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2002 Ford F-150 Pickup CAR/TRUCK REPAIR PROCEDURES AND DIAGRAMS - WHAT Ford REPAIR SHOPS DON'T WANT YOU TO KNOW
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- Component Locations
- Wiring Diagrams
- Technical Service Bulletins
- Specifications
- A/C & Heater Service
- Brake Service
- Fuel Filter Replacement
- Driveline, U-Joint & CV Axles Replacement
- Starter & Alternator Replacement
- Cabin Air Filter Locations & Replacement
- Maintenance Lamp Reset
- Radiator & Hose Replacement
- Serpentine Belt Service
A/C & HEATER SERVICE PROCEDURES FOR 2002 Ford F-150 Pickup AUTOMOBILES
Air Bag System Precautions -> Ford Motor Co. -> Arming -> 1990-91 -> 1990-92 -> 1991-92 -> 1992-93 -> 1992-94 -> 1992-96 -> 1992-98 -> 1993 -> 1993-94 -> 1993-95 -> 1994 -> 1994-95 -> 1994-96 -> 1994-97 -> 1995 -> 1995-2004 -> 1995-96 -> 1995-98 -> 1996-97 -> 1996-99 -> 1997-2000 -> 1997-2001 -> 1997-2004 -> 1997-99 -> 1998 -> 1998-2000 -> 1998-2002 -> 1999-2000 -> 1999-2001 -> 1999-2002 -> 1999-2004 -> 2000 -> 2000-01 -> 2000-04 -> 2001-02 -> 2001-03 -> 2001-04 -> 2002-03 -> 2002-04 -> 2004 -> Aerostar & Bronco -> Aspire -> Aviator -> Blackwood, Expedition & Navigator -> Built After February 2002 -> Built Before March 2002 -> Capri -> Continental -> Contour & Mystique -> Cougar -> Crown Victoria Grand Marquis & Marauder -> Econoline -> Escape -> Escort, Tracer & ZX2 -> Excursion -> Explorer & Mountaineer -> Explorer Sport & Sport Trac -> F Series -> Focus -> Freestar & Monterey -> Light Trucks & Vans -> LS -> Mark VII -> Mark VIII -> Mustang -> Passenger Cars -> Probe -> Ranger -> Sable & Taurus -> Tempo & Topaz -> Thunderbird -> Town Car -> Villager -> Windstar
Vehicle: 2002 Ford F-150 Pickup 5.4 V8 BI-FUEL
Passenger Cars
Aspire
- Disconnect battery ground cable.
- Wait one minute for back-up power supply to deplete stored energy.
- Remove restraint system diagnostic tool from driver's side air bag module electrical connector.
- Connect driver's side air bag module electrical connector.
- Install driver's side air bag module as outlined under "Component Service."
- Remove restraint system diagnostic tool from passenger's side air bag module electrical connector.
- Install passenger's side air bag module as outlined under "Component Service."
- C...
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BRAKE SERVICE PROCEDURES FOR 2002 Ford F-150 Pickup AUTOMOBILES
Drum Brakes -> Expedition, Explorer, E-Series, F-Series, Mountaineer, Navigator & Ranger -> Brake Service -> Heavy Duty -> Installation -> Removal -> Standard Duty
Vehicle: 2002 Ford F-150 Pickup 4.6 V8 GAS
Drum brakes are available in standard versions or in heavy duty versions. Refer to Figs. and for component locations when performing the following procedures.
Removal
Standard Duty
- Raise and support vehicle, remove rear wheel and tire assemblies.
- Remove and discard spring nut.
- If brake drum is rusted to axle shaft pilot diameter, tap center of brake drum between wheel studs.
- Pull brake drum off of axle.
- If brake drums will not come off, sing a screwdriver, move brake shoe adjusting lever off of brake adjusting screw, then loosen brake adjuster to allow drum to release.
- Remove long brake...
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FUEL FILTER REPLACEMENT PROCEDURES FOR 2002 Ford F-150 Pickup AUTOMOBILES
Ford Motor Co. Light Trucks, SUVs & Vans -> Fuel Pressure Relief -> Gasoline Fuel Injected Engines Except Escape, Freestar, Mariner, Monterey, Villager, 2005-06 Aviator, Explorer & Mountaineer, 2005-06 Expedition & Navigator & 2004-06 F150 & Mark LT
Vehicle: 2002 Ford F-150 Pickup 5.4 V8 CNG
The fuel system remains under high pressure even when the engine is not running. This residual pressure must be relieved before servicing the fuel system. To avoid injury or fire, release pressure from the fuel system before disconnecting any fuel line.
The fuel system pressure must be relieved prior to disconnecting fuel lines to prevent accidental spray of fuel.
After the battery ...
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DRIVELINE, U-JOINT & CV AXLES REPLACEMENT PROCEDURES FOR 2002 Ford F-150 Pickup AUTOMOBILES
CV AXLE SHAFT, Replace -> Front
Vehicle: 2002 Ford F-150 Pickup Lightning 5.4 V8 GAS
Front
Warning: The electrical power to the air suspension system must be shut off prior to hoisting, jacking or towing an air suspension vehicle. This can be accomplished by turning off the air suspension switch located in the righthand kick panel area. Failure to do so can result in unexpected inflation or deflation of the air springs, which can result in shifting of the vehicle during these operations.
- With vehicle in NEUTRAL, position on a hoist.
- Remove the front wheel and tire assembly.
- Remove dust cap and nut from axle halfsha...
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STARTER & ALTERNATOR REPLACEMENT PROCEDURES FOR 2002 Ford F-150 Pickup AUTOMOBILES
Alternator, Replace
Vehicle: 2002 Ford F-150 Pickup 5.4 V8 BI-FUEL
- Disconnect battery ground cable.
- Remove air cleaner inlet and outlet tubes.
- Rotate accessory drive belt tensioner clockwise, then position drive belt aside.
- Release alternator harness locator from alternator bracket.
- Remove alternator harness bracket mounting bolts, then bracket.
- Loosen alternator mou...
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CABIN AIR FILTER LOCATIONS & REPLACEMENT PROCEDURES FOR 2002 Ford F-150 Pickup AUTOMOBILES
Cabin Air Filter Service -> Ford Motor Co. -> 1997-2007 Expedition, F-150, Navigator, 2002 Blackwood & 2006-07 Mark LT
Vehicle: 2002 Ford F-150 Pickup 4.6 V8 GAS
On these models, the cabin air filter is an option.
Under normal operating conditions the cabin air filter should be replaced every 15,000 miles. In dusty areas change the cabin air filter more often.
- From under passenger side of the instrument panel behind the glove compartment, remove the cabin air filter cover to the bottom of the heater plenu...
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MAINTENANCE LAMP RESET PROCEDURES FOR 2002 Ford F-150 Pickup AUTOMOBILES
Ford Motor Co. Trucks -> Electronic Throttle Control ->
Vehicle: 2002 Ford F-150 Pickup 4.6 V8 GAS
Electronic throttle displays when the system has malfunctioned and the engine has defaulted to a limp-home operation. On vehicles equipped with ...
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RADIATOR & HOSE REPLACEMENT PROCEDURES FOR 2002 Ford F-150 Pickup AUTOMOBILES
Radiator, Replace
Vehicle: 2002 Ford F-150 Pickup 5.4 V8 CNG
- Drain cooling system into a suitable container.
- Remove front air deflector if required.
- Remove fan blade and lefthand thread clutch using a suitable fan clutch holding tool and fan clutch wrench tool.
- Disconnect transmission fluid coole...
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SERPENTINE BELT SERVICE PROCEDURES FOR 2002 Ford F-150 Pickup AUTOMOBILES
Serpentine Drive Belt, Replace
Vehicle: 2002 Ford F-150 Pickup 5.4 V8 BI-FUEL
- Rotate drive belt tensioner counterclockwise, using a 1/2 square hole in drive belt tensioner pull...
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COMPONENT LOCATION DIAGRAMS FOR 2002 Ford F-150 Pickup AUTOMOBILES
Component location diagrams for most 2002 Ford F-150 Pickup cars and light trucks sold in the U.S. from 1990+.
Daytime Running Lamps System Diagram for 2002 Ford F-150 Pickup 4.6 V8 GAS Components on diagram: |
Front Seats,Passenger Seat Diagram for 2002 Ford F-150 Pickup 4.2 V6 GAS Components on diagram: |
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WIRING DIAGRAMS FOR 2002 Ford F-150 Pickup AUTOMOBILES
OEM drawn wiring diagrams for most 2002 Ford F-150 Pickup cars and light trucks sold in the U.S.
2002 Ford F-150 Pickup HARLEY-DAVIDSON Edition 5.4 V8 GAS Wiring Diagram Components on diagram: |
2002 Ford F-150 Pickup 4.2 V6 GAS Wiring Diagram Components on diagram: |
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TECHNICAL SERVICE BULLETINS FOR 2002 Ford F-150 Pickup AUTOMOBILES
OEM TSB listings for most 2002 Ford F-150 Pickup cars and light trucks sold in the U.S. from 1985+.
Document: WHITE FLAKES COMING FROM A/C VENTS - REVISED Vehicle: 2002 Ford F-150 Pickup 4.6 V8 GAS Auto Systems: |
Document: RECALL - CERTAIN 1992-2003 MODEL YEAR CARS AND TRUCKS - FUSED JUMPER HARNESS REPLACEMENT FOR VEHICLES SERVICED WITH AN INCOMPATIBLE FUSED JUMPER HARNESS Vehicle: 2002 Ford F-150 Pickup 4.6 V8 GAS Auto Systems: |
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COMPONENT/PARTS SPECIFICATIONS FOR 2002 Ford F-150 Pickup AUTOMOBILES
BRAKE SPECIFICATIONS: Brake drum, rotor, caliper, and related specifications for most 2002 Ford F-150 Pickup cars and light trucks sold in the U.S. and Canada from 1970+.
- Brake caliper mounting bolt torque
- Brake drum runout, machining, & discard specs
- Minimum brake lining thickness.
- Brake rotor runout, parallelism, machining, discard, & finish specs
A/C SYSTEM SPECIFICATIONS: Air conditioning refrigerant capacity and type as well as lubricant capacity for most 2002 Ford F-150 Pickup cars and light trucks sold in the U.S. and Canada from 1980+.
- Refrigerant capacity & type, compressor oil viscosity, total system oil capacity & compressor clutch gap
COOLING SYSTEM BLEED: Cooling system bleeder valve identification, bleeder type and bleed procedures for most domestic and imported cars and light trucks sold in the U.S. and Canada from 1986+.
PREVENTIVE MAINTENANCE: Preventive maintenance recommendations and required services for most domestic and imported cars and light trucks sold in the U.S. and Canada from 1980+. Includes severe and routine service schedules
QUICK-LUBE and ILLUSTRATIONS: Fluid recommendations, capacities, drain plug torques, tire data, and severe service recommended preventive maintenance schedules. Information covers most 2002 Ford F-150 Pickup cars and light trucks sold in the U.S. and Canada from 1980+. Engine and chassis service images.
- Automatic transmission/transaxles capacities, lubricant recommendations
- Differential/final drive capacities, lube recommendations, grades, & viscosities
- Final drive fill & drain plug torques
- Number of lubrication fittings & plugs
- Power steering, brake, & clutch fluid recommendations
- Manual transmission/transaxle capacities, lube recommendations, grades, & viscosities
- Number of lubrication fittings & plugs
- Power steering, brake, & clutch fluid recommendations
- Engine oil capacities, API grade recommendations, SAE viscosity recommendations, drain plug torque
- Severe service maintenance & interval recommendations
- Tire sizes, wheel nut/bolt torque, pressures & rim sizes
- Transfer case capacities, lube recommendations, grades, & viscosities
TUNE-UP & DRIVEABILITY SPECIFICATIONS: Most tune-up specifications for most 2002 Ford F-150 Pickup cars and light trucks sold in the U.S. and Canada from 1980+
- Airflow sensor electrical specifications
- Tensioning specifications for systems with automatic tensioners
- Barometric pressure sensor specs
- Battery group number and cranking performance
- Crankshaft & camshaft position sensor resistance
- Engine compression pressures
- Coolant temperature sensor specs
- Computer advance.
- Diesel fuel temperature sensor resistance.
- Distributor advance specifications
- Ignition pickup coil resistance
- Exhaust gas recirculation temperature sensor resistance
- Engine fastener torque values
- Firing order diagrams
- Fuel system pressures
- Generator (alternator) specs
- Intake air temperature sensor specs
- Ignition coil specifications
- Fuel injector resistance
- Engine idle speeds
- Knock sensor resistance
- Manifold absolute pressure sensor specs
- Mixture control solenoid resistance
- Voltage regulator specs
- Spark plug applications & gaps
- Starter motor electrical specs.
- Tensioning specifications for systems without automatic tensioners
- Throttle body temperature sensor resistance
- Ignition timing in degrees at rpm
- Transmission oil temperature sensor resistance
- Throttle position sensor specs
- Vacuum sensor valve specs
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