🏷️ Basic Information

Make:

Ford

Model:

F-Series Super Duty

Sub Model:

F-250

Year:

2003

Engine Options:

Available with 5.4L Triton V8, 6.8L Triton V10, and 7.3L Power Stroke V8 Turbo Diesel engines.

Chassis Code:

GMT800 (though often referred to by engine codes like 7.3L Power Stroke, 5.4L Triton, 6.8L Triton)

👋 Introduction

Market Position:

The 2003 Ford F-Series Super Duty (F-250) was a highly capable heavy-duty pickup truck, known for its towing and hauling prowess, robust construction, and the availability of powerful diesel engines. It competed in a segment dominated by Chevrolet Silverado HD, GMC Sierra HD, and Dodge Ram HD.

Target Audience:

Owners of the 2003 Ford F-250 Super Duty seeking to perform their own maintenance, diagnostics, and repairs, as well as professional mechanics looking for dealership-level information.

Competitive Analysis:

This manual provides the same level of detail as factory service manuals used by Ford dealerships, offering a significant advantage over generic repair guides. It empowers owners to perform a wide range of maintenance and repairs, saving time and money.

Key Features:

Comprehensive, model-specific repair information, high-quality diagrams and illustrations, wiring schematics, step-by-step instructions, user-friendly PDF format, printable pages, and coverage of all major vehicle systems.

📋 Manual Details

Coverage Areas:

All models and all repairs A-Z for the 2003 Ford F-250 Super Duty.

Page Count:

Not specified, but described as comprehensive for all repairs.

Manual Type:

Service and Repair Manual

Language:

English

Format:

PDF (Printable, Zoomable Images, Searchable)

Compatibility:

Compatible with all versions of Windows and Mac.

Requirements:

Requires Adobe PDF Reader and WinZip (free online).

📖 Manual Coverage

Systems Covered:

Engine, Control System, Mechanical, Fuel Service Specifications, Emission Control, Intake Exhaust Cooling, Lube, Ignition Starting Charging, Automatic Transmission, Clutch, Manual Transmission, Transfer Propeller Shaft, Drive Shaft, Differential, Axle Suspension, Tire & Wheel, Brake Control, Brake, Parking Brake, Steering Column, Power Steering, Air Condition, Supplemental Restraint System, Seat Belt, Engine Immobilizer, Cruise Control, Wiper & Washer, Door Lock, Meter Audio/Visual, Horn, Windshield/Glass Mirror, Instrument Panel, Seat, Engine Hood/ Door, Exterior & Interior, Electrical, Multiplex/CAN Communication, and much more.

Electrical Systems Detail:

Comprehensive electrical schematics, wiring diagrams for all systems including lighting, ignition, charging, starting, instruments, power accessories, and body control modules. Troubleshooting guides for electrical faults.

Fuel System Coverage:

Fuel pump testing, fuel filter replacement (especially critical for diesel), fuel injector diagnostics, fuel tank service, fuel pressure testing, and emission control system diagnostics related to fuel delivery.

Air Conditioning System:

Diagnosis and repair of AC system components, refrigerant handling procedures (referencing EPA guidelines), compressor service, condenser and evaporator maintenance, and blower motor operation.

Procedures Included:

Complete step-by-step instructions for maintenance, service, diagnosis, and repair of all vehicle components. Includes troubleshooting, diagnostic procedures, and component replacement. Specific repair procedures for all listed systems.

Engine Repair Procedures:

Engine disassembly, assembly, component testing, cylinder head removal/installation, piston/ring replacement, valve train overhaul, timing component replacement (for gasoline engines), fuel injection system service (for diesel), turbocharger diagnosis and repair.

Brake System Procedures:

Brake pad and rotor replacement, caliper service, brake fluid flush and bleed, parking brake adjustment and repair, hydraulic system diagnosis, ABS component testing and replacement.

Transfer Case And Drivetrain Procedures:

Service and repair of manual and electronic transfer cases, propeller shaft maintenance, U-joint replacement, differential fluid changes, axle shaft removal and installation, and bearing adjustments.

Technical Depth:

Factory-level detailed repair information, equivalent to that used by dealership technicians. Covers basic maintenance to complex diagnostics and complete rebuilds.

Diagnostic Capabilities:

Detailed diagnostic flowcharts, component testing procedures, and specifications for diagnosing engine performance, transmission issues, brake system malfunctions, and electrical gremlins. Covers On-Board Diagnostics (OBD-II) system interpretation.

Chassis And Suspension Repair:

Detailed instructions for front and rear suspension component replacement (shocks, springs, control arms, bushings), steering gear service, wheel bearing replacement, and alignment specifications.

📊 Manual Specifications

File Format:

PDF

Searchability:

Searchable text within the PDF allows for quick location of specific information.

Print Quality:

High-quality, printable pages with zoomable images and diagrams.

Binding Type:

Digital (PDF), allowing for selective printing and portability.

Paper Type:

N/A (Digital format, printable on user's choice of paper)

⚙️ Engine Specifications

Primary Engine Options:

5.4L Triton V8 (330 cid), 6.8L Triton V10 (415 cid), 7.3L Power Stroke V8 Turbo Diesel (444 cid).

Typical Horsepower Range:

5.4L V8: ~260 hp, 6.8L V10: ~310 hp, 7.3L Power Stroke: ~250 hp (varies slightly by year/configuration).

Torque Specifications Diesel:

The 7.3L Power Stroke diesel is renowned for its torque output, typically in the range of 500-525 lb-ft, making it ideal for towing.

Fuel System Types:

Port Fuel Injection (PFI) for gasoline engines, Direct Injection with HEUI (Hydraulically Actuated Electronically Controlled Unit Injector) for the 7.3L Power Stroke diesel.

Engine Codes:

5.4L: 3V Triton (though typically 2V in this era), 6.8L: Triton V10, 7.3L: Power Stroke (IDI or DI Turbo depending on specific sub-variant).

🔧 Transmission

Standard Transmission:

5-speed manual (likely ZF S6-650 for gasoline, ZF S6-750 for diesel)

Optional Transmission:

4-speed automatic (4R100 for V8/V10, maybe a diesel-specific variant like the E4OD predecessor for 7.3L variants).

Transmission Features:

Manual transmissions typically featured overdrive gears. Automatic transmissions often included electronic control and overdrive for improved fuel economy and performance. Transfer case options likely included manual shift and electronic shift-on-the-fly.

Transmission Fluid Type:

Automatic transmissions typically used MERCON V ATF (Automatic Transmission Fluid). Manual transmissions used specific gear oils (e.g., SAE 75W-90 GL-5).

📐 Dimensions

Wheelbase Options:

Multiple wheelbase options available, typically ranging from 137 to 172 inches depending on cab and bed configuration (e.g., Regular Cab, SuperCab, Crew Cab with 8ft bed).

Body Styles:

Regular Cab, SuperCab (extended cab), Crew Cab (four-door).

Gvwr Range:

Gross Vehicle Weight Rating (GVWR) typically ranged from 8,800 lbs to 11,500 lbs, depending on configuration and axle ratings.

Curb Weight Range:

Curb weight varied significantly based on configuration, typically from approximately 5,800 lbs to over 7,500 lbs.

🛡️ Safety Features

NHTSA Ratings:

Specific NHTSA ratings for 2003 models are not universally documented in the provided product information, but generally, Super Duty trucks of this era aimed for high safety standards for their class. The manual would contain specific diagnostic and repair procedures for safety systems.

Passive Safety Features:

Front airbags, three-point seat belts, reinforced passenger compartment structure, side-impact door beams.

Active Safety Features:

Four-wheel Anti-lock Braking System (ABS), Traction Control (potentially optional on some models).

💡 Technology Features

Infotainment Options:

Base models featured a standard AM/FM/CD player. Higher trims could include upgraded audio systems with cassette players, CD changers, and premium speaker options. Navigation systems were not common in this era for trucks.

Instrument Cluster Features:

Includes tachometer, speedometer, fuel gauge, engine temperature gauge, oil pressure gauge, and warning lights for various systems. Trip computer functionality may be present on higher trims.

Driver Assistance Features:

Limited by modern standards. Features included cruise control. ABS (Anti-lock Braking System) was standard on all wheels. Some models might have had optional trailer brake controllers.

Connectivity Features:

Basic connectivity features were limited. Some models might have offered a basic auxiliary input for external audio devices. Ford's PATS (Passive Anti-Theft System) was a key electronic security feature.

🔧 Maintenance

Typical Oil Change Interval:

For gasoline engines, typically 5,000-7,500 miles or 6 months. For the 7.3L Power Stroke diesel, it was often 5,000-10,000 miles or 6 months, with specific intervals for severe service. The manual will detail exact intervals based on engine and usage.

Differential Fluid Change Interval:

Typically every 30,000-50,000 miles or based on towing conditions. Fluid type would be SAE 80W-90 GL-5 for conventional differentials, and potentially synthetic or limited-slip additive required for specific axle types.

Engine Oil Specifications:

Gasoline engines typically required 5W-20 or 5W-30 synthetic blend or full synthetic oil meeting Ford specifications (e.g., WSS-M2C153-H). The 7.3L Power Stroke diesel required 15W-40 heavy-duty diesel engine oil (e.g., CJ-4 or CK-4 rated).

Coolant Specifications:

Conventional green ethylene glycol coolant, typically a 50/50 mixture with distilled water. Ford specification likely WSS-M97B44-D. Capacity varied by engine.

Power Steering Fluid:

Likely Ford's specification for power steering fluid, typically a Dexron-III/MERCON compatible fluid or a specific Mercon ATF.

Common Issues And Maintenance Points:

The 7.3L Power Stroke diesel is known for its durability, but common areas for maintenance include fuel filter replacement (critical for longevity), checking the CPS (Camshaft Position Sensor), and ensuring proper cooling system maintenance. Gasoline engines can experience spark plug issues (especially on the Triton V10's rear plugs) and intake manifold leaks. Brake wear and suspension component wear are common due to the heavy-duty nature of the truck.

Suspension And Steering Maintenance:

Regular inspection of ball joints, tie rod ends, and steering linkages for wear is crucial due to the heavy-duty nature. Greasing points on the suspension and steering components should be addressed per the maintenance schedule.

Electrical System Maintenance Points:

Checking for corrosion on battery terminals and ground connections, inspecting wiring harnesses for damage or chafing, and ensuring proper operation of all lights and accessories.

📚 Vehicle History

Brand Heritage:

Ford has a long-standing legacy in the pickup truck market, with the F-Series being a perennial best-seller in North America for decades. The Super Duty line was introduced to differentiate heavy-duty trucks from the lighter-duty F-150.

Model Evolution:

The 2003 model year falls within the second generation of the Super Duty F-Series (1999-2007), which saw significant updates and refinements. This generation was known for its bold styling and powerful drivetrain options.

Manufacturing Locations:

Major assembly plants included Kentucky Truck Plant (USA) and Cuautitlán Stamping and Assembly (Mexico).