical (all variants), Engine control systems (PCM, sensors, actuators), Fuel system, Ignition system, Exhaust system, Cooling system, Lubrication system, Drivetrain (4x4 transfer case, differentials, axles), Transmission (automatic and manual), Brakes (hydraulic, ABS), Steering system, Suspension (front and rear), Electrical system (wiring diagrams, lighting, accessories), HVAC system, Body and chassis, Restraints (airbags), Diagnostic trouble codes (DTCs)

Procedures Included:

Scheduled maintenance, Routine inspections, Diagnostic procedures, Repair and replacement of components, Reassembly and torque specifications, Wiring harness repair, Airbag system servicing, Drivetrain component overhaul, Engine rebuild, Transmission service and rebuild, Brake system bleeding and component replacement, Suspension alignment and component replacement, HVAC system troubleshooting and repair, Body panel repair and adjustment, Diagnostic scan tool usage and data interpretation

Technical Depth:

Comprehensive: Covers all aspects from basic fluid changes and filter replacements to in-depth component diagnostics, overhauls, and complete system rebuilds. Includes detailed OEM-level troubleshooting trees and repair procedures.

📊 Manual Specifications

File Format:

PDF (Portable Document Format)

Print Quality:

High-resolution scans/digital creation with clear, legible text and detailed illustrations/diagrams.

Binding Type:

N/A (Digital Format)

Paper Type:

N/A (Digital Format)

⚙️ Engine Specifications

Primary Engine Gas:

5.4L Triton V8 (SOHC, 24-valve)

Primary Engine Gas Performance:

Approx. 260 hp @ 4500 rpm, 350 lb-ft @ 3000 rpm

Secondary Engine Gas:

6.8L Triton V10 (SOHC, 30-valve)

Secondary Engine Gas Performance:

Approx. 310 hp @ 4250 rpm, 425 lb-ft @ 3250 rpm

Primary Diesel Engine:

7.3L Power Stroke V8 Turbodiesel (OHV, 16-valve)

Primary Diesel Engine Performance:

Approx. 250 hp @ 2600 rpm, 505 lb-ft @ 1600 rpm (with manual transmission) / 275 hp @ 2600 rpm, 525 lb-ft @ 1600 rpm (with automatic transmission)

Fuel System Gas:

Electronic Fuel Injection (EFI)

Fuel System Diesel:

Direct Injection, HEUI (Hydraulically Actuated Electronically Controlled Unit Injector)

🔧 Transmission

Standard Transmission:

5-speed manual transmission (for gas engines); 6-speed manual transmission (for 7.3L Power Stroke diesel)

Optional Transmission:

4-speed automatic transmission (4R100 for 7.3L Power Stroke; E4OD/4R70W for gas engines, though E4OD was more common on higher-GVWR models)

Transmission Features:

Heavy-duty construction, robust torque converters for automatics, available PTO (Power Take-Off) provisions on some models.

📐 Dimensions

Wheelbase Options:

Available in multiple wheelbases (e.g., 137, 158, 178 inches for SRW; 140, 160, 180 inches for DRW) depending on cab and bed configuration.

Overall Length Range:

Varies significantly with cab and bed configuration, generally ranging from approximately 211 inches to over 250 inches.

Width Range:

Approx. 79.9 inches (cab width, excluding mirrors).

Gvwr Range:

Ranges from approximately 8,800 lbs to over 12,500 lbs depending on configuration (F-350 Single Rear Wheel - SRW, and F-350 Dual Rear Wheel - DRW).

Curb Weight Range:

Typically ranges from 5,500 lbs to 7,500+ lbs, highly dependent on configuration.

Max Towing Capacity:

Up to 12,500 lbs (conventional towing) and 24,500 lbs (5th-wheel/gooseneck towing) depending on configuration and axle ratio.

Max Payload Capacity:

Up to approximately 4,700 lbs, varies by configuration.

🛡️ Safety Features

NHTSA Rollover Rating:

RWD models typically 3-star, 4WD models 4-star (as per NHTSA testing for similar era vehicles, specific rating varies by configuration)

Active Safety Features:

Four-wheel disc brakes with ABS (Anti-lock Braking System) standard on all models. Available integrated trailer brake controller on some higher trims.

Passive Safety Features:

Front airbags for driver and passenger, high-strength steel frame, side-impact door beams, three-point seat belts with pretensioners.

💡 Technology Features

Infotainment Features:

Base models featured a basic AM/FM radio with cassette player or single-CD player. Higher trims offered upgraded audio systems with CD changers, and optional premium sound. Digital displays for odometer and vehicle status were standard.

Driver Assistance Features:

ABS (Anti-lock Braking System) was the primary electronic driver assistance system. Cruise control was standard on most trims. Integrated trailer brake controllers became more common on later models or as an option.

Connectivity Features:

Limited by modern standards. Auxiliary input jacks were not common. Ford's early attempts at integrated communication systems were rare on trucks of this era. Primarily analog controls.

🔧 Maintenance

Oil Change Interval:

Gasoline engines: 5,000 miles / 6 months (severe service) or 7,500 miles / 6 months (normal service). Diesel engine: 5,000 miles / 6 months (severe service) or 10,000 miles / 12 months (normal service). Consult manual for detailed definitions of service conditions.

Filter Replacement Interval:

Engine oil filter: Replace with every oil change. Fuel filter (Diesel): Consult manual, typically around 15,000-30,000 miles. Air filter: Inspect every oil change, replace as needed or at recommended intervals (e.g., 15,000-30,000 miles).

Engine Oil Gasoline:

API SG, SH, SJ or higher; SAE 5W-30 (preferred for most operating temperatures). 5.4L Triton requires approx. 6 quarts. 6.8L Triton requires approx. 7 quarts.

Engine Oil Diesel:

API CG-4 or CH-4; SAE 15W-40 (preferred for most operating temperatures). 7.3L Power Stroke requires approx. 15 quarts.

Coolant Type:

Ford Premium Engine Coolant (Green) or equivalent meeting specification WSS-M97B51-A1. Typically a 50/50 mix with distilled water.

Transmission Fluid Automatic:

Mercon V (for 4R100, 4R70W) or Mercon (for older E4OD, though 4R100 superseded it for most of this generation). Capacity varies by transmission type and configuration.

Transmission Fluid Manual:

Refer to manual; typically dedicated manual transmission fluid (e.g., SAE 75W-90 GL-4 or GL-5 gear oil, depending on specific transmission).

Differentials Fluid:

Refer to manual for specific front/rear differentials (e.g., SAE 75W-90 GL-5 gear oil, possibly with limited-slip additive for certain axles).

Known Issues Diesel:

Injector O-rings, UVCH (Under Valve Cover Harness) chafing, turbocharger issues (sticking vanes or bearing wear), FICM (Fuel Injection Control Module) failures, exhaust back pressure sensor issues, coolant filtration issues (if not maintained).

Known Issues Gasoline:

Spark plug ejection (especially on early 5.4L 2-valve Triton), intake manifold leaks (plastic manifolds), exhaust manifold cracks, DPFE sensor failures.

Common Wear Items:

Ball joints, tie rod ends, wheel bearings, U-joints, brake components, leaf springs (due to heavy loads).

📚 Vehicle History

Brand Heritage:

Ford has a long and storied history in the pickup truck market, dating back to the early 20th century. The F-Series line, introduced in 1948, has consistently been a best-selling vehicle in North America.

Model Evolution:

The 'Super Duty' designation for Ford's heavy-duty trucks was introduced in 1999, creating a distinct line separate from the F-150. The 2002 model year falls within the first generation of the Super Duty platform (1999-2007), which featured significant upgrades in powertrain, chassis, and interior design over previous heavy-duty Ford trucks.

Production Location:

Kentucky Truck Plant, Louisville, Kentucky; Cuautitlán Stamping and Assembly Plant, Mexico.

🏆 Awards & Recognition

Recognitions:

The Ford Super Duty line consistently received accolades for its towing and hauling capabilities. Specific awards for the 2002 model might include 'Most Dependable Large Pickup' from J.D. Power and Associates, or positive reviews from automotive publications for its robust construction and powerful engines.

Ratings:

High ratings in consumer satisfaction surveys for heavy-duty trucks, particularly for powertrain reliability and towing performance, especially for models equipped with the 7.3L Power Stroke diesel.

Certifications:

Certified to meet all relevant EPA and DOT emissions and safety standards for 2002 model year vehicles.