2002 FORD F-250 SD Electrical System Problems

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

Mileage: 89,745

THE VSM (VEHICLE SECURITY MODULE) FAILED. SYMPTOMS INCLUDE, BUT ARE NOT LIMITED TO: POWER DOOR LOCKS DO NOT WORK, KEY FOB DOES NOT WORK, AUTO HEADLIGHTS DO NOT WORK, RADIO DOESN'T TURN OFF WHEN KEY IS OUT OF THE IGNITION AND DOOR OPENS, NO AUDIBLE INDICATOR FOR KEY IN THE IGNITION, NO AUDIBLE INDICATOR FOR HEADLIGHTS ON WITH DOOR OPEN, DOME LIGHTS STAY ON. THIS PROBLEM IS WIDESPREAD WITH THIS MODEL YEAR AND THERE ARE MANY REPORTS ON FORUMS AROUND THE INTERNET. FORD HAS ALSO STOPPED MAKING THE ORIGINAL PART AND REPLACED ITS MANUFACTURE WITH A NEW PART WHICH SUPPOSEDLY DOES NOT EXHIBIT THE SAME RANDOM FAILURE RATE. HEADLIGHTS NOT WORKING IS A MAJOR LIFE SAFETY ISSUE. I DROVE WITHOUT HEADLIGHTS ON FOR SOME TIME (AS THE AUTO HEADLIGHTS DID NOT COME ON) AND DID NOT NOTICE IT UNTIL I WAS ON AN UNLIT STREET. ALL OF THE OLD VSMS SHOULD BE CHANGED TO THE NEW MODEL FREE OF CHARGE TO PREVENT THIS FROM HAPPENING. *TR

Mileage: 110,500

WHILE DRIVING I BEGAN TO HEAR A LOUD POPPING NOISE COMING FROM THE ENGINE. AFTER STOPPING AND CHECKING THE ENGINE I NOTICE I HAD A BLOWN OUT SPARK PLUG AND BUSTED IGNITION COIL. I HAVE A 2002 FORD F 250 SD. I HAVE ATTEMPTED TO PUT IN A NEW PLUG BUT IT WILL NOT SCREW INTO THE HOLE. DAMAGE ESTIMATES ARE FROM $150.00 ON LABOR FEES AND $75-100 ON A TEMP. FIX HELICOIL OR HEAD REPLACEMENT FOR $2500.00. FORD MECH. SAID IT HAPPENS ALL THE TIME, DUE TO POOR DESIGN. *JS

Mileage: 150,000

THE WIRING HARNESS FOR THE INJECTORS STARTED FALLING APART. DEALER WHERE I BOUGHT THE TRUCK NEW SAID THEY HAVE BEEN HAVING PROBLEMS WITH THE HARNESS. THEY SAID THEY HAVE A NEW AND IMPROVED HARNESS THAT WILL NOT FALL APART. *TR

Mileage: 137,000

2002 FORD F-250 5.4L TRITON MOTOR. 95,950 MILES ON ENG. SPARK PLUG BLOW OUT. JUST COST ME $775 DOLLARS TO HAVE SPARK PLUG INSERT,NEW SPARK PLUG, AND SPARK PLUG COIL REPLACED. I DID NOT GET THE OLD PARTS BACK. *TR

Mileage: 95,988

MY 2002 FORD F250 V10 WITH AN IMMACULATE MAINTENANCE RECORD AND 70,000 MILES ON IT, STARTED TO TIC, TIC, TIC? I BROUGHT IT TO THE DEALER TODAY TO GET CHECKED OUT, HE GOT IN THE TRUCK AND REVVED THE ENGINE AND....BOOM! A SPARK PLUG SHOT OUT RIGHT BEFORE MY EYES AND GASOLINE/OXYGEN MIST REPEATEDLY SHOT OUT OF THE HOLE!!!. SIMPLY PUT, TIRES WEAR OUT, BALL JOINTS WEAR OUT, WHEEL BEARINGS WEAR OUT. SPARK PLUGS DON'T SHOOT OUT OF CYLINDER HEADS UNLESS THE CYLINDER HEAD IS DEFECTIVE!!!!!!!!!!!! THE REPAIR COST ME $600.00! THERE ARE 1000'S OF COMPLAINTS ON THE WEB OF THE SAME THING HAPPENING TO MANY PEOPLE. FORD NEEDS TO BE HELD ACCOUNTABLE......AND I WANT MY MONEY BACK! *TR

Mileage: 70,500

THE VEHICLE IS DEPENDENT UPON A VEHICLE SECURITY MODULE TO OPEN DOORS, SHOW IF DOORS ARE OPEN OR CLOSED, AUTOMATICALLY LOCK AND UNLOCK DOORS, TURN ON AND OFF LIGHTS, ETC. THE UNIT INSTALLED IN MY VEHICLE HAS BEEN REPLACED BY ANOTHER UNIT BY FORD. FORD HAS NOT RECALLED THIS DEVICE. MANY OWNERS HAVE REPORTED AND HAVE HAD TO REPLACE THESE DEVICES BECAUSE OF THE PROBLEMS WITH LOCKS NOT WORKING (OPEN AND CLOSE), HEADLIGHTS NOT WORKING OR TURNING OFF WHILE DRIVING, FALSE SAFETY INDICATIONS BEING DISPLAYED, ETC. I AM NOW EXPERIENCING THIS PROBLEM AND HAVE TO REPLACE THIS MODULE TO STOP THESE SAME ISSUES IN MY VEHICLE. IT IS A THERMAL PROBLEM AND ONLY OCCURS WHENEVER THE VEHICLE IS WARMED DURING THE DAY IN THE HEAT. IT BEGINS TO WORK PROPERLY AFTER THE AIR CONDITIONER COOLS THE CAB DOWN OR AT NIGHT WHEN THE TEMPERATURES ARE COOLER. THE ORIGINAL PART # IS 2C7T-15K602-AJ, THE REPLACEMENT PART # IS 4C7Z-15604-AC. *TR

Mileage: 133,000

TL* THE CONTACT OWNS A 2002 FORD F-250 SUPER DUTY. THE CONTACT WAS DRIVING AT APPROXIMATE SPEEDS OF 10 MPH WITH A BOAT HITCHED TO THE REAR TRAILER. HE PROCEEDED TO DRIVE DOWNHILL AND SHIFTED INTO SECOND GEAR AND ACTIVATED THE VEHICLE OVERDRIVE. WHEN THE OVERDRIVE WAS ACTIVATED, THE INSTRUMENT PANEL IMMEDIATELY WENT BLANK AND THE VEHICLE WENT IDLE. THE VEHICLE WAS TOWED TO A LOCAL DEALER WHERE THE CONTACT WAS INFORMED THAT A FUSE HAD BLOWN IN THE VEHICLE AND THE DEALER SERVICED THE VEHICLE ACCORDINGLY. THE FAILURE RECURRED ON A SEPARATE OCCASION WHILE TOWING A CAMPER DOWNHILL UNDER SIMILAR CONDITIONS AS THE FIRST FAILURE. THE VEHICLE WAS TAKEN TO AN AUTHORIZED DEALER TO BE SERVICED. THE FAILURE MILEAGE WAS 64,000 AND THE CURRENT MILEAGE WAS 64,100.

Mileage: 64,000

MY 2002 FORD F-250 SUPER DUTY TRUCK CAUGHT FIRE DUE TO THE BRAKE SWITCH RECALL PROBLEM. THE BRAKE SWITCH (UNDER THE HOOD) BURNED AND THE FUSE BLOCK (UNDER THE DASH) MELTED. THE CAB FILLED WITH SMOKE WHILE MY SPOUSE WAS DRIVING. THE SWITCH, FUSE BLOCK, AND CABLE END WERE REPLACED DUE TO THIS INCIDENT. *TR

Mileage: 96,000

2002 F250 SD WOULD STOP ON ME. HAD CPS SENSOR REPLACED CORRECTED PROBLEM. NHTSA HAS A RECALL ON THIS PART.*A

Mileage: 98,745

2002 FORD F250 DIES WHILE DRIVING. *AK

FAILURE OF CAM POSITION SENSOR ON 2002 F250 7.3 DIESEL SUPERDUTY. VEHICLE STARTED TO DIE FOR NO REASON AT RANDOM TIMES. TOOK VEHICLE TO FORD DEALER, AND THEY POINTED TO CPS. REPLACED CPS AT A COST OF $200 AND PROBLEM WENT AWAY. THOUGHT THE PROBLEM WAS FUEL RELATED TO BEGIN WITH UNTIL I WENT ONLINE AND FOUND THE FAILURE ON THE INTERNET ,AND THEN SUSPECTED BY THE DEALER. NO CODES READ.*AK

Mileage: 105,000

I OWN A 2002 FORD F250 7.3L POWER STROKE DIESEL. ON 10-20-06 THE CPS FAILED IN A RAINSTORM. MY WIFE (7 MONTHS PREGNANT) WAS DRIVING AND WAS NEARLY INVOLVED IN A CRASH BECAUSE WHEN THE FAILURE OCCURRED ALL ELECTRONICS DIED AS DID THE MOTOR. THIS RENDERED THE POWER STEERING AND POWER BRAKES USELESS. THIS PROBLEM COULD HAVE CAUSED A FATALITY IF NOT TO MY WIFE BUT OTHER DRIVERS AS WELL. THE TRUCK STRANDED MY WIFE ON THE SIDE OF A COUNTRY ROAD FOR 2 HRS. WAITING FOR A TOW SERVICE. THE VEHICLE HAD TO BE TOWED AND THE CPS REPLACED BEFORE THE TRUCK WOULD RESTART. *JB

Mileage: 123,575

OVER THE LAST 2 MONTHS, THE GENERIC ELECTRONIC MODULE (GEM) HAS SHOWN SIGNS OF FAILURE. FIRST THE DOOR LOCKS WOULD RANDOMLY LOCK AND UNLOCK WHILE THE VEHICLE WAS IN MOTION. FINALLY, THE DOOR LOCKS STOPPED WORKING ALL TOGETHER, THE DOME LIGHT WILL NOT AUTOMATICALLY TURN ON AND THE DOOR AJAR INDICATOR STAYS ILLUMINATED. THE RENO FORD DEALER WOULD NOT RETURN PHONE CALLS TO SCHEDULE A REPAIR. THE PICKUP TRUCK REMAINS UNREPAIRED. *NM

Mileage: 51,500

CAMSHAFT POSITION SENSOR FAILURE. *NM

Mileage: 52,190

ON NOVEMBER 30, 2006, I WAS DRIVING MY 2002 F250 DIESEL SUPER DUTY FORD TRUCK ON INTERSTATE 25 IN DENVER AT 6 AM AND IN THE MIDDLE LANE, EVERYTHING JUST SHUT DOWN. NO POWER BRAKES, STEERING, ETC. I WAS ABLE TO PULL OVER TO THE SHOULDER BUT NOT ALL THE WAY OFF THE INTERSTATE DODGING RUSH HOUR TRAFFIC. I CALLED AAA AND HAD IT TOWED TO A FORD DEALERSHIP. IT WAS A BAD CAM SENSOR AND THIS IS THE SECOND TIME IT HAS FAILED IN LESS THAN 18 MONTHS. THIS WAS A VERY DANGEROUS SITUATION AS I DID NOT GET OFF THE HIGHWAY AND CARS WERE BUZZING BY ONLY A FEW FEET FROM MY DOOR. FORD SAID THIS PART GOES OUT EVERY 25,000 MILES. WHAT A SAFETY HAZARD!! THIS KNOW IT FAILS FREQUENTLY AND THEY ARE NOT PROACTIVE IN INITIATING A RECALL TO IMPROVE THIS PART. I SENT THEM A MESSAGE AND THEY JUST GAVE ME THE STANDARDIZED REPLY. I FEEL THIS NEEDS TO BE REPORTED TO SOMEONE THAT CAN DO SOMETHING ABOUT IT TO PREVENT SOMEONE FROM GETTING HURT. I WENT TO AN AUTO SAFETY WEB SITE AND NOTICED THERE WERE MANY SIMILAR COMMENTS REGARDING THIS SAME PART. CAN YOU HELP? IT MAY SAVE SOMEONE'S LIFE. *NM

Mileage: 125,000

2002 FORD F250 DIESEL TRUCK ON INTERSTATE 25 IN DENVER. PROCEEDING AT 70 MPH IN MIDDLE LANE IN HEAVY FAST TRAFFIC AND SUDDENLY EVERYTHING SHUT DOWN. NO POWER, NO ELECTRICAL, NO BRAKES, NO STEERING, VERY DANGEROUS SITUATION IN RUSH HOUR TRAFFIC. HAD IT TOWED. THIS IS THE SECOND TIME THE CAM SENSOR HAS JUST QUIT WITHIN 1.5 YEARS AT $500 COST TO REPLACE EACH TIME. BUT, I COULD HAVE BEEN SERIOUSLY INJURED. I BELIEVE THIS JUSTIFIES A RECALL TO PREVENT SOMEONE FROM BEING SERIOUSLY HURT. CAM SENSOR!!! *JB

Mileage: 90,000

DT: THE CONTACT STATED ON JUNE 24, 2006 THE VEHICLE BATTERY LIGHT ILLUMINATED. WHEN THE DEALER WAS CONTACTED, THEY RECOMMENDED THE VEHICLE TO BE TOWED TO THE DEALERSHIP. THIS IS THE FOURTH TIME VEHICLE HAS BEEN TAKEN TO THE DEALER FOR ALTERNATOR. THE FIRST THREE TIMES, THE VEHICLE WOULD NOT START AND THE ALTERNATOR WAS REPLACED BY THE DEALER.

Mileage: 42,000

DT*: THE CONTACT STATED THE VEHICLE CAUGHT FIRE DUE TO AN ELECTRICAL SHORT IN THE WIRES AND FUSE BOX. THE INSURANCE COMPANY IS CURRENTLY INVESTIGATING AND WILL PROVIDE ADDITIONAL DETAILS AT A LATER TIME.

I HAVE A FORD 2002 F-250 SUPER DUTY THAT THE SPARK PLUG BLEW OUT F THE CYLINDER HEAD. THIS CAUSED A VERY SIGNIFICANT POWER LOSS CAUSING THE TRUCK TO SLOW VERY QUICKLY MUCH LIKE APPLYING THE BRAKES BUT NOT USING THEM. THIS CAUSED A VERY NEAR ACCIDENT ON A HIGHWAY TRAVELING AT 50 MPH AND THE SLOWING WITHOUT BRAKE LIGHTS NEARLY CAUSED AN ACCIDENT. AFTER APPROXIMATELY 1 MIN OF RESEARCHING THE PROBLEM ABOUT THE ACCIDENT I REALIZED THAT THIS PROBLEM IS HUGE !!!! TO SAY THE LEAST. THERE HAVE BEEN COUNTLESS REPORTS OF SPARK PLUGS BLOWING AND EITHER PEOPLE BEING STRANDED TO NEAR COLLISIONS. ALSO I AM A FIREFIGHTERS PARAMEDIC AND MY NOSE IS NO HYDROCARBON METER BUT THE LEVELS OF GASOLINE VAPORS THAT ACCUMULATE IN A VERY SHORT TIME. MY QUESTION TO THAT IS HOW MUCH VAPOR COLLECTS IN THE CAB COMPARTMENT AND CAN IT CAUSE A COMPARTMENT FIRE BEFORE THE DRIVER CAN SAFELY GET THE VEHICLE TO A SAFE AREA TO EXIT THE VEHICLE? I BRING THIS TO YOUR ATTENTION BECAUSE OF MY RESEARCH I DO NOT BELIEVE ANY LETTERS OR CALLING FORD MOTOR AS JUST A VEHICLE OWNER CAN MAKE FORD MOTOR COMPANY MORE AWARE OF THIS PROBLEM. THANK YOU! *JB

Mileage: 42,000

CAMSHAFT POSITION SENSOR (CPS) HAS FAILED 3 TIMES SINCE I'VE HAD THE VEHICLE. MY TRUCK HAS ONLY 77,000 MILES ON IT. WHEN THIS SENSOR FAILS THE TRUCK DIES INSTANTLY AND WILL NOT RESTART. I WAS LUCKY ALL 3 TIMES TO NOT BE PULLING A TRAILER IN HEAVY TRAFFIC. *JB

Mileage: 77,200

I WAS DRIVING ON THE HIGHWAY WHEN MY TRUCK DIED. I STARTED IT AND IT WENT FOR HOURS AND THEN DIED AGAIN. THEN IT WOULD GO TWO FEET AND DIE AND THEN DAYS AND DIE. I HAD NO WARRING. THIS IS VERY DANGEROUS AND SOME ONE COULD GET KILLED. JUST LOOK ON THE INTERNET AND YOU CAN SEE MANY PEOPLE HAVING PROBLEMS WITH THE CPS, CAM POSITIONING SENSOR. THEY EVEN SAY TO CARRY AN EXTRA ONE WITH YOU, CAUSE OF THEM GOING OUT ALL THE TIME??? WE REPLACED OURS AFTER REPLACING MANY OTHER WRONG PARTS, BECAUSE WE HAD NO IDEA OF THIS BEING A PROBLEM WITH FORD TRUCKS. WE REPLACED THE ACCELERATOR PEDAL, SENSORS, AND OTHER PARTS UNTIL WE FOUND THE CPS WAS THE PROBLEM. MANY WASTED DOLLARS. PLEASE LOOK INTO THIS, BEFORE IT IS TO LATE AND SOMEONE GETS HURT. *NM

WHILE DRIVING MY 2002 FORD F250 7.3 DIESEL TRUCK, MY TRUCK LOST ALL POWER. I RESTARTED THE TRUCK AND HAD TRAVELED ABOUT 1/2 MILE WHEN THE FAILURE OCCURRED AGAIN. I RESTARTED THE TRUCK AGAIN AND HAD TRAVELED ABOUT 1/2 A MILE WHEN THE FAILURE OCCURRED AGAIN. AT THIS POINT I WAS IN MY DRIVEWAY. AFTER FURTHER RESEARCH ON THE INTERNET, I DISCOVERED THAT THIS FAILURE IS VERY COMMON IN THIS VEHICLE AND HAPPENS WITH NO WARNING AND AT ANY SPEED. SEVERAL PEOPLE ON THE INTERNET WENT SO FAR AS TO SUGGEST CARRYING A SPARE PART WITH YOU AT ALL TIMES AS WELL AS THE TOOLS NEEDED TO MAKE THE REPAIR ON THE ROAD. MY LOCAL FORD DEALER INFORMED ME THAT THIS A VERY COMMON PROBLEM. I FEEL THAT THIS ISSUE SHOULD BE ADDRESSED BEFORE ANY FATALITIES OCCUR AS THIS HAS HAPPENED WHILE DRIVING AT HIGH RATES OF SPEED WITH NO WARNING. *JB

Mileage: 50,000

DT: THE CONSUMER STATED THAT 2002 FORD F250 HAD TWO WIRES THAT MELTED TOGETHER IN THE WIRING HARNESS. THE ENTIRE CIRCUIT BOARD SHORTED OUT. THE CONSUMER TOOK THE TRUCK TO THE DEALERSHIP. THE CONSUMER CONTACTED FORD, AND THEY INFORMED HER THAT THERE WAS NO WARRANTY TO FIX THE TRUCK. THE OWNER STATED THAT SHE HAD NO MONEY TO FIX THE VEHICLE. *AK

Mileage: 120,000

MY FORD TRUCK WOULD STALL WHENEVER YOU STOPPED OR PRESSED THE BRAKE TO SLOW DOWN AT INTERSECTIONS ,I TOOK IT TO THE DEALER AND THEY SAID IT HAD A FAULTY CAM SENSOR,FAULTY O-RINGS AND HIGH PRESSURE PUMP,I DONT HAVE THE ORIGINAL PART ONLY THE WORK ORDER FROM THE REPAIRS THAT WERE MADE

MY F-250 SUPER DUTY 4X4 PICKUP RECENTLY STALLED WHILE DRIVING OFF THE FREEWAY. THE FOLLOWING DAY THE TRUCK STALLED A SECOND TIME IN TRAFFIC AND A THIRD TIME WHILE ENTERING I15 IN BARSTOW, CA. THE TRUCK WAS TOWED TO SOUTARS FORD IN BARSTOW, CA. THE FOLLOWING MONDAY SOUTARS REPLACED A CAM SENSOR ASSEMBLY. THE CAM SENSOR WAS COVERED UNDER THE FORD 100,000 WARRANTY WITH $100 DEDUCTIBLE. TWO WEEKS AGO I RETURNED FROM A 4000 TRIP TO YELLOWSTONE AND GLACIER NATIONAL PARKS. ON THIS TRIP I TOWED A 9000 LB 5TH WHEEL WITH MY F250. HAD THE CAM SENSOR GONE OUT WHILE I WAS TOWING THE TRAILER, PARTICULARLY ON MANY MILES OF STEEP MOUNTAIN ROADS, I CAN ONLY IMAGINE THE CONSEQUENCES. WHEN THE TRUCK STALLED THERE WAS NO WARNING - NO DIFFERENCE IN ANY OF THE GAUGES TO INDICATE SOMETHING WAS WRONG. THE POWER STEERING AND BRAKES QUIT WORKING WHEN THE ENGINE STALLS. LOSS OF CONTROL AND A COLLISION COULD CERTAINLY OCCUR WHEN THE TRUCK SUDDENLY STALLS. AN F250 4X4 IS A VERY HEAVY VEHICLE - IT DOESN'T MOVE WITHOUT THE ENGINE RUNNING UNLESS YOU ARE ON A HILL. I AM CONCERNED THAT THE CAM SENSOR MAY FAIL AGAIN WITHOUT WARNING. I HAVE CALLED THE 800 NUMBER FOR FORD MOTOR COMPANY AND REGISTERED MY CONCERNS. THERE DOESN'T SEEM TO BE ANY INTEREST ON THE PART OF FORD TO TALK TO ME ABOUT THIS PROBLEMS AND THE POTENTIAL SERIOUSNESS OF THE FAILURE. I HAVE SPOKEN TO THE LOCAL FORD DEALER AND HAVE FOUND THAT THEY HAVE REPLACED THIS PART ON OTHER FORD DIESELS WITH THE 7.3L ENGINE. . I AM THANKFUL THAT I AM REPORTING NO INJURIES OR DEATHS FROM THIS FAILURE. I COULD HAVE EASILY BEEN KILLED ON INTERSTATE 15 HAD I STALLED OUT IN 70 MPH TRAFFIC WHICH IS VERY HEAVY ON A FRIDAY NIGHT. I CHOSE TO CALL A TOW TRUCK INSTEAD. WHAT PROTECTION IS THERE FROM A PROBLEM LIKE THIS ONE? A VEHICLE OF OVER TWO TONS IS NOT SAFE WHEN IT CAN STOP RUNNING WITHOUT WARNING AT ANY TIME, PARTICULARLY WHEN IT IS USED FOR TOWING A TRAILER. *NM

Mileage: 37,015

SPARK PLUG BLOW OUT ON 2002 F250 SUPER DUTY 4X4 PICKUP. *NM

Mileage: 121,000

FORD 2002, F250 CREW CAB PICKUP, DIESEL, STARTED ON FIRE IN THE DRIVEWAY ON DECEMBER 1, 2003, 4-5 HOURS AFTER IT WAS PARKED. I BURNED DOWN OUR GARAGE AND THE SECOND VEHICLE THAT WAS PARKED NEXT TO IT. THE GARAGE IS NOT ATTACHED TO THE HOUSE.

Mileage: 30,000

I OWN A 2002 FORD F-250 SUPER DUTY,4X4,EXTENDED CAB. THE VEHICLE HAS LESS THAN 12000 MILES AND WAS TOWED TO FORD DEALER AS IT WOULD NOT START. I WAS INFORMED THAT DUE TO "MOTHER NATURE" EXCESSIVE CORROSION WAS THE CAUSE OF STARTER GOING BAD AND CABLES ALSO,I HAD TO PAY OVER $600.00 REPAIRS,NOT WARRANTED BY FORD. *NLM