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 severity
Typical 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 severity
Typical 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 severity
Typical 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 severity
Typical 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 severity
Typical 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 severity
Typical 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 severity
Typical 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 severity
Typical 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
Owner tips
Change fuel filters religiously every 10,000-15,000 miles — the 7.3L is sensitive to dirty fuel and it's cheap insurance
Monitor coolant and transmission fluid at every oil change for cross-contamination signs
Carry a spare CPS sensor in the glovebox if you depend on this truck — it's the only common failure that leaves you dead on the road
Use Motorcraft or premium oils and filters — the HEUI injection system is sensitive to oil quality and viscosity
Inspect turbo and EBPV for oil leaks annually; small leaks turn into expensive problems if ignored
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.
Fitment notes: 7.3L Power Stroke diesel requires high CCA battery; dual battery setup available on some configurations
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Every control module on the 1999-2004 Ford F-350 — where it lives, replacement time, and what it takes to program a replacement. Modules marked dealer / factory tool won't work after a part swap alone — budget for programming.
📍 Distributed system: transceiver in Instrument Cluster, authentication in PCM
🔧 Ford NGS or Ford IDS
⚠️ Not a separate module. Key programming requires dealer tool access to PCM and IC. Two programmed keys required to self-program additional keys.
Lighting Control Module (LCM)dealer / factory toolwith automatic headlamps or advanced lighting features▸ programming details
📍 Integrated within GEM/SJB
🔧 Ford NGS or Ford IDS
⚠️ Not a separate module; function integrated in GEM/SJB. Configuration handled during GEM programming.
Aftermarket tool coverage varies by software version and vehicle build — treat "aftermarket tool" rows as "usually possible" and verify against your tool maker's coverage list before promising a customer. Spot a wrong location or hour? Tell us — corrections ship fast here.
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 THROUGH 2011 MODEL YEAR RANGER TRUCKS, 2002 THROUGH 2005 MODEL YEAR EXCURSION VEHICLES, AND 2002 THROUGH 2007 MODEL YEAR F-250, F-350, F-450, AND F-550 TRUCKS FOR FAILING TO COMPLY WITH THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 108, "LAMPS, REFLECTIVE DEVICES, AND ASSOCIATED EQUIPMENT." THE MULTI-FUNCTION SWITCH WAS SHIPPED WITH A SUBCOMPONENT (SLIDER) THAT MAY EXPERIENCE DEFORMATION. A MULTI-FUNCTION SWITCH WITH A DEFORMED SLIDER MAY MALFUNCTION CAUSING THE TURN SIGNAL, TAIL LIGHTS, HAZARD WARNING SIGNAL FLASHERS AND/OR BRAKE LIGHTS NOT TO ACTIVATE.
Consequence: NON-FUNCTIONING LIGHTS COULD INCREASE THE RISK OF A CRASH.
Remedy: DEALERS WILL REPLACE THE SWITCHES FREE OF CHARGE. THE SAFETY RECALL BEGAN ON AUGUST 15, 2011. OWNERS MAY CONTACT FORD MOTOR COMPANY CUSTOMER RELATIONSHIP CENTER AT 1-866-436-7332.
EQUIPMENT:ELECTRICAL · 07E066000
2007-08-28
CERTAIN CEQUENT 90 DEGREE 7-WAY RIGHT ANGLE ADAPTORS SOLD BY DISTRIBUTORS IN TOW PACKAGES FOR AFTERMARKET SALES TO TOW 5TH WHEEL RV TRAVEL TRAILERS. DUE TO INCORRECT WIRING OF THE HARNESS, THE TRAILER LIGHTS MAY NOT OPERATE PROPERLY.
Consequence: IF THE TRAILER LIGHTS ARE NOT WORKING PROPERLY, A VEHICLE CRASH CAN OCCUR.
Remedy: ALL OF THE DEFECTIVE TOW PACKAGES ARE STILL AT THE DISTRIBUTOR LEVEL AND HAVE NOT BEEN SOLD TO ANY CONSUMERS.
VEHICLE SPEED CONTROL · 06V286000
2006-08-01 · EA05005
ON CERTAIN TRUCKS EQUIPPED WITH SPEED CONTROL, GASOLINE OR NATURAL GAS ENGINES, THE SPEED CONTROL DEACTIVATION SWITCH MAY OVERHEAT.
Consequence: OVERHEATING COULD RESULT IN SMOKE OR BURN AND AN UNDERHOOD FIRE.
Remedy: DEALERS WILL INSTALL A FUSED WIRING HARNESS INTO THE SPEED CONTROL SYSTEM FREE OF CHARGE. THE RECALL BEGAN ON AUGUST 7, 2006. OWNERS MAY CONTACT FORD AT 1-866-436-7332. (NOTE: ALSO SEE RECALLS 05V017 AND 05V388)
Performance
Horsepower
250hp
Torque
505lb-ft
0–60 mph
9.8sec
Quarter mile
17.4sec
Top speed
95mph
Capability & size
Towing capacity
12,500lb
Payload
3,940lb
Curb weight
6,800lb
Wiper blades
Tenth generation F-Series Super Duty (1999-2004). Standard hook arm configuration.
Size-standard part numbers — verify your connector type before buying. Rear blades are model-specific; check the package's vehicle list.
Fuel economy figures are EPA data via fueleconomy.gov (median across matching trims). Performance figures are compiled estimates for the 2002 Ford F-350 7.3L V8 Power Stroke Diesel and can vary by trim.
🔧 Database maintained under the daily editorial review of Chris Hackleman · Master Technician · 20+ years and Jeff Moore · Master Lexus & Toyota Mechanic · 20+ years.