2002 model year · NHTSA recalls, manufacturer TSBs, and owner forum reports · Updated September 2026
2002 · All trims · All engines
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According to Au7o's research across NHTSA recalls, manufacturer TSBs, and owner forum reports, the 2002 Ford F-250 Super Duty has 5 documented known issues, with 3 rated critical. The most serious are 6.8L V10 and 5.4L Triton 2-Valve Spark Plug Ejection from Aluminum Cylinder Head ($300-$1,500 repair), 7.3L Power Stroke Camshaft Position Sensor Failure - Sudden Stall and No Restart ($80-$300 repair) and Speed Control Deactivation Switch Underhood Fire - Recall 07V-078 ($0-$0 repair). Across all issues with published estimates, repair costs range from $80 to $1,500. DIY maintenance guides at au7o.io.
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According to Au7o's research across NHTSA recalls, manufacturer TSBs, and owner forum reports, the 2002 Ford F-250 Super Duty has 5 documented issues. The most frequently reported are: 6.8L V10 and 5.4L Triton 2-Valve Spark Plug Ejection from Aluminum Cylinder Head, 7.3L Power Stroke Camshaft Position Sensor Failure - Sudden Stall and No Restart, Speed Control Deactivation Switch Underhood Fire - Recall 07V-078. Of these, 3 are rated critical and should be addressed promptly.
The 2002 Ford F-250 Super Duty has 5 known issues compiled from NHTSA recalls, manufacturer TSBs, and owner forum reports. 3 issues are rated critical: 6.8L V10 and 5.4L Triton 2-Valve Spark Plug Ejection from Aluminum Cylinder Head and 7.3L Power Stroke Camshaft Position Sensor Failure - Sudden Stall and No Restart and Speed Control Deactivation Switch Underhood Fire - Recall 07V-078. Prospective buyers should inspect for these issues and factor potential repair costs into their purchase decision. Regular maintenance following the manufacturer's schedule helps prevent many common problems.
Repair costs for known Ford F-250 Super Duty issues range from $0 to $1,500, depending on the specific problem and whether you choose DIY or professional repair. The most critical issue, 6.8L V10 and 5.4L Triton 2-Valve Spark Plug Ejection from Aluminum Cylinder Head, typically costs $300-$1,500 to repair. Au7o provides step-by-step DIY maintenance guides that can help reduce repair costs.
The early 2-valve Triton aluminum heads used in the gas Super Duty carry only about four threads in the spark plug bore. Combustion pressure and heat cycling gradually pull those few aluminum threads until the plug backs out and is ejected from the head, often taking the coil-on-… Repairs typically run $300-$1,500. Severity: high.
On the 1999-2003 7.3L Power Stroke the camshaft position sensor is the PCM's only engine-position input. When it fails the PCM no longer knows when to fire the injectors and the engine simply shuts off - often at speed, with no warning and no check engine light. It may restart af… Repairs typically run $80-$300. Severity: high.
The speed control deactivation switch threads into the brake master cylinder and is electrically live at all times, even with the key out and the truck parked. Brake fluid migrates past the internal diaphragm into the electrical side of the switch, where it corrodes and short cir… Repairs typically run $0-$0. Severity: high.
The 1999-2003 7.3L routes exhaust from each head to the turbo through two up-pipes sealed with crush-type 'donut' gaskets, one of which is buried under the engine in an awkward position. Constant heat cycling and expansion blow those gaskets out, so exhaust escapes before it reac… Repairs typically run $500-$1,500. Severity: medium.
The factory steering damper on the F-250 Super Duty wears out and fails, leading to increased steering shimmy, vibration at highway speeds, and reduced ability to dampen road imperfections. The single factory damper is often inadequate for the weight and solid front axle of the S… Repairs typically run $100-$400. Severity: low.
Content on this page was compiled with AI assistance using NHTSA complaints, TSBs, owner reports, and public automotive data. While we strive for accuracy, this information may contain errors. Always verify repair procedures and specifications with your vehicle's service manual or a qualified mechanic.
