2002 Ford F-650 Service and Repair Manual

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Factory-Grade Data

The 2002 Ford F-650 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

  • Base Straight Truck - Long Conventional 2-Door
  • Base Straight Truck - Extended Cab 4-Door
  • Base Straight Truck - Crew Cab 4-Door

Engines covered

  • 5.9L 359Cu. In. l6 DIESEL Turbocharged
  • 7.2L 441Cu. In. l6 DIESEL Turbocharged
  • 7.3L 444Cu. In. V8 DIESEL Turbocharged

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-650 Recalls & Complaints

NHTSA #02V02400018/01/2002Component: SERVICE BRAKES, AIR:SUPPLY:HOSES, LINES/PIPING, AND FITTINGS

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

Consequence

A LEAK IN THE PRIMARY AIR CIRCUIT OR SECONDARY AIR CIRCUIT COULD RESULT IN A REDUCTION OR

Remedy

DEALERS WILL RE-ROUTE THE AIR LINES CONNECTED TO THE TRACTOR PROTECTION VALVE. OWNER NOTIF

TSB #10019075

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

TSB #10018067

VACUUM PUMP INOPERATIVE OR RUNS CONTINUOUSLY - CLIMATE CONTROL DEFAULTS TO DEFROST MODE. *TT

TSB #10017865

HEADLIGHT ADJUSTMENT - CHASSIS CAB INCOMPLETE VEHICLES. *TT

TSB #10013113

ADDING ADDITIONAL BULBS TO TURN INDICATOR OR HAZARD FLASHER CIRCUITS - SERVICE TIPS. *TT

TSB #10013071

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

TSB #10011168

VACUM PUMP INOPERATIVE OR RUNS CONTINUOSLY - CLIMATE CONTROL DEFAULT TO DEFROST. *AR

TSB #10010734

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

TSB #10010731

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.

20151112Component: SERVICE BRAKES

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

20151112Component: ELECTRICAL SYSTEM

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

20151112Component: EXTERIOR LIGHTING

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

20031001Component: POWER TRAIN:CLUTCH ASSEMBLY

THE HYDRAULIC UNIT SLAVE CYLINDER WHEN PUSHING INTO THE CLUTCH DISENGAGED, WHICH CAUSED THE VEHICLE TO ACCELERATE SIMULTANEOUSLY. *AK FLUID LEAKED OUT OF THE MASTER CYLINDER

Showing the 4 most serious of 8 complaints filed with NHTSA.

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