2002 Ford F-550 Super Duty Service and Repair Manual
This factory service and repair manual for the 2002 Ford F-550 Super Duty covers three chassis cab body styles, the four-door crew cab, the two-door conventional and the four-door extended cab, in Base, XL, XLT and Lariat trims. The engine choice is the 6.8L SOHC V10, a 415 cubic inch naturally aspirated engine that could run on gasoline or LPG propane, and the turbocharged 7.3L OHV V8 diesel of 445 cubic inches. With four trims, three cabs and a propane option on the V10, the procedures, specifications, torque values, wiring diagrams and diagnostics have more variants to keep straight than in a simpler year.
Engines covered
- 6.8L V10 (415 cu in) — SOHC, naturally aspirated, gasoline or LPG (propane)
- 7.3L V8 (445 cu in) — OHV, turbocharged, diesel
Body styles covered
- 4-door cab & chassis, crew cab
- 2-door cab & chassis, conventional
- 4-door cab & chassis, extended cab
Trims covered
- Base
- Lariat
- XL
- XLT
Known issues on the 2002 F-550 Super Duty. Five recalls are on federal record for the 2002 F-550: a speed control deactivation switch that may overheat and burn, a second speed control switch defect that can cause a vehicle fire with or without the engine running, and a 7.3L diesel camshaft position sensor that may work intermittently and stall the engine, among others. Owners have logged 22 complaints with NHTSA, with the fuel system at eight, the engine and engine cooling at three and the electrical system at two. The manual's fuel system procedures for gasoline, propane and diesel, its cooling system specifications and its wiring diagrams cover those systems.
FORD IS RECALLING CERTAIN MODEL YEAR 2011 RANGER TRUCKS BUILT FROM JANUARY 25, 2011, THROUGH APRIL 25, 2011 AT THE TWIN CITIES ASSEMBLY PLANT, AND SERVICE PARTS DISTRIBUTED TO DEALERS FOR CERTAIN 2004
ON CERTAIN TRUCKS EQUIPPED WITH SPEED CONTROL, GASOLINE OR NATURAL GAS ENGINES, THE SPEED CONTROL DEACTIVATION SWITCH MAY OVERHEAT.
FORD IS RECALLING MODEL YEARS 1995-2003 WINDSTAR, 2000-2003 EXCURSION DIESEL, 1993-1997 AND 1999-2003 F-250 SD THROUGH F-550 SD DIESEL, 1992-2003 E-150 THROUGH E-550, 1995-2002 EXPLORER, 1997 AND 2002
CERTAIN FEDERAL-MOGUL REPLACEMENT WHEEL HUB ASSEMBLIES WITH THE BRAND NAMES: NATIONAL, CARQUEST P/NOS. 515020, 515021, 515025, 515053, 515054, 515059, AND 515060, SHIPPED BETWEEN JANUARY 23, 2006, AND
ON CERTAIN HEAVY DUTY TRUCKS EQUIPPED WITH 7.3L DIESEL ENGINES, THE CAMSHAFT POSITION SENSOR LOCATED ON THE ENGINE OF THE VEHICLE MAY FUNCTION INTERMITTENTLY, POSSIBLY RESULTING IN AN ENGINE STALL.
FORD: THE RESTRAINT CONTROL MODULE (RCM) WHEN USING VCM II, WOULD HAVE AN ERROR CODE 35 AND DIAGNOSTIC TROUBLE CODE (DTC) B1035, AND DIFFICULTY ATTEMPTING PROGRAMMABLE MODULE INSTALLATION (PMI). MODEL 2001-2004 F-SUPER DUTY. *PE
1999-2008 F250-F550 SUPER DUTY 4X4 WITH ELECTRONIC SHIFT TRANSFER CASE NOT ENGAGING 4X4. *NJ
VACUUM PUMP INOPERATIVE OR RUNS CONTINUOUSLY - CLIMATE CONTROL DEFAULTS TO DEFROST MODE. *TT
SERVICE KIT AVAILABLE FOR WIPER MOTOR WIRING. *TT
HEADLIGHT ADJUSTMENT - CHASSIS CAB INCOMPLETE VEHICLES. *TT
SAFETY BELT RETRACTION SPEED. *TT
GENERAL (PCM) POWER TRAIN CONTROL MODULE PROGRAMMING PROCEDURES. *TT
MEMONTARY RETURN TO IDLE DURING AGGRESSIVE ACCELERATION - DIAGNOSTIC TROUBLE CODE (DTC) P0123. *TT
Showing the 8 most recent of 45 technical service bulletins on file with NHTSA.
TL* THE CONTACT OWNS A 2002 FORD F-550 SD. THE CONTACT STATED THAT WHILE DRIVING APPROXIMATELY 60 MPH, THICK WHITE SMOKE WAS SEEN FROM UNDERNEATH THE VEHICLE. AFTER INSPECTING THE VEHICLE, THE CONTACT DISCOVERED FLAMES COMING FROM UNDER THE
CONNECTOR #270B MELTED AT CENTRAL JUNCTION CONNECTOR. VEHICLE WAS BOTH IN MOTION AND PARKED
Showing the 2 most serious of 22 complaints filed with NHTSA.
