2002 Ford F-650 Service and Repair Manual
This factory service and repair manual for the 2002 Ford F-650 covers the medium duty straight truck in Base trim with three cab configurations, two-door long conventional, four-door extended cab and four-door crew cab, and three turbocharged diesel engines: the 5.9L inline-six of 359 cubic inches, the 7.2L inline-six of 441 cubic inches and the 7.3L V8 of 444 cubic inches. The procedures, specifications, torque values, wiring diagrams and diagnostics treat each diesel on its own and the air brakes, electrical system and power train of the chassis together, since those are shared across every cab.
Engines covered
- 5.9L inline-six (359 cu in) — turbocharged, diesel
- 7.2L inline-six (441 cu in) — turbocharged, diesel
- 7.3L V8 (444 cu in) — turbocharged, diesel
Body styles covered
- 2-door straight truck, long conventional
- 4-door straight truck, extended cab
- 4-door straight truck, crew cab
Trims covered
- Base
Known issues on the 2002 F-650. One recall is on federal record for the 2002 F-650: on air brake trucks fitted with the optional trailer package, the brake lines connected to the tractor protection valve were misrouted, so a leak in the primary or secondary air circuit could reduce or remove trailer braking. Owners have logged three complaints with NHTSA, one each on the electrical system, the service brakes and the power train, with no single system standing out. The manual's air brake procedures and line routing specifications, its wiring diagrams and its power train coverage for the three diesels address the systems on record.
CERTAIN MEDIUM DUTY PICKUP TRUCKS EQUIPPED WITH AIR BRAKES THAT INCLUDE THE OPTIONAL TRAILER PACKAGE FAIL TO COMPLY WITH THE REQUIREMENTS OF FMVSS NO. 121, "AIR BRAKE SYSTEMS." TH
FUEL CONDITIONER. LOW POWER, POOR FUEL ECONOMY, FUEL GELLING IN COLD WEATHER, EXCESSIVE WHITE SMOKE ON COLD START, HARD START, OR COKING OF COMPONENTS EXPOSED TO EXHAUST. *TT
VACUUM PUMP INOPERATIVE OR RUNS CONTINUOUSLY - CLIMATE CONTROL DEFAULTS TO DEFROST MODE. *TT
HEADLIGHT ADJUSTMENT - CHASSIS CAB INCOMPLETE VEHICLES. *TT
ADDING ADDITIONAL BULBS TO TURN INDICATOR OR HAZARD FLASHER CIRCUITS - SERVICE TIPS. *TT
LOUD SQUEALING NOISE FROM THE ENGINE AREA WHEN THE ENGINE FAN CLUTCH IS UNDER LOAD WHILE OPERATED IN HOT DUSTY CLIMATES. VEHICLES EQUIPPED WITH A 7.3L ENGINE. *TT
VACUM PUMP INOPERATIVE OR RUNS CONTINUOSLY - CLIMATE CONTROL DEFAULT TO DEFROST. *AR
VACUUM PUMP INOPERATIVE OR RUNS CONTINUOUSLY - CLIMATE CONTROL DEFAULTS TO DEFROST. OASIS. TO ALSO INCLUDE 2005 SUPER DUTY F-SERIES, EXCURSION, AND F650/750. *TT
MULTIPLE VEHICLES - FUEL LEVEL INDICATION CONCERNS - SERVICE TIP. VARIOUS MODELS INCLUDING 2005 SUPER DUTY F-SERIES, EXCURSION, EXPEDITION, EXPLORER, MOUNTAINEER AND AVIATOR. *TT
Showing the 8 most recent of 29 technical service bulletins on file with NHTSA.
WHEN IT RAINS OUT IT MAY START ON ITS OWN TURN LIGHTS ON SITTING IN THE DRIVEWAY IN THE MIDDLE OF THE NIGHT WAS THE FIRST TIME IT ALWAYS STARTS WHILE SITTING TOLD THERE WAS A PROBL
WHEN IT RAINS OUT IT MAY START ON ITS OWN TURN LIGHTS ON SITTING IN THE DRIVEWAY IN THE MIDDLE OF THE NIGHT WAS THE FIRST TIME IT ALWAYS STARTS WHILE SITTING TOLD THERE WAS A PROBL
Showing the 2 most serious of 3 complaints filed with NHTSA.
