Superduty Specifications (2002)

2002 Superduty Specifications

2002 Superduty Vehicle Identification Label Information

Air Conditioning

Air Gap Between Pulley and Clutch Plate: 0.014" - 0.030"

Refrigerant: R-134A (F7AZ-19589-DA)

System Capacity: 1.24 kg ml (42 oz) W/O aux climate control, 1.93 kg (68 oz) W aux climate control

Evaporator Core Orifice: 0.062" (Color Red)

A/C Compressor Type: FS-10 Swashplate, 5 Double Acting Pistons

Capacity: 266 ml (9 oz) W/O aux climate control, 414 ml (14 oz) W aux climate control

A/C Compressor Displacement: 170 cc (10.4 cu in)

A/C Compressor Rotation: Clockwise

A/C Pressure Relief Valve: Open=550-650 psi

A/C Cycling Switch: Open 22-24 psi, Close 46 psi (max)

Pressure Cutoff Switch: Open 435-475 psi, Close 230-290 psi

Axle Specifications (Dana 60 & Ford 10.5")

Front Axle Lubricant: SAE 90 Premium Axle Lube (5.9 Pts.)

Rear Axle Lubricant: SAE 75W-140 Synthetic F1TZ-19580-B (7.0 Pts)

Friction Modifier: C-AZ-19B546-A (8 Oz)

RABS Sensor Gap: 0.005"-0.045"

Brake System

Lining Wear Limit (above backing plate or rivets): 0.039")

Front Disc Brake

Rotor Thickness: 1.51"

Rotor Minimum Thickness: 1.417"

Rotor Runout (max): 0.0015" (SRW/DRW 4x4), 0.0028" (DRW 4x2), 0.0020" (SRW 4x2)

Rear Disc Brake

Rotor Thickness: 1.5"

Rotor Minimum Thickness: 1.417"

Rotor Runout (max): 0.0015"

Parking Brake

Drum Inner Diameter (max) 8.120" (F-250 & F-350), 9.540" (F-450 & F-550)

Power Brake

Power Brake Booster Push Rod Length: 0.980"-0.995"

Charging System

(Dual Alternators)

Current Output (max) 110 amps each 220 amps total.

Ratio: Upper 2.49:1, Lower 2.32:1

(Single Alternator)

Current Output (max): 130 amp

Voltage Regulator: Internal to the generator

Batteries: 750 Cold Cranking Amp, 78 Amp Hour

Clutch (7.3L Diesel)

Total Plate Pressure: 2361 lbs

Lining Material: F808 MCC Woven Non-Asbestos

Outside Diameter: 12.9"

Inside Diameter: 8.2"

Facing Area: 158 sq in

Compressed Thickness: 0.330"

Flywheel

Total Indicated Reading (TIR) AKA "runout

Flywheel Surface: 0.008"

Ring Gear : 0.022"

Clutch Pedal Travel 7.9" - 8.0"

Drive Belt System

Tension: 85 lbs Minimum

Drive Belt: 8 Rib Design 122.3" Cold Weather Package, 122.7" Non Cold Weather Package

Engine 7.3L Powerstroke Diesel

Specifications

Bore & Stroke: 4.11 in x 4.18 in

Firing Order: 1-2-7-3-4-5-6-8

Oil Pressure: 40-70 psi

Compression Ratio: 17.5:1

Cylinder Block

Cylinder Bore Diameter: 4.1096" - 4.1103" (std) Maximum Out of Round 0.002", Maximum Taper 0.003"

Main Bearing Inside Diameter: 3.3152" - 3.3162"

Head Gasket Surface Flatness: 0.001" in any 6", .004" Overall

Camshaft

End-play: 0.002" - 0.008"

Camshaft Journal to Bearing Clearance: 0.002 - 0.006"

Intake Lobe Lift: 0.2535" Max

Exhaust Lobe Lift: 0.2531" Max

Camshaft Thrust Plate Thickness: Thrust Area 0.154" - 0.156", Outside of Thrust Area 0.149" - 0.157"

Camshaft Bearing Inner Diameter: 2.102" - 2.105"

Camshaft Front Bearing Location: 0.020" - 0.050"

Gear Backlash: 0.0055" - 0.0101"

Connecting Rod

Rod Bearing I.D.: 2.5005" - 2.5025"

Rod Length (Center to Center): 7.130"

Twist Per Inch (max): 0.002"

Bend Per Inch (max): 0.001"

Rod to Crankshaft Assembled Side Clearance: 0.012" - 0.024"

Piston Pin I.D.: 1.308" - 1.309"

Crankpin Bearing Bore Diameter: 2.6905" - 2.6915"

Bearing Bore: Max Out of Round 0.0005", Max Taper per Inch 0.0005"

Crankshaft and Flywheel

Crankshaft Diameter:

Main Bearing Journal Diameter: 3.1228" - 3.1236"

Main Bearing Journal Out of Round Max: 0.00022"

Main Bearing Thrust Face Runout: 0.001"

Main Journal Taper Max: 0.00015"

Thrush Bearing Journal Width: 1.2405" - 1.2435"

Main Journal Rod Bearing Finish RMS: 10

Main Bearing Thrust Face Finish RMS: 20

Connecting Rod Journal Diameter: 2.4980" - 2.4990"

Connecting Rod Journal Taper per Inch Max: 0.00026"

Crankshaft End Play: 0.0025" - 0.0085"

Flywheel and Ring Gear Runout: 0.008"

Flywheel and Ring Gear Concentricity: 0.008"

Crankshaft Bearings

Connecting Rod Bearing to Crankshaft Clearance: 0.0015" - 0.0045"

Main Bearing to Crankshaft Clearance: 0.0018" - 0.0046"

Cylinder Head

Valve Guide Bore Diameter: Intake 0.3141" - 0.3151", Exhaust 0.3141" - 0.3151"

Valve Seat Width: Intake 0.065" - 0.095", Exhaust 0.065" - 0.095"

Valve Seat Runout: 0.002"

Valve Arrangement Front to Rear: L/H= I-E-I-E-I-E-I-E, R/H= E-I-E-I-E-I-E-I

Gasket Surface Flatness: 0.001" in any 2.0", .004" Overall

Drive Gear

Backlash: 0.0012" - 0.0015"

HPOP

Oil Pump Backlash: 0.0055" - 0.0101"

Lifter

Standard Diameter: 0.9209" -0.9217"

Clearance to Bore: 0.0011" - 0.0034"

Hydraulic Lifter Leak-down Rate: 18-90 seconds for 0.125" travel

Collapsed Lifter Gap: 0.185" max

Oil Capacity

Oil Capacity: 13.0 qts. (15.0 qts with new FL-1995 Filter)

Oil Pump

Pressure: 10 psi Curb Idle, 40-70 psi @ 3,300 rpm

Drive Gear Radial Clearance: 0.028" - 0.032"

Drive Gear End Clearance: 0.001" - 0.003"

Exhaust Manifolds

Maximum Allowable Warpage: 0.005" Between Ports, 0.010" Total

Maximum Allowable Material Removal: 0.010"

Piston

Skirt Diameter: 4.10475"

Piston Bore Diameter: 1.3085" - 1.3088"

Piston Height Above Crankcase: 0.010" - 0.031"

Piston Pin

Length: 2.99" - 3.00"

Diameter: 1.3079" -1.3081"

To Piston Pin Bore Clearance: 0.0003" - 0.0007"

To Connecting Rod Bushing Clearance: 0.0004" - 0.0009"

Piston Rings

Ring Side Clearance (second ring only): 0.002" - 0.004"

Ring Gap (Compression): Top= 0.014" - 0.024", Second= 0.062" - 0.072"

Ring Gap (Oil): 0.012" - 0.024"

Rocker Arm, Push Rods, and Lifter

Type: Hydraulic Roller Follower

Push Rod Runout: 0.02"

Starter

Motor Diameter: 3.4"

Current Draw Under Normal Load: 230-630 AMPS

Normal Cranking Speed: 150-200 RPM

Minimum Stall Torque @ 2.5 Volts: 27.5 ft-lbs

Max Load: 2400 AMPS

No Load: 170 AMPS

Brushes: MFGR. Length = 0.71"

Spring Tension: 122 oz

Steering

Type: XR50 (QSC) Recirculating Ball

Ratio: 17:1

Steering Gear Turns (Stop to Stop): 4.0

Steering Gear Meshload Rotating Torque (at steering wheel): 18 in-lb, minimum 13 in-lb

Flow Rate (Idle): 2.1 -2.5 GPM

Pressure (Idle): 150 psi

Minimum Flow Rate (Power Steering Analyzer set at 750 psi): 1.5 GPM

Relief Pressure: 1450-1530 psi

Suspension

4x4 Alignment Specifications

Caster L/H 3.5* +/- 2* R/H 3.5* +/- 2* Total Split 0* +/- 1*

Camber L/H 0.25* +/- 1* R/H 0.25* +/- 1* Total Split 0* +/- 1*

Toe In Total Split 0.03* +/- 0.25*

Curb Ride Height 4x4

Front: 4.25"-5.20" (F-250 & F-350)

Rear: 5.7"- 8.1" (F-250 & F-350)

Rear (HD): 5.2"- 7.6" (F-250 & F-350)

Transmission (4R100 Automatic)

Shift Speeds

Closed Throttle (Drive): 4-3 Shift= 41-44 MPH (3.73), 37-40 MPH (4.10)

3-2 Shift= 17-18 MPH (3.73), 15-16 MPH (4.10)

2-1 Shift= 8-9 MPH (3.73, 7-8 MPH (4.10)

Light Throttle (Drive): 1-2 15-17 MPH (3.73), 14-15 MPH (4.10)

(TP Voltage 1.25 V) 2-3 27-30 MPH (3.73), 25-27 MPH (4.10)

3-4 46-50 MPH (3.73), 42-45 MPH (4.10)

4-3 41-44 MPH (3.73), 37-40 MPH (4.10)

3-2 17-18 MPH (3.73), 15-16 MPH (4.10)

2-1 8-9 MPH (3.73), 7-8 MPH (4.10)

Wide Open Throttle (Drive): 1-2 28-30 MPH (3.73), 25-27 MPH (4.10)

2-3 50-54 MPH (3.73), 45-48 MPH (4.10)

3-4 76-83 MPH (3.73), 69-75 MPH (4.10)

4-3 71-77 MPH (3.73), 64-69 MPH (4.10)

3-2 46-49 MPH (3.73), 41-45 MPH (4.10)

2-1 34-37 MPH (3.73), 19-21 MPH (4.10)

Gear Ratio: 1st = 2.71:1, 2nd = 1.54:1, 3rd = 1.00:1, 4th = 0.71:1, Reverse= 2.18:1

Clutch Plate Usage and Clearance (7.3L Diesel Applications)

Steel Friction Clearance

Direct Clutch: 5 5 0.081" - 0.045"

Intermediate Clutch: 3 3 --

Overdrive Clutch: 3 3 0.059" - 0.033"

Coast Clutch (non PTO): 2 2 0.044" - 0.029"

Coast Clutch (PTO): 3 3 0.043" - 0.030"

Forward Clutch: 4 4 0.055" - 0.030"

Low/Reverse Clutch: 6 6 0.105" - 0.012"

Band/Clutch Application Chart

Friction Elements

a. In (D) range with transmission control switch pressed, the coast clutch is applied and the overdrive one-way clutch is bypassed.

b. On certain applications in (D) range, the coast clutch solenoid and clutch is controlled by the PCM.

1-Way Clutches