The 2002 F-350 with the 7.3L Power Stroke is one of the last and most desirable of the legendary pre-6.0L diesel Super Duties, known for bulletproof longevity but not without specific high-mileage issues around injectors, turbo seals, and transmission cooling that can get expensive when they hit.
Injector O-Ring and Cup Failure
Common · medium severityTypical onset: 150,000-250,000 mi
Symptoms: Hard starting when engine is cold, White smoke on startup that clears after warm-up, Fuel dilution in oil (check dipstick for fuel smell), Rough idle and loss of power under load
Fix: Requires removing valve covers and injectors to replace O-rings and sometimes injector cups in the cylinder head. Budget 8-12 hours labor for all eight injectors. Many shops recommend doing all eight at once since you're already in there.
Estimated cost: $1,800-3,200
Turbo Exhaust Back-Pressure Valve (EBPV) and Pedestal Oil Leak
Common · medium severityTypical onset: 120,000-200,000 mi
Symptoms: Oil leak visible on top of turbo or running down engine block, Turbo pedestal oil pooling, Loss of power on acceleration (if EBPV sticks), Occasional turbo whistle or shaft play
Fix: Turbo pedestal O-rings fail and leak oil. Many techs delete the EBPV (exhaust brake valve) entirely during turbo service. Turbo R&R is 6-8 hours; just pedestal seal is 4-5 hours. If turbo bearings are worn, replace the whole unit.
Estimated cost: $800-2,500
Transmission Oil Cooler Line Failure and Cooler Contamination
Common · high severityTypical onset: 80,000-150,000 mi
Symptoms: Transmission fluid in coolant (strawberry milkshake in overflow), Coolant in transmission (check trans dipstick for foamy pink fluid), Transmission slipping or delayed engagement, Engine overheating or erratic temp gauge
Fix: Internal transmission cooler in radiator fails, mixing fluids. Requires new radiator, full trans flush, often torque converter replacement, and sometimes full transmission rebuild if contamination is severe. This is a catastrophic failure if not caught early. 8-15 hours labor depending on trans damage.
Estimated cost: $1,500-5,500
Cam Position Sensor (CPS) Failure
Occasional · high severityTypical onset: 100,000-180,000 mi
Symptoms: Sudden no-start condition with no warning, Engine stalling while driving (dangerous), Intermittent crank/no-start that comes and goes, No codes thrown in many cases until total failure
Fix: The CPS on the 7.3L is buried behind the front cover and requires significant disassembly. Budget 3-5 hours labor. Many owners carry a spare sensor because failure is unpredictable and leaves you stranded. This is the Achilles heel of an otherwise reliable engine.
Estimated cost: $400-800
Glow Plug Relay and Glow Plug Failure
Occasional · low severityTypical onset: 120,000-200,000 mi
Symptoms: Extended cranking in cold weather (below 40°F), White smoke on cold start, Check engine light with glow plug circuit codes, One or more cylinders not firing until warm
Fix: Glow plug relay under valve cover fails, or individual glow plugs break. Relay replacement is 2 hours; full glow plug set is 4-6 hours. Plugs can break off in head if not careful during removal (adds significant time and cost).
Estimated cost: $300-1,200
High-Pressure Oil Pump (HPOP) and IPR Valve Issues
Occasional · high severityTypical onset: 180,000-280,000 mi
Symptoms: Long crank times (10-15 seconds) before starting, Loss of power under heavy throttle, Stalling at idle or when coming to a stop, ICP (injection control pressure) codes, Engine won't start when hot
Fix: The HEUI injection system relies on high-pressure oil. IPR valve (Injection Pressure Regulator) fails first usually (2-3 hours), but HPOP itself can wear out or develop internal leaks. Full HPOP replacement is 8-10 hours and requires removing turbo and valley cover.
Estimated cost: $500-2,800
Fuel Bowl Heater O-Ring Leak
Occasional · low severityTypical onset: Any mileage, climate-dependent
Symptoms: Diesel fuel dripping from top of engine, Strong fuel smell in engine bay, Fuel staining on top of engine block, Usually worse in cold weather due to thermal cycling
Fix: The fuel filter housing has a bowl heater with an O-ring that hardens and leaks. Simple fix: 1 hour labor, inexpensive part. Often overlooked but creates a fire hazard and makes a mess.
Estimated cost: $150-300
Ball Joint and Front Axle U-Joint Wear
Common · medium severityTypical onset: 80,000-120,000 mi
Symptoms: Clunking from front end over bumps, Wandering or loose steering feel, Tire wear on inner or outer edges, Vibration during turns (U-joints)
Fix: Dana 50 or 60 front axles are stout but ball joints wear, especially on 4x4 models. Budget 3-4 hours per side for ball joints. Front axle U-joints require axle shaft removal, 4-6 hours for both sides. Heavy truck = heavy wear.
Estimated cost: $800-1,800
Absolutely buy one used if maintained — the 7.3L is the last of the simple, reliable Ford diesels, but budget for injector work and trans cooler on higher-mileage examples.
AI-assisted summary drawn from NHTSA recall data, our labor-times database, and platform knowledge. Not a substitute for a pre-purchase inspection on a specific vehicle.