2003 Ford F-550 Super Duty Service and Repair Manual
This factory service and repair manual for the 2003 Ford F-550 Super Duty covers three engines: the turbocharged 6.0L OHV V8 diesel of 363 cubic inches, the naturally aspirated 6.8L SOHC V10 gasoline engine of 415 cubic inches, and the turbocharged 7.3L OHV V8 diesel of 445 cubic inches. Body styles are the four-door crew cab, two-door conventional and four-door extended cab chassis, and the trims are Base, XL, XLT and Lariat. Procedures, specifications, torque values, wiring diagrams and diagnostics are set out for each of the three engines separately, with the fuel and cooling systems of the two diesels given their own figures.
Engines covered
- 6.0L V8 (363 cu in) — OHV, turbocharged, diesel
- 6.8L V10 (415 cu in) — SOHC, naturally aspirated, gasoline
- 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 2003 F-550 Super Duty. Five recalls are on federal record for 2003. Two concern the speed control deactivation switch that may overheat and burn; one covers the 7.3L diesel camshaft position sensor that can cut out and stall the engine; and one a loose engine ground stud on 6.0L diesels that can overheat the radio suppression strap. Owners have logged 33 complaints with NHTSA, 16 on the fuel system and six on the engine and engine cooling. The manual's fuel system procedures for all three engines, ground circuit wiring diagrams and cooling diagnostics cover those areas.
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
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
ON CERTAIN TRUCKS EQUIPPED WITH SPEED CONTROL, GASOLINE OR NATURAL GAS ENGINES, THE SPEED CONTROL DEACTIVATION SWITCH MAY OVERHEAT.
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.
ON CERTAIN PICKUP TRUCKS AND SPORT UTILITY VEHICLES EQUIPPED WITH 6.0L DIESEL ENGINES, THE ENGINE GROUND STUD THAT ATTACHES THE NEGATIVE BATTERY TERMINAL EYELET TO THE ENGINE BLOCK MAY BE LOOSE.
When performing any transmission fluid changes or topoffs involving MERCON SP, MERCON LV has replaced all versions of MERCON SP and can be used going forward. Mixing MERCON LV and MERCON SP in the same transmission is acceptable. After 30-J
This SKU is a Transmission Line. The customer communication requested return of unsold inventory to inspect the connector. The transmission line connector may have an incorrect thread size, which will prevent it from being installed.
FORD: WHEN SHIFTING BETWEEN PARK, REVERSE AND/OR DURING 2-3 SHIFT, AN INTERMITTENT CLUNK OCCURS WITH A TORQSHIFT TRANSMISSION. MODEL 2003-2014 F-SUPER DUTY, E SERIES, EXCURSION, F-53 MOTORHOME CHASSIS, LOW CAB FORWARD. *PE
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
FORD: ON SOME TRUCKS, THERE IS A NO CRANK SITUATION AND IF VOLTAGE ON TRANSMISSION RANGE SENSOR AT PIN 21, IS LESS THAN 5 VOLTS, DISCONNECT THE ENGINE COOLING FAN CLUTCH, ELECTRONICALLY, AND RECHECK VOLTAGE. MODEL 2003-2007 F SUPER DUTY, 20
6.0L TURBOCHARGER CARBON DEPOSIT DIAGNOSTICS AND SERVICE TIPS. *NJ UPDATED 5/29/08. *NJ
6.0L--MIL ON--P0401, P0402, P0404, P1335--LACK OF POWER OR SURGE WITH SOME 2003-2007 F-SUPER DUTY, 2003-2005 EXCURSION AND 2004-2008 E-SERIES VEHICLES. *NJ
1999-2008 F250-F550 SUPER DUTY 4X4 WITH ELECTRONIC SHIFT TRANSFER CASE NOT ENGAGING 4X4. *NJ
Showing the 8 most recent of 91 technical service bulletins on file with NHTSA.
DT: THE CONTACT STATED THAT THE SEAT BELT LOCKED AROUND HIS CHEST LIMITING MOVEMENT TO THE POINT OF CAUSING SLIGHT WHIPLASH. THE CONSUMER WAS TRYING TO GET A DIET PEPSI POSITIONED IN A CUP HOLDER TRAY. WHILE THE CONSUMER WAS RESTRICTED,
WATTER SEPERATOR VALVE DUMPED FUEL ON THE TURBO CAUSING A FIRE.
Showing the 2 most serious of 33 complaints filed with NHTSA.
