FordE-2502002Overview/ford/e-250/2002/base/
250 platform

2002 Ford E-250

Factory specifications, fluid capacities, torque values, EPA fuel economy and the federal safety record for the 2002 E-250.

The 2002 Ford E-250 is a heavy-duty van built on the 250 chassis, requiring 6.0 quarts of 5W-20 API oil. With only 13 owner complaints and 3 recalls, its reliability record places it in the middle of the model’s 1990–2023 history, well below the 1998 peak of 28 complaints but above the 1990 low of 1, and its most common issue involves tires.

Model year201120102009200820072006200520042002

Quick specs

Fluid capacities, tune-up values and fuel economy at a glance.

Engine oil capacity6.0 qtOEM · verified
Engine oil type5W-20 APIOEM · verified
Lug nut torque140 ft-lbsOEM · verified

Fitment & sizes

Replacement part sizes and factory part numbers — battery, bulbs, filters and belts.

From the factory this vehicle uses a BCI 65 - AUXILARY · 625 - AUXILARY CCA battery. Each part links to every other vehicle that shares it, so a part you already stock may fit more of your fleet than you'd expect.

Battery groupBCI 65 - AUXILARY · 625 - AUXILARY CCAOEM · verified
Tire sizeLT245-75R16EOEM · verified
Wheel / rim7-K inOEM · verified

Full specifications

Engine, drivetrain, dimensions and economy.

Dimensions & weight NHTSA vPIC

Overall length211.8 in
Overall width79.5 in
Overall height81.1 in
Wheelbase138.2 in
Curb weight5000 lb
Track (front / rear)70.1 / 66.5 in

Service quick specs OEM factory data

Capacities, torques and tune-up values from the factory service manual.

This engine holds 6.0 qt of 5W-20 API engine oil, DOT 3 brake fluid. Torque lug nuts to 140 ft-lbs, the oil drain plug to 10.0 ft-lbs. The firing order is 1-3-7-2-6-5-4-8. Note the cylinder-head bolts finish on a torque angle (torque-to-yield) — they stretch permanently and should be replaced, not reused, during any head service.

Lubricants & capacities

Brake FluidDOT 3
Engine Oil5W-20 · API
Engine Oil Capacity6.0 qt
Engine Oil5W-20 · API
Engine Oil Capacity6.0 qt
Power Steering FluidATF

Engine torques

Camshaft Bearing/Carrier Cap Bolts or Studs6-9 ft-lbs
Crankshaft Pulley and/or Damper Bolts118 ft-lbs
Engine Flywheel Bolts55-64 ft-lbs
Engine Flywheel Bolts55-64 ft-lbs
Exhaust Manifold to Cylinder Head Bolts18 ft-lbs
Exhaust Manifold to Cylinder Head Bolts18 ft-lbs
Engine Oil Pan Drain Plug19.0-29.0 ft-lbs
Engine Oil Pan Drain Plug10.0 ft-lbs

Chassis torques

Leaf Spring to Axle (U-bolts)110.0-150.0 ft-lbs
Leaf Spring to Chassis Bracket240.0-289.0 ft-lbs
Leaf Spring Rear Shackle to Chassis Bracket57.0-76.0 ft-lbs
Lug Nuts140 ft-lbs

Ignition

Cylinder Firing Order1-4-2-5-3-6
Cylinder Firing Order1-3-7-2-6-5-4-8
Curb Idle Speed (No Load)800 rpm
Curb Idle Speed Variance (No Load)50 rpm
Spark Plug ManufacturerMotorcraft
Spark Plug Gap0.052-0.056 in
Spark Plug Torque11.0 ft-lbs
Spark Plug ManufacturerMotorcraft

Battery & A/C

RefrigerantR134a
Refrigerant CapacityFront A/C only, 2.75; front and rear A/C, 4.00 lbs
Oil GroupPAG
Oil Type68
Oil CapacityFront A/C only, 9.00; front and rear A/C, 13.00 oz
Standard BCI Group Number65 - AUXILARY
Standard BCI Cranking Performance625 - AUXILARY cca
Optional BCI Group Number65 - PRIMARY

Service checks

Key ON Engine OFF (KOEO)30-45
Key ON Engine OFF (KOEO)30-45
Key ON Engine OFF (KOEO)40-120 CNG
Injector Primary Resistance11-18 na ohms
Engine Oil Pressure40-125 psi
Engine Oil Pressure RPM2500 rpm
Engine Oil Pressure20-45 psi
Engine Oil Pressure RPM1500 rpm

Brakes

Torque to Knuckle141-191 ft-lbs
Torque Caliper to Bracket16-30 ft-lbs
Minimum Pad ThicknessFront: 0.030; Rear: 0.030 in
Drum Nominal Diameter12 in
Drum Maximum Machining12.06 in
Drum Discard at-or-over12.09
Rotor Max Parallel Variation0.0005 in
Rotor Runout Limit0.003 in

Multi-step torque procedures OEM · verified

Connecting Rod (Large End) Bearings — tightening sequence 1 stages
115-18 ft. lbs., Step 2: 30 ft. lbs., Step 3: 90-12015–18 ft. lbs
Connecting Rod (Large End) Bearings — tightening sequence 1 stages
133 ft. lbs., Step 2: 90 degrees, Step 3: 12033 ft. lbs
Crankshaft Pulley and/or Damper Bolts — tightening sequence 1 stages
166 ft. lbs., step 2: Loosen one turn., step 3: 37 ft. lbs., step 4: 9066 ft. lbs
Cylinder Head — tightening sequence 3 stages
1all bolts15 ft. lbs
2all bolts30 ft. lbs
3all bolts37 ft. lbs
1loosen 2-3 turn
2if long bolt33 ft. lbs
3180 degrees; Proceed to next bolt in sequence180 degrees
Cylinder Head — tightening sequence 3 stages
130 ft. lbs.30 ft. lbs
290 degrees90 degrees
390
Cylinder Head — tightening sequence 3 stages
130 ft. lbs.30 ft. lbs
290 degrees90 degrees
390
Intake Manifold to Engine Bolts — tightening sequence 1 stages
13 ft. lbs., step 2: 183 ft. lbs
Main Bearings — tightening sequence 1 stages
137 ft. lbs., Step 2: 115-12537 ft. lbs

Factory maintenance schedule OEM · verified

Normal service, condensed from the factory interval matrix.

Under the factory schedule, replace the engine oil and filter every 5,000 mi; spark plugs every 100,000 mi; coolant every 30,000 mi. The big-interval services (every 30,000 mi for coolant, and the transmission fluid) are the ones owners most often skip — on a lower-mileage example, assume the original fluids are still in it and check them first.

Every 5,000 miEngine Oil (drain & refill) · Engine Oil Filter (replace) · Tire & Wheel Assembly (rotate)
Every 15,000 miBrake System (inspect) · Cabin Air Filter (replace) · Engine Coolant System Hoses (inspect) · Steering Linkage (inspect) · Suspension Ball Joint (inspect) · Suspension System (inspect)
Every 30,000 miEngine Air Filter Element (replace) · Engine Coolant System (drain, flush & refill) · Exhaust System Heat Shield (inspect) · Fuel Filter (replace) · Fuel Tank (inspect) · Transmission Assembly (drain & refill)
At 45,000 miEngine Coolant System (drain, flush & refill)
Every 100,000 miAccessory Drive Belt (inspect) · Spark Plugs (replace)
At 120,000 miPCV Valve (replace)
At 150,000 miDrive Axle Assembly (drain & refill) · Transmission Filter (replace)

Reliability & federal safety record

Owner-reported issues, recalls, investigations and service bulletins on record with NHTSA — an unfiltered look at what owners actually experience.

The federal record places 2002 between the 1998 data point—28 complaints and 4 recalls—and the 2005 entry, when complaints had fallen to 11 but recalls had risen to 10. For 2002 specifically, the target-year data shows zero crash complaints and five tire-related complaints, plus single entries for engine, structure, and electrical system/exterior lighting, along with one fire complaint. Viewing the arc of the record, complaints peaked in 1998 then trended downward, while recalls climbed sharply from 2005 onward, reaching 30 in 2006 and remaining far higher than pre-2005 levels for the rest of the generation. Because 2002 sits before that pronounced recall surge and its own federal profile contains no crash complaints, it occupies a comparatively quiet interval in the model run. That relative calm, combined with the absence of crash complaints in the target-year data, makes 2002 a solid candidate for a used purchase, provided a pre-buy inspection addresses the tires and electrical system/exterior lighting categories documented for that year.

3
Open recalls
NHTSA campaigns
9
Service bulletins
Manufacturer communications
2
ODI investigations
Office of Defects Investigation
13
Owner complaints
0 involved a crash · 1 a fire
Owner complaints by model year NHTSA · this generation & adjacent

Owner complaints filed with NHTSA, by component

All 13 complaints on record, top 8 components.

Tires5
Engine1
Structure1
Electrical System,Exterior Lighting1
Engine,Fuel/Propulsion System1
Engine & Engine Cooling,Electrical System1
Power Train1
Electrical System1

Source: NHTSA Office of Defects Investigation complaint database.

Recalls NHTSA · verified

Showing 2 of 3 campaigns on record for this vehicle.

06V286000Vehicle Speed ControlReported 01/08/2006

ON CERTAIN TRUCKS EQUIPPED WITH SPEED CONTROL, GASOLINE OR NATURAL GAS ENGINES, THE SPEED CONTROL DEACTIVATION SWITCH MAY OVERHEAT. Remedy: DEALERS WILL INSTALL A FUSED WIRING HARNESS INTO THE SPEED CONTROL SYSTEM FREE OF CHARGE. THE RECALL BEGAN ON AUGUST 7, 2006. OWNERS MAY CONTACT FORD AT 1-866-436-7332. (NOTE…

06E056000Fuel System, GasolineReported 13/06/2006

CERTAIN AFTERMARKET FUEL FILTERS SOLD UNDER THE PUROLATOR BRAND NAME, P/N F65277, SHIPPED FROM JANUARY 16 THROUGH JUNE 2, 2006, FOR USE ON THE ABOVE LISTED PASSENGER VEHICLES. DUE TO INCORRECT DESIGN, THE QUICK… Remedy: UFI WILL NOTIFY OWNERS AND REPLACE THE FILTERS FREE OF CHARGE. THE RECALL BEGAN ON AUGUST 4, 2006. OWNERS MAY CONTACT UFI FILTERS USA AT 800-230-5876.

Technical service bulletins NHTSA · verified

Showing 5 of 9 bulletins on record with NHTSA.

BulletinDateComponentSummary
05112005-11-14StructureCRACKS IN THE LEFT OR RIGHT SPRING TOWER FLANGE. *TT SPRING TOWER WELD REPAIR AND…
183822005-01-01Power TrainFLUID LEAKING FROM THE VENT ON THE TRANSMISSION MOUNTED PARKING BRAKE ASSEMBLY. *TT
052482005-01-01SuspensionVIBRATION/HARSHNESS ABOVE 45 MPH (72 KM/H) AFTER TIRE BALANCE. *TT
182502004-10-01Power TrainINTERMITTENT CLUNK ON 3-2 DOWNSHIFT DURING COASTDOWN/TIP-IN. OASIS. TO INCLUDE 2005…
177992004-05-01Engine And Engine CoolingENGINE ROUGHNESS AND DRIVEABILITY SYMPTOMS. *TT

Common OBD-II trouble codes

The most common OBD-II codes for this vehicle's emissions system. These are standardized SAE J2012 definitions, not vehicle-specific fault reports.

P0420
Catalyst system efficiency below threshold — Bank 1
P0300
Random / multiple cylinder misfire detected
P0171
System too lean — Bank 1
P0455
Evaporative emission system leak detected — large leak
P0128
Coolant thermostat below regulating temperature
P0442
Evaporative emission system leak detected — small leak

VIN tools

Decode factory build data for a specific vehicle by VIN.

VIN
Decode a VIN to confirm the transmission and build data for a specific E-250. OEM
Build data
Plant, GVWR class, engine and body data for any 17-character VIN.
Recalls
Check open recall campaigns against a specific vehicle by VIN.

Vehicles with shared specs

Find every vehicle that shares this one's battery, bulbs, oil capacity, platform or parts.

Reference guides

Cross-vehicle references for the kinds of data on this page.

Frequently asked

How much oil does the 2002 E-250 take?

6.0 qt of 5W-20 API MEETING FORD SPECIFICATION WSS-M2C945-A, per the factory manual.

Does the 2002 E-250 have open recalls?

NHTSA lists 3 recall campaign(s) for this model year. Check your specific vehicle by VIN.