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2002 Ford F-350 Recalls, Problems & Maintenance

The 2002 Ford F-350 has no open NHTSA recalls. Owners report 7 recurring issue clusters, led by “Spark plug ejection from cylinder head.” Ford uses the Intelligent Oil-Life Monitor (IOLM) to determine when oil changes are due based on actual driving load — not just mileage. Ford's published cap is 10,000 miles or 1 year, whichever comes first. The schedule below reflects Ford's Normal service intervals; F-Series trucks and Super Duty have additional towing-specific items.

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No open recalls on file. NHTSA lists no unrepaired safety recalls for this year, make and model. A recall can be issued at any time, and a specific car can still have one open — check yours by VIN at nhtsa.gov/recalls.

Known issues & problems for this vehicle

What drivers and federal regulators have officially reported about the 2002 Ford F-350.

Reported to NHTSA

Spark plug ejection from cylinder head

ENGINE AND ENGINE COOLING

13 NHTSA complaints · 2004-12 → 2013-10

“I HAVE A 2002 FORD F350 WITH TRITON V10 ENGINE. ON 07/27/06 THE SPARK PLUG BLEW OUT CAUSING LACK OF POWER TO MY VEHICLE AND A DAMAGED COIL. *JB”
— Owner report, NHTSA ODI #10163738
“2002 FORD 350 CREW CAB 4X4 - 52,000 MILES - BLOWN SPARK PLUG AT 42,000 AND NOW AGAIN AT 52,000 MILES. *NM”
— Owner report, NHTSA ODI #10162868
“WHILE DRIVING HEARD A LOUD POPPING NOISE AND TRUCK BEGAN RUNNING ROUGH AND LOST SOME POWER. PULLED TO SIDE OF HIGHWAY, OPENED HOOD AND SAW THAT I LOST #9 SPARK PLUG. WAS OFFERED THROUGH FORD TO EITHER REPLACE THE HEAD FOR $3400.00 OR REPLACE ENTIRE MOTOR FOR $6200.00”
— Owner report, NHTSA ODI #10160827

Read all complaints on NHTSA →

Tire tread separation and blowout

TIRES

39 NHTSA complaints · 2003-10 → 2024-03

“I HAVE A 2002 FORD F-350 SUPER DUTY WITH DUAL REARS. THE TRUCK CAME WITH SEVEN GENERAL TIRES, 23585R16. OF THE SEVEN TIRES, FOUR HAVE FAILED SUDDENLY AND UNEXPECTEDLY WITH TREAD/PLY SEPARATION AND BLOWOUTS”
— Owner report, NHTSA ODI #10152572
“FIRESTONE STEELTEX R4S LT265/R75-16 LEFT REAR TIRE BLEW OUT ON RTE 95 IN S. CAROLINA, 36500 MILES ON TRUCK AT TIME OF BLOWOUT. THE TREAD SEPARATED FROM THE TIRE, WITH NO WARNING”
— Owner report, NHTSA ODI #10060028
“I HAVE A 2002 F350 DUALLY TRUCK WITH GENERAL GRABBER AW M + S LT235/85R16 TIRES WITH 21,700 MILES ON THEM. I HAD A TREAD SEPERATION AND BLOW OUT ON HIGHWAY. I AM VERY UNHAPPY WITH THIS TIRE. THE TREAD ON TIRES IS GOOD NOT SURE WHY IT SEPERATED/BLEW OUT.*AK”
— Owner report, NHTSA ODI #10114432

Read all complaints on NHTSA →

Seat belt unlatching while driving

SEAT BELTS

6 NHTSA complaints · 2011-11 → 2019-12

“TL* THE CONTACT OWNS A 2002 FORD F-350. WHILE DRIVING AT 50 MPH, THE FRONT DRIVER AND PASSENGER SIDE SEAT BELTS INDEPENDENTLY UNLATCHED. THE VEHICLE WAS TAKEN TO A DEALER WHERE IT WAS DIAGNOSED THAT THE SEAT BELTS NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED”
— Owner report, NHTSA ODI #10722329
“TL* THE CONTACT OWNS A 2002 FORD F-350. WHILE DRIVING VARIOUS SPEED, THE SEAT BELT UNLATCHED INDEPENDENTLY. THE FAILURE RECURRED NUMEROUS TIMES. THE VEHICLE WAS TAKEN TO THE DEALER WHERE IT WAS DIAGNOSED THAT THE SEAT BELT NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED”
— Owner report, NHTSA ODI #10865673
“SEAT BELTS UNBUCKLE BY THEMSELVES. THIS HAS HAPPENS WITH THE DRIVER AND PASSENGER SEAT BELTS. DRIVER BUCKLE FAILURE IS MOST FREQUENT. ONE DAY IT WON'T HAPPEN THEN THE NEXT DAY IT WILL UNBUCKLE 5 TIMES IN A SHORT PERIOD OF TIME. AFRAID THIS WILL HAPPEN DURING AN ACCIDENT”
— Owner report, NHTSA ODI #11283085

Read all complaints on NHTSA →

Oil pan rust and leakage

ENGINE AND ENGINE COOLING

7 NHTSA complaints · 2005-10 → 2018-12

“2002 F350 DIESEL, I BOUGHT THIS VEHICLE NEW IN AUGUST 2003 AND HAVE PRESENTLY 93,000 MILES. THE OIL PAN TO THE MOTOR HAS RUSTED THROUGH. I FEEL THIS ITEM SHOULD LAST THE LIFE OF THE VEHICLE”
— Owner report, NHTSA ODI #10140472
“TL* THE CONTACT OWNS A 2002 FORD F-350. THE CONTACT STATED THAT THE ENGINE OIL PAN WAS LEAKING. THE VEHICLE WAS TOWED TO A PRIVATE MECHANIC WHERE IT WAS DIAGNOSED THAT THE OIL PAN WAS RUSTED AND NEEDED TO BE REPLACED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE”
— Owner report, NHTSA ODI #10558174
“TL* THE CONTACT OWNS A 2002 FORD F-350. WHILE PARKED, THE CONTACT DETECTED THAT THE ENGINE OIL PAN WAS LEAKING. THE CONTACT PLANNED TO HAVE VEHICLE REPAIRED BY AN INDEPENDENT MECHANIC. THE MANUFACTURER WAS NOTIFIED OF THE PROBLEM. THE APPROXIMATE FAILURE MILEAGE WAS 123,000”
— Owner report, NHTSA ODI #10448223

Read all complaints on NHTSA →

Camshaft position sensor failure with engine stall

ENGINE AND ENGINE COOLING

19 NHTSA complaints · 2005-11 → 2014-09

“DEFECTIVE CAM POSITION SENSOR CAUSED VEHICLE TO STALL ON FREEWAY. REPLACED CPS. *TR”
— Owner report, NHTSA ODI #10189437
“7.3 L DIESEL ENGINE IN MY 2002 FORD F-350 WOULD JUST STOP DEAD AT NUMEROUS RANDOM TIMES, SOMETIMES WHILE JUST SITTING STILL AND IDLING, OTHERS WHILE DRIVING IN TRAFFIC. AFTER TURNING IGNITION OFF, ENGINE WOULD RESTART AND RUN NORMALLY”
— Owner report, NHTSA ODI #10192849
“I WAS DRIVING MY 2002 FORD F-350 DIESEL WHEN THE ENGINE SUDDENLY SHUT DOWN. THERE WAS A DUMP TRUCK BEHIND ME WHICH WAS FORCED OFF OF THE ROAD IN ORDER TO AVOID HITTING MY VEHICLE. I WAS ABLE TO RESTART THE VEHICLE ONLY TO HAVE IT STALL AGAIN”
— Owner report, NHTSA ODI #10190775

Read all complaints on NHTSA →

Engine compartment fire with block heater plugged in

ENGINE AND ENGINE COOLING

4 NHTSA complaints · 2007-01 → 2013-03

“2002 FORD F350 SUPER DUTY QUAD CAB LE 7.3L DIESEL PARKED IN MY BACK YARD WITH THE ENGINE BLOCK HEATER PLUGGED IN. I HEARD AN EXPLOSION AND LOOKED OUT THE WINDOW. MY TRUCK WAS BURNING FROM UNDER THE HOOD. THE WHOLE FRONT END WAS ON FIRE”
— Owner report, NHTSA ODI #10238306
“MY FORD F350 SUPERDUTY QUAD CAB LARIAT LE DIESEL HAD BEEN SITTING IN MY BACK YARD FOR ABOUT 5 HOURS WITH THE BLOCK HEATER PLUGGED IN. I HEARD AN EXPLOSION AND LOOKED OUT THE WINDOW. THE FRONT OF MY TRUCK WAS ON FIRE”
— Owner report, NHTSA ODI #10220278
“TL* THE CONTACT OWNS A 2002 FORD F-350 SD. THE CONTACT STATED THAT HE PLUGGED AN ENGINE BLOCK WARMER UP FOR APPROXIMATELY 1.5 HOURS. THE CONTACT LATER HEARD A LOUD EXPLOSION AND FOUND THAT THE VEHICLE CAUGHT ON FIRE. THE POLICE AND FIRE DEPARTMENT WERE CONTACTED”
— Owner report, NHTSA ODI #10504423

Read all complaints on NHTSA →

Unintended acceleration and speed control activation

VEHICLE SPEED CONTROL

8 NHTSA complaints · 2003-12 → 2017-03

“OUR 2002 F-350 CRUISE CONTROL ENGAGED ITSELF AND WENT TO FULL THROTTLE WHILE WE WERE STOPPED. A FOUR CAR FENDER BENDER WAS THE RESULT. HAD THIS HAPPENED AT HIGHER SPEED, IT COULD HAVE BEEN CONSIDERABLY MORE SERIOUS. THE CRUISE CONTROL TOOK OVER CONTROL OF THE VEHICLE!! *TR”
— Owner report, NHTSA ODI #10228962
“TL*THE CONTACT OWNS A 2002 FORD F350 SUPER DUTY. WHILE DRIVING AT ANY SPEED, THE VEHICLE SPEED CONTROL WILL ACTIVATE ON ITS OWN. THE ONLY WAY TO DEACTIVATE THE CRUISE CONTROL IS TO STAND ON THE BRAKE PEDAL AND PRESS THE OFF SWITCH”
— Owner report, NHTSA ODI #10235763
“WHILE COMING TO A STOP ACCELERATED TO A HIGH RATE. CONSUMER MANAGED TO STOP THE VEHICLE. DEALERSHIP WAS NOTIFIED, BUT DID NOT RESOLVE THE PROBLEM.*AK DEALER INSTALLED A FLIGHT RECORDER WHICH WAS BORROWED FROM ANOTHER VEHICLE”
— Owner report, NHTSA ODI #10055361

Read all complaints on NHTSA →

Issues on other model years

Source: NHTSA Office of Defects Investigation (ODI). Complaint data refreshed Sep 20, 2026. Investigation data refreshed Sep 20, 2026.

We display NHTSA's record with attribution; we don't editorialize on what these complaints mean for any specific vehicle.

Raw data + downloads for this vehicle →

Essential maintenance

Critical for safety and preventing major damage

Engine Oil & Filter

Every 7,500 mi

Replace synthetic-blend or full-synthetic Motorcraft oil per the IOLM, or every 7,500-10,000 miles. EcoBoost engines require full synthetic; Coyote 5.0L V8 specifies SAE 5W-30.

Estimated cost — typical U.S. ranges

Dealer

~$120–$160

Shop

~$85–$115

DIY

~$25–$55

Full synthetic costs more than conventional. 5-quart 0W-20 + filter is the typical bill.

Tire Rotation

Every 10,000 mi

Rotate tires every 10,000 miles, or with every other oil change. F-150 4x4 owners should rotate every 5,000-7,500 miles to even out drivetrain bias wear.

Estimated cost — typical U.S. ranges

Dealer

~$85

Shop

~$60

DIY

Free

Often free at the shop where you bought the tires — worth asking before paying.

Brake Inspection

Every 10,000 mi

Inspect brake pads, rotors, and brake fluid level every 10,000 miles. Front pads on F-150 and Explorer typically last 40,000-60,000 miles.

Estimated cost — typical U.S. ranges

Dealer

~$85

Shop

~$60

DIY

Free

Most shops do this free as a courtesy with any service. Don't pay separately if you can avoid it.

Brake Fluid

Every 45,000 mi

Ford specifies brake fluid replacement on an inspection basis, but moisture testing every 3 years is recommended. Replace if reading exceeds 3% water content.

Estimated cost — typical U.S. ranges

Dealer

~$180–$200

Shop

~$125–$140

DIY

~$10–$25

DOT 3 or 4 — match the cap. Vacuum bleeders make this a one-person DIY.

Important maintenance

Keeps your vehicle running smoothly and efficiently

Engine Air Filter

Every 30,000 mi

Replace the engine air filter every 30,000 miles. EcoBoost turbocharged engines are sensitive to airflow restriction — don't extend.

Estimated cost — typical U.S. ranges

Dealer

~$60–$95

Shop

~$45–$70

DIY

~$15–$40

5-minute job on most cars; the airbox lid usually has clips, no tools needed.

Automatic Transmission Fluid

Every 150,000 mi

Ford 6R80, 10R80, and 8F transmissions use Mercon LV fluid rated 150,000 miles under normal service. Severe service (towing, plowing) drops this to 60,000 miles.

Estimated cost — typical U.S. ranges

Dealer

~$330–$500

Shop

~$235–$355

DIY

~$60–$180

Some sealed transmissions have no dipstick — fill is precise and best left to a shop. Many drivers can still DIY drain-and-fill.

Transfer Case Fluid (4WD models)

Every 60,000 mi

On 4x4 models, replace transfer case fluid every 60,000 miles. Use Motorcraft XL-12 — do not substitute generic transfer case fluid.

Estimated cost — typical U.S. ranges

Dealer

~$105–$140

Shop

~$75–$100

DIY

~$15–$40

AWD/4WD vehicles only. Easy drain-and-fill on most platforms.

Rear Differential Fluid

Every 100,000 mi

F-Series and Expedition: replace rear axle fluid every 100,000 miles, or 50,000 miles if towing. Limited-slip rear ends require friction-modifier additive.

Estimated cost — typical U.S. ranges

Dealer

~$150–$195

Shop

~$105–$135

DIY

~$20–$50

Drain plug + fill plug — straightforward DIY. AWD vehicles have two; budget for both.

Spark Plugs

Every 100,000 mi

Iridium spark plugs on Coyote 5.0L, EcoBoost 2.7L/3.5L, and 2.3L are rated 100,000 miles. EcoBoost engines: never exceed the interval — gap erosion causes coil failure.

Estimated cost — typical U.S. ranges

Dealer

~$285–$390

Shop

~$200–$275

DIY

~$25–$100

Iridium plugs cost more but last 100k+ miles. V6/V8 access varies wildly — some are tough.

Engine Coolant

Every 50,000 mi

Motorcraft Orange (Dex-Cool compatible) coolant: first change at 100,000 miles, then every 50,000. Older trucks with Yellow Motorcraft coolant: 50,000 miles throughout.

Estimated cost — typical U.S. ranges

Dealer

~$285–$330

Shop

~$200–$235

DIY

~$25–$60

Use the manufacturer-specified coolant — wrong color/chemistry can damage the cooling system.

Recommended maintenance

Extends the life of your vehicle and improves comfort

Cabin Air Filter

Every 20,000 mi

Replace the cabin air filter every 20,000 miles. On F-150, located behind the glove box; on Escape and Explorer, accessed from the passenger footwell.

Estimated cost — typical U.S. ranges

Dealer

~$60–$95

Shop

~$45–$70

DIY

~$15–$40

Usually behind the glovebox. Shops charge labor for a 10-minute job — easy DIY win.

Fatal crash history & reported problems

Occupant deaths in fatal crashes (FARS)

1,790 crashes 1990–2024

How the 1,790 occupant deaths break down

1,376

driver deaths

407

passenger deaths

7

not recorded by seat

1,790

occupant deaths

Crash years covered: 1990–2024 This model year first appears in 2001 crashes. Older models have had more years on the road to appear in these crashes, so a higher count here does not by itself mean a vehicle is less safe.

FARS counts every occupant death in a fatal crash, whatever the cause — it does not mean the vehicle was at fault or defective. Counts are not adjusted for how many of each vehicle are on the road. How to read this number

FARS 2024 data is an annual report file. NHTSA revises these records when the final file is published, so this count can change.

Why we show driver deaths too

Every vehicle has exactly one driver seat, so driver deaths line up fairly when you compare one model to another. Occupant deaths include passengers, so a three row SUV can show a higher number than a two seat car simply because it carries more people.

Both figures are plain counts, not rates. A rate would need to know how many of each vehicle are on the road, and that registration data is not public, so we do not publish rates or scores of any kind.

IIHS publishes driver death rates using this same driver only idea, paired with a registered vehicle years denominator we do not have. Their rates and these counts answer different questions, so do not read either number here as a safety rating.

Owner-reported problem signals

Separate from the federal fatality data above: complaints owners filed with NHTSA about this year and model. These are reports of problems, unverified, and are counted here only as signals.

18

complaints mentioning a crash

15

complaints mentioning a fire

Reviewed known issues for this vehicle

Typical U.S. ranges. Actual quotes vary by shop, parts choice, and vehicle condition.

How we estimate: Dealer = OEM parts × 1.4 + labor × $165/hr. Shop = parts + labor × $115/hr. DIY = parts only.

This maintenance schedule for the 2002 Ford F-350 reflects Ford's published service intervals and the Intelligent Oil-Life Monitor system. Your actual service needs may vary based on driving conditions, climate, and vehicle usage. Always consult your owner's manual for model-specific recommendations.

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