2002 Ford F-250 SD problems & reliability
245 owner complaints filed with NHTSA for the 2002 Ford F-250 SD, alongside 3 safety recall campaigns. Last verified Aug 7, 2026. Complaints are unverified reports submitted by owners to the federal Office of Defects Investigation.
Each complaint is counted once (by NHTSA case number), even when it names several vehicles.
9 complaints report injuries (11 injured, 2 deaths reported).
Most reported problems
| Component | Complaints | Share |
|---|---|---|
| Engine and Engine Cooling → | 101 | 41% |
| Electrical System → | 29 | 12% |
| Service Brakes, Hydraulic → | 25 | 10% |
| Tires → | 25 | 10% |
| Vehicle Speed Control → | 14 | 6% |
| Power Train → | 12 | 5% |
| Steering → | 12 | 5% |
| Suspension | 7 | 3% |
| Latches/locks/linkages | 5 | 2% |
| Seat Belts | 5 | 2% |
Component groups as classified by NHTSA. A complaint can name more than one component, so shares may sum to more than 100%.
Common symptoms owners describe
Keyword analysis of complaint narratives; one complaint can describe several symptoms.
Mileage when problems occurred
Half of the failures with a reported odometer reading occurred by 76,000 miles (middle 50% between 47,500 and 105,000 miles), based on 199 complaints that included mileage.
Complaints by incident year
What owners report
“My speed control stopped working in 2012. It is a ford f-250 super duty. Vin [xxx]. Information redacted pursuant to the freedom of information act (foia), 5 u.s.c. 552(b)(6). *tr”
Electrical System · filed May 1, 2017
“The seat belts come unbuckled when driving. This happens to the drive's side more often than passenger side. The belt come undone on highway, in town, just starting out or after an hour there isn't a warning before it happens.the speed of the truck also doesn't make a difference. But it is happening more frequent now…”
Seat Belts · filed Mar 30, 2017
“Truck dies while driving without any warning, can-not find the problem and ford will not acknowledge that there is an issue. *tr”
Engine · filed Jan 17, 2017
Verbatim excerpts from complaints filed with NHTSA. Reports are not independently verified.
Federal defect investigations
- ENGINE STALLING
Engineering Analysis EA06012 · opened Jun 22, 2006 · closed Dec 7, 2007 · led to recall 07V553000
- SPARK PLUG EJECTION FROM CYLINDER HEAD
Defect Petition DP05005 · opened Sep 22, 2005 · closed Jan 4, 2006
- ENGINE COMPARTMENT FIRES
Engineering Analysis EA05005 · opened Mar 22, 2005 · closed Aug 2, 2006 · led to recall 08V025000
- ACCELERATOR PEDAL SENSOR (ETC)
Engineering Analysis EA04006 · opened Feb 23, 2004 · closed Feb 10, 2005
Technical service bulletins
36 manufacturer communications (TSBs, service campaigns, warranty extensions) are on file with NHTSA for the 2002 Ford F-250 SD. The 10 most recent:
This SKU is a Spare Tire Hoist. Test results identified that the pull force parameter was not within specification, as a precautionary measure unsold inventory was requested to be returned for testing and containment…
DOR-U2J7Y-02 · Service Bulletin/Repair Instructions · issued Jan 13, 2020
This SKU is a Spare Tire Hoist. Test results identified that the pull force parameter was not within specification, as a precautionary measure unsold inventory was requested to be returned for testing and containment…
DOR-C2C6H-02 · Service Bulletin/Repair Instructions · issued Jan 13, 2020
Some 2002-2008 F-Super Duty, F-150 and Mark LT vehicles may exhibit concern during or after programing the VSM. The programming may fail or vehicle symptoms such as inoperative door locks, dome lamps, door ajar…
SSM 48157 · Service Bulletin/Repair Instructions · issued Sep 2, 2019
This SKU is a front upper ball joint. The Customer communication requested return of unsold inventory to inspect for ball studs with excessive rotational friction in the ball joint assembly. Excessive friction in the…
DOR-B8H4Z-11 · Service Bulletin/Repair Instructions · issued Oct 2, 2018
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…
ASI-44408 · Service Bulletin/Repair Instructions · issued Feb 1, 2014
Ford trucks service campaign: see document search button for owner letter. Vehicles have experienced severe steering wheel and front wheel vibrations and oscillations after traveling over a bump or dip in the road…
LP-09L02 · Service Bulletin/Repair Instructions · issued Dec 1, 2013
1999-2008 7.3l/6.0l/6.4l/4.5l diesel f-super duty - clean the charge air cooler (cac) system after certain turbo or engine failures - service tip. *nj
20228 · Service Bulletin/Repair Instructions · issued Apr 1, 2008
1999-2008 f250-f550 super duty 4x4 with electronic shift transfer case not engaging 4x4. *nj
20052 · Service Bulletin/Repair Instructions · issued Nov 1, 2007
Lack of power due to low fuel pressure - fuel tank liner seperation. *kb
19728 · Service Bulletin/Repair Instructions · issued Apr 1, 2007
Lack of power due to low fuel pressure, fuel tank liner seperation. *kb
19621 · Service Bulletin/Repair Instructions · issued Feb 1, 2007
TSBs are repair guidance manufacturers send to dealers — they are not recalls and repairs are not automatically free. Full documents are available on NHTSA’s site.
Safety recalls
The 2002 Ford F-250 SD has 3 NHTSA recall campaigns — recall repairs are free at franchised dealers regardless of the vehicle’s age.
Check whether your specific vehicle is affected
Recall campaigns often cover only certain VIN ranges. Enter your VIN on the official NHTSA site to confirm whether your vehicle is included and whether the repair is still open.
Check VIN on NHTSA →Buying a used 2002 Ford F-250 SD?
- · Decode the seller’s VIN with our free VIN decoder to confirm the exact year, engine and trim.
- · Check for unrepaired recalls by VIN on NHTSA’s official lookup — recall repairs are free.
- · Owners most often reported problems around 76,000 miles — budget accordingly if the car is approaching that mileage.