Ford 7.3L Power Stroke (1999-2003) :: 2002 - 4x4 Won't Working - Engages Randomly While Running?
Sep 4, 2016
I have a mostly stock '02 F-250.
The other day I parked the truck and as I was walking away I could hear what sounded like the 4x4 clicking on and off. I wasn't sure. I figured I would continue to run the truck to get more symptoms and come up with a diagnosis.
Later, backing out of the driveway, I heard what sounded like a buzzing/grinding noise, like something was trying to engage. It quickly went away.
The next day, the 4x4 light came on as I merged onto the interstate. I pulled over, tried switching the ESOF switch to get it to turn off. I never heard 4x4 engage or "felt" it. Re-starting the truck got the light to turn off. It hasn't been on since.
Today the truck made more buzzing/grinding noises. When I tried turning on 4 high with the ESOF switch I got no response. It went into 4 low and the light came on.
I re-started the truck. Tried putting it into 4 high again and the light came on. When I put it into 4 low the light quit and wouldn't come back on.
I run with my hubs unlocked and they were unlocked at the time, FYI. Also, I have air coming out of the vents, so no vacuum issues. I actually disconnected the 4x4 vacuum lines because I don't use the automatic locking future anyways.
I did do some work with my truck and boat during the flood in Louisiana and I took her through really sketchy stuff. My guess is that the ESOF motor is shot, most likely from being submerged.
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I have stock 02 F350 7.3 with 74,000 miles ... Today i looked down and noticed my RPM gauge sitting there at 0 ... It was working just fine yesterday. I figured before i go digging around looking for the issue id see what is causing it not to read ..
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My engine suddenly stops while driving. There is no warning or loss of power, it just stops randomly after running fine for a while. After some time (might be minutes or hours) the engine turns on and runs fine.
I have no clue what it might be, I believe it might be an electrical problem affecting the diesel pump. The pump has a pair of cables coming in to a white plug at the pump's back, I disconnected them but the engine still runs.
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I have a 2001 F350 and over the past few nights the horn has started honking once randomly. It always only honks once but will do it several times a night (may be more that I don't hear). I'm thinking that this has something to do with the alarm maybe? I can't afford to take it to the shop at the moment (nor any moments in the foreseeable future, come to think of it) and am hoping that its something that I can fix myself?
I'm having other miscellaneous electrical type issues, but don't know it there are related at all. For example, the power locks don't work (they try to, but don't seem to have enough power), the overhead console that digitally displays the outside temp/mpg/etc. stopped working suddenly and the lighter/power plug outlet stopped working, but I was able to fix this by replacing the fuse.
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Ok, so my 2002 f250 died on me last Tuesday out of the blue, pulled it home and found fuse 23 I think ECU power was blown. I removed my Hydra, and put a new fuse in it and all seemed well, then Friday evening on my way to dinner was driving along and truck shuts off like someone turned the key off. I replace the Crank sensor, even though I had put a new one in after the first time it died, which was last Tuesday, still would not start.
Pulled it home, went out Saturday morning to look at it and hit the key and it fired right off. At this point I don't really know where to look, I wiggled every wire I could find while it was running Saturday and no change, but it does seem to have a miss in it while it is idling...... I am not sure where to start looking....
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I have a 2003 F250 7.3L. I put new injectors in my truck four months ago and all of a sudden, I have 2 cylinders not working correctly, making the truck to run really badly. I sent the 2 injectors from the bad cylinders back for warranty and they replaced both of the injectors but nothing was wrong. I put them in and the truck still runs badly. I have a new fuel filter, new ICP, new CPS and glow plug relay. I cannot drive the truck, it smokes white at idle. I can unplug each injector at a time and cyclinder 5 does not change how the truck runs
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A little background information is that I was towing a large gooseneck trailer about a year ago when half way to the destination the lights quit. Not just the trailer but the truck tail lights, turn signals and everything except the headlights. Well after getting there and unplugging everything it stayed the same. Well on the way home without the trailer the lights began working again. All the truck lights acted as it never happened. No blown fuses or anything.
Well things are are going ok since then but I can never get running lights to any of my 3 trailers to work. Turns and brake lights are fine. What gives? All the fuses are fine and the truck running lights work just fine. One thing I have noticed is that on my horse trailer I have the little led lights on the sides operational... I would have assumed these to be the same as the tail running lights.
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2002 F250 7.3L suddenly idling and running very rough, and doesn't have any power. Truck has been running perfect, it's my daily driver, and just put a couple hundred miles on it yesterday with no problems. I had been having some transmission issues when I tow heavy so I bought a new transmission yesterday. This morning I pulled the truck into my garage to change the transmission. Again truck ran fine, no signs of any issues before the trans swap. I changed out the transmission, which included unhooking the trans wiring harness from all the various sensors, and unbolting the starter.
I didn't mess with anything in the engine bay except for unhooking the batteries. I had also repaired the overdrive button wires, as they had been pinched in the steering column and the button wasn't working. When I got everything hooked back up I cranked it up to get the trans fluid flowing through the transmission, it started right up and idled good. I had it running for a few minutes and it was beginning to make a little more noise than usual. When I started to back out of the garage it was getting pretty rough, almost like it was running out of diesel. I put it in neutral and gave it some throttle and noticed I was getting white smoke out of the exhaust and could smell diesel pretty strong.
I checked my injector resistance at the valve covers and got around 4 ohms +/- on all of the injectors. I rechecked all of the clips and harness that I had messed with. I took a look at the ICP sensor and it has oil in the connector which I know can cause a rough running condition in some cases. It looks like it has had oil on it for a while. I unhooked the batteries again for about 20 minutes to try and reset anything that may have messed up. I checked a bunch of connections under the hood to see if anything was unhooked or loose.
I also cleaned up the connector on the ICP sensor. I started the truck back up and it idled perfect so I pulled it back out of the garage and headed down the driveway. It almost immediately started running rough again and barely had the power to go up a small hill. I pulled back in and tried unplugging the ICP while it was running, which made a slight difference in the idle but still very rough. I plugged it back in and the idle progressively got worse until it was chugging really bad. I shut it off after that and haven't messed with it again.
What might have happened? Could it be a bad sensor or transmission position sensor in the new trans? Is it just coincidence that this happened with a transmission swap? I am going to get a new ICP, but if there is anything else I can try/check before I can pick up the ICP on Monday let me know.
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7.3 auto, starts and idles OKAY, drives fine if you have a light foot but trying to go faster than 50mph or more than 2000 rpm and the whole thing has an anxiety attack. Starts sputtering and popping, lots of grey smoke when it runs rough rough, let off the throttle and it MIGHT behave nicely again.
New lift pump, cleaned the pickup tube, fuel bowl fills nice and fast, just had my edge attitude juice tuner removed since it was causing similar issues that went away for the last 2 months, changed my IPR and CPS (had a mechanic test everything when the tuner was taken out, all injectors buzzed good, sensors good)
When this first happened after the initial problem with the tuner was resolved, it did throw the CEL, but I have since been able to get it to come back on, and my buddies OBD2 scanner wasn't even registering my truck when I hooked up... Dare I say PCM is to blame?
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My truck was stolen over the weekend. Fortunately, it was recovered but they broke the key lock on the steering column and I'm having a hard time getting it started. I can turn the ignition all the way to the start position with my key or a screwdriver but the starter never engages. I'm sure I'm missing something simple but I can't seem to figure it out. Looking for instructions on how to get this started again?
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so got to work today, truck engine light comes on all foward motion stops. Just coasts and idles along. I have 280k on the orig stock trans. I also have dp tuner and did the valve body upgrade along with adding the 6.0 cooler hoping to extend the life of the trans. Reverse works. So i asume I am needinf a new trans. My options are Ford HDr4100 orig 4100, Or BTS built trans. I also pull a toy hauler as well. My question is If I order the BTS can I have a my local shop install it or does it need to be programmed at the dealer. If I get the HD from ford installed will I have to remove the dp tuner chip to get it programmed and also will i need another new valve body replacement.
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I have an 02 F350 7.3 ... I just installed my glowshift tripple gauge pillar set. I have an EGT, Boost and fuel pressure gauge ... I followed all the constructions on installing them. The boost is working just fine and the EGT was too, but after a while the needle started going back and forth and the red warning light what blinking and then it just sat at 0 with the warning light on and stay that way. My fuel pressure gauge is connected to a sensore i put in my fuel filter housing, my fuel pressure gayge right from the start stayed at 30 psi with the red warning light on and just stays there .... Also the buttons to change the color and set the peak on the EGT gauge are sticking for some reason and staying down and aren't letting me change the color ...
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I have 2002 F250 7.3 Auto, I recently tried to put my truck in to 4 wheel drive and it is not working. It has WARN manual locking hubs, which I locked. Dash indicator came on and I can hear it click on the transfer case. Yet it isn't driving the front tires. It shouldn't be a vacuum issue considering it had been converted to manual hubs should it?
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I have a 02 f350 4x4 6 SPD one of my transmission lines has went bad is there anywhere that sales them.
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I installed a new trailer wiring harness onto the back of my 2002 F250 Super Duty with 7.3 diesel engine. Unfortunately, I was 180 degrees off on my wiring. When I hooked up to the camper I blew Fuse #115 (Trailer Tow Battery Charge) as it connected directly to the camper ground wire. I replaced the 20amp fuse and all other fuses were good. Currently, I have all the truck wires to the harness isolated and have power to all of them except for the parking lights. All the lights on the truck work fine.
My truck has a interior fuse panel on the driver's side as well as two small black boxes under the hood, near the brake booster. The under-hood boxes had only relays in them. Two relays in one black box, three in the other. The box with three relays had trailer left turn and right turn relays. which worked fine. The third in that box, apparently, is for the A/C clutch, controlled by fuse #10. The other black box (with two relays), apparently, are for 4WD Shift on the fly, controlled by fuse #111. So, no relay for the parking lights.
Next, I pulled the fuse panel out a little and checked continuity from the end of the parking light wire (brown with white stripe) at the back of the truck to the back of the fuse box and found that it was a good wire with no breaks or shorts to ground, however no voltage is showing at the parking light wire when I turn on the parking lights. The harness at the back of the fuse box has several wires going into it. The parking light wire (brown with white stripe) is in the same harness as the back-up light wire (black with green stripe) and the back-up light does have voltage, when I put it in reverse.
I'm not sure what happens inside of the fuse box, i.e., how does one fuse run a few wires... is there some kind of circuit board? I know the easy way would be to run a vampire connector from the truck parking lights, or maybe the license plate light to power the trailer lights, however, I'm just not built that way.
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I have a 02 PSD, and sometimes after I start it up my radio and power windows do not work. I have a red "security" light on my Kenwood radio that turns on when the truck is off. That light keeps flashing after I turned on the truck so I know it's still getting power, but for some reason it thinks the truck is off, and the windows don't go down. Other days it works perfectly fine, sometimes the radio and windows will stop working after driving normal.
At first it was a routine where I knew they'd start working shortly. But today was the last straw, I drove into work with no radio and windows not rolling down for 30 miles. Of course after I park, I turn off the truck, turn it back on and everything comes on like nothing ever happened. What can be causing this, I have checked all the wiring, no kinks, cuts, nothing. I remember reading something about a relay that can cause this but can't find that info.
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So the truck has been stalling out and dropping power randomly, symptoms pointed to needing the 50 cent mod, changed the cps for cheap insurance and peace of mind just in case it wasn't the uvch, no dice. So last night I yanked valve covers for the first time here's what I did while I was under there, check my work.
1st I ohmed out injectors thru the 42pin harness according to tuglys sig link. My meter would only go down to a 0.4 when testing the test leads just to each other
DS injector ohms
#2 3.5
#4 3.4
#6 3.6
#8 3.6
PS injector ohms
#1 3.6
#3 3.6
#5 3.5
#7 3.6
DS glow plug ohms
#2 prong to ground 2" away 0.9 ; white connecting wire back to gp relay 0.3
#4 0.9 wire to relay 0.5
#6 infinity ohms up thru highest meter setting, checked multiple times and different ground spots,(replacing tonight) wire to relay 0.5
#8 0.5 wire to relay 0.5
PS glow plug ohms
#1 1.0 ; white wire back to relay 0.6
#3 infinity multiple tests as well (replacing tonight) wire to relay 0.5
#5 0.9 wire to relay 0.6
#7 1.0 wire to relay 0.7
Next up, ebp sensor was reading 1.9 higher than map/baro koeo, gently cleaning sensor earlier didn't work. Installed new motorcraft, will check it with Torque pro koeo once the batteries are reconnected
Next I checked the uvch connections which felt good, darn it, maybe a smidge of movement from the DS, but nothing halfway disconnected or anything. Hmm. I ground down the quarters to the top of his head and installed.
Next I torqued down the 4 bolts per cylinder of the rocker arms at 20 ft/lbs, all were perfect and snug
Next up, injector torque. I've read on here below 50, or 80 in/lbs depending on different threads and opinions that I would need to replace o-rings.
So I set the in/lb click torque wrench at 50 in/# and tested the wrench's click on the higher torqued rocker bolts, then checked all the injectors, all were good
Reset for 80in/lbs, tested, then hit all injectors, #6 almost budged but clicked immediately before the handle moved
Reset for 100 in/lb, tested on larger bolt, 2 injectors took a 1/8 turn;
Reset for official spec of 120 in/lb , tested wrench, all injectors took 1/3 to 1 full turn
Reset for 130 in/lb (above official spec, but highly recommended on here by those way more knowledgeable than me on our engines) tested on a larger bolt, slowly and carefully gave all injectors almost an extra 1/2 turn to click; whew, finally a relaxed sphincter.
At this point I knew I needed to buy 2 glow plugs today, replace, then I'll check all glow plug torque at 14 ft/lb in one go, so I got everything ready for a hot torque after I do glow plugs tonight ("unloaded" the torque wrenches) and finally installed the RiffRaff AIH delete plug. My cell phone's alarm went off to get the kids ready for school, so hit the snooze and got everything put up. Now for a nap, then buy 2 Motorcraft GP and check back on here before going back at it tonight.
I also checked the turbo for play in all directions, was nicely solid and spun smooth, no wheel damage. Up pipes and well basically everything exhaust under hood had zero signs of soot/leaks with inspection mirror.
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2001 Excursion 7.3 - stalls randomly, sometimes will not start. After the IPR was replaced it was rough for about 4 miles (I thought maybe air in the system), next 40 miles was flawless with 3 stops and restarts. Then it sat for a few hours and I went to leave again and the problem was off and on again for another 5 mile drive. Now it won't start in the driveway. It will start if I disconnect the ICP but the idle is still a little rough.
I replaced the normal culprits after a lot of searching on here:
CPS - replaced with autozone part, thought maybe it was bad new so went to ford and replaced with official part from the dealer
ICP - had oil in the plug and it would idle better removed so I replaced the plug and as much wire as I could - soldered, heat shrunk, good connections - both the pigtail and sensor came from Ford dealer
IPR - replaced with part from the Ford Dealer (FYI - 1 1/8" 1/2" drive craftsman deep socket from sears fit in the ratchet and on the part).
Grounds - found somewhere that the ground on the firewall for the windshield wipers can interfere with the CPS so I pulled it, clean the connections and made sure it was tight and secure.
No check engine light now - I received a few through the process, but did not clear them and there are no codes at this time (self cleared on the 40 mile drive)
I'm thinking it may be some electrical issue/short or a fuel issue at this point, bowl is full and the filter is fairly new (few thousand miles). I haven't done the Hutch mod, but have over 1/2 a tank.
I'm trying to get this going as quick as I can so I don't want to waste too much time, but I also don't want to miss a critical troubleshooting step to take.
Below are my thoughts on the next steps.
Research and test fuel pressure
Tow it somewhere to test each injector - I only have Torque pro to read codes and engine status
If fuel delivery checks out ok, start testing wire by wire on all of the above parts.
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My 7.3 will cough randomly on the interstate not towing or anything. It has a new turbo and filters...
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I have a 2003 F250 Super Duty 5.4 crew cab. Cruise light comes on when engaged but does not work. I did some research on why its not working checked wiring at the throttle body it seemed ok, Fuse is ok. Also did the self test and everything passed with just one flash but cruise still does not work. I read about many problems with the brake pressure switch but would it pass the self test if that pressure switch was bad? Also what should a switch cost. Local dealer wanted $125.00 for a new one and I have read where they cost around $15.00 - $20.00.
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When driving my truck it coughs randomly not towing or anything going about 70 mph drops rps slightly and goes right back. It has 212000 miles new turbo and filters...
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