2002 Ford F-150 Service and Repair Manual

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Factory-Grade Data

The 2002 Ford F-150 service and repair manual is a detailed, OEM-style reference for diagnostics, maintenance, and repair work. Use it to verify procedures, specifications, and system information before you start a job.

You'll find coverage across key vehicle systems with clear section structure, including wiring diagrams and powertrain, braking, steering, suspension, HVAC, and electrical topics. Digital format makes it easy to search while you work.

Trims covered

  • Lariat Crew Cab Pickup 4-Door
  • XLT Standard Cab Pickup 2-Door
  • XLT Crew Cab Pickup 4-Door
  • XLT Extended Cab Pickup 4-Door
  • King Ranch Crew Cab Pickup 4-Door
  • Lariat Extended Cab Pickup 4-Door
  • Lightning Standard Cab Pickup 2-Door
  • Harley-Davidson Edition Crew Cab Pickup 4-Door
  • XL Standard Cab Pickup 2-Door
  • King Ranch Extended Cab Pickup 2-Door
  • XL Extended Cab Pickup 4-Door

Engines covered

  • 5.4L 330Cu. In. V8 CNG SOHC Naturally Aspirated
  • 4.6L 281Cu. In. V8 GAS SOHC Naturally Aspirated
  • 5.4L 330Cu. In. V8 BI-FUEL SOHC Naturally Aspirated
  • 5.4L 330Cu. In. V8 GAS SOHC Naturally Aspirated
  • 4.2L 256Cu. In. V6 GAS OHV Naturally Aspirated
  • 5.4L 330Cu. In. V8 GAS SOHC Supercharged

Index / Table of contents

  • Body
  • Brakes
  • Chassis Electrical
  • Driveline
  • Engine Cooling
  • Engine Electrical
  • Engine Mechanical
  • Engine Performance & Emission Controls
  • Fuel System
  • General Information & Identification
  • Heating, Ventilation, & Air Conditioning
  • Hybrid & Electric Vehicle Systems
  • Steering
  • Suspension
  • Transmission, Clutch, & Transfer Case
  • Wiring Diagrams

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Vehicle Safety Data

2002 Ford F-150 Recalls & Complaints

NHTSA #11V38500029/07/2011Component: FUEL SYSTEM, GASOLINE:STORAGE:TANK ASSEMBLY:MOUNTING

FORD IS RECALLING CERTAIN 1997 THROUGH 2003 MODEL YEAR FORD F-150, 2004 MODEL YEAR FORD F-150 HERITAGE, 1997 THROUGH 1999 MODEL YEAR F-250 LESS THAN 8,500 LBS. GROSS VEHICLE WEIGHT

Consequence

AS A RESULT OF THE CORROSION, ONE OR BOTH STRAPS MAY FAIL ALLOWING THE FUEL LINES TO SEPAR

Remedy

FORD WILL NOTIFY OWNERS AND INSTRUCT THEM TO TAKE THEIR VEHICLES TO A FORD OR LINCOLN DEAL

NHTSA #08E05000011/08/2008Component: EXTERIOR LIGHTING:HEADLIGHTS

K2 MOTOR IS RECALLING 1,921 AFTERMARKET HEADLAMPS OF VARIOUS MODELS SOLD FOR USE ON THE ABOVE LISTED VEHICLES. THESE HEADLAMPS ARE MISSING THE AMBER SIDE REFLEX REFLECTOR WHICH FA

Consequence

WITHOUT THE AMBER SIDE REFLEX REFLECTORS, THE LIGHTING VISIBILITY MAY BE AFFECTED, POSSIBL

Remedy

K2 MOTOR WILL NOTIFY OWNERS AND OFFER A FULL REFUND. THE RECALL BEGAN ON DECEMEBER 17, 20

NHTSA #09E02500011/05/2009Component: EXTERIOR LIGHTING:HEADLIGHTS

DOPE, INC. IS RECALLING 42,540 COMBINATION CORNER AND BUMPER LAMP ASSEMBLIES OF VARIOUS PART NUMBERS SOLD FOR USE AS AFTERMARKET EQUIPMENT FOR VARIOUS PASSENGER VEHICLES. THESE HE

Consequence

DECREASED LIGHTING VISIBILITY MAY RESULT IN A VEHICLE CRASH.

Remedy

DOPE, INC. WILL NOTIFY OWNERS AND OFFER A FULL REFUND FOR THE NONCOMPLIANT COMBINATION LAM

NHTSA #05V38800007/09/2005Component: VEHICLE SPEED CONTROL

ON CERTAIN PICKUP TRUCKS AND SPORT UTILITY VEHICLES EQUIPPED WITH SPEED CONTROL, THE SPEED CONTROL DEACTIVATION SWITCH MAY OVERHEAT, SMOKE, OR BURN.

Consequence

A FIRE AT THE SWITCH COULD OCCUR.

Remedy

BY LETTER DATED SEPTEMBER 12, 2005, OWNERS WERE INSTRUCTED TO RETURN THEIR VEHICLES TO THE

NHTSA #09E01200007/04/2009Component: EXTERIOR LIGHTING

SABERSPORT IS RECALLING 16,270 COMBINATION CORNER AND BUMPER LAMP ASSEMBLIES OF VARIOUS PART NUMBERS SOLD FOR USE AS AFTERMARKET EQUIPMENT FOR VARIOUS PASSENGER VEHICLES. THESE HE

Consequence

DECREASED LIGHTING VISIBILITY MAY RESULT IN A VEHICLE CRASH.

Remedy

SABERSPORT WILL NOTIFY OWNERS AND OFFER A FULL REFUND FOR THE NONCOMPLIANT COMBINATION LAM

TSB #10205038

Safety recall 11S21 - Fuel tank strap fracture - requests for recall service action

TSB #10183774

For 1997-2003 F-150, 2004 F-150 Heritage, 1997-1999 F-250 Light Duty, or 2002-2003 Blackwood vehicles Safety Recall 11S21 has been issued for vehicles that are operated in high corrosion areas for an extended period, where one or both fuel

TSB #10172885

This SKU is an Oil Dipstick. The customer communication requested return of unsold inventory to inspect the dipstick tube. The dipstick tube inner diameter may be small enough that it prevents installation of the OE dipstick.

TSB #10058101

FORD/LINCOLN: SAFETY RECALL REGARDING HIGH CORROSION AREAS FOR OPERATING, FOR AN EXTENDED TIME, VEHICLES WHERE BOTH OR ONE STRAP OF FUEL TANK CAN FRACTURE, AFTER CONTACTING GROUND. MODEL 1997-99 F250 LD, 1997-03 F150, 2004 F150 HERITAGE, 20

TSB #10056624

FORD/LINCOLN: SAFETY RECALL ISSUED DUE TO ONE OR BOTH FUEL TANK STRAPS FRACTURING DUE TO BEING IN HIGH CORROSION AREAS FOR AN EXTENDED PERIOD AND DISLODGING FUEL TANK. MODEL 1997-99 F250, 1997-03 F150, 2004 F150 HERITAGE, 2002-2003 BLACKWOO

TSB #10024865

1999-2008 7.3L/6.0L/6.4L/4.5L DIESEL F-SUPER DUTY - CLEAN THE CHARGE AIR COOLER (CAC) SYSTEM AFTER CERTAIN TURBO OR ENGINE FAILURES - SERVICE TIP. *NJ

TSB #10023943

SOME 1997-2008 VEHICLES EQUIPPED WITH A 4.6L 2V, 5.4L 2V, OR 6.8L 2V ENGINE--SPARK PLUG THREAD REPAIR PROCEDURE--NOT COVERED UNDER NEW VEHICLE LIMITED WARRANTY. *NJ THIS INCLUDES F-53 MOTORHOME CHASSIS. UPDATED 2/23/10. *PE

TSB #10018745

WDS COP KIT DIAGNOSTIC TIP - COIL ON PLUG (COP) IGNITION SYSTEMS - ENGINE MISFIRE OR ROUGH RUNNING. *TT

Showing the 8 most recent of 134 technical service bulletins on file with NHTSA.

20161201Component: AIR BAGSCrash reportedFire reported1 injured

TL* THE CONTACT OWNED A 2002 FORD F-150. WHILE DRIVING APPROXIMATELY 55 MPH, THE DRIVER CRASHED INTO THE REAR OF A TRAILER THAT WAS STALLED IN THE MIDDLE OF AN INTERSECTION. THE IN

20180401Component: ELECTRICAL SYSTEMCrash reportedFire reported

WOKE UP AT 1AM ONE 4-1-2018 TO MY FORD F 150 ON FIRE DRIVERS SIDE FRONT UNDER THE HOOD. UNKNOW TO US OUR LOCAL SHERIFF HAD SPOTTED THE FIRE AND ALREADY CALLED THE FIRE DEPARTMENT.

20051025Component: AIR BAGSCrash reportedFire reported

2002 FORD F150 AIR BAG DEPLOYED DURING AN ACCIDENT. THE AIR BAG KNOCKED THE CONSUMER OUT OF THE VEHICLE COMPLETELY KNOCKING THE AND GAVE HIM CHEMICAL BURNS. *TS THE CONSUMER WAS

20051025Component: SEAT BELTSCrash reportedFire reported

2002 FORD F150 AIR BAG DEPLOYED DURING AN ACCIDENT. THE AIR BAG KNOCKED THE CONSUMER OUT OF THE VEHICLE COMPLETELY KNOCKING THE AND GAVE HIM CHEMICAL BURNS. *TS THE CONSUMER WAS

Showing the 4 most serious of 964 complaints filed with NHTSA.

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