2002 Ford E-150

Here’s a comprehensive list of common issues and complaints for the 2002 Ford E-150, broken down by category and engine/transmission option, following your specified format.

The 2002 Ford E-150 is a full-size van known for its cargo capacity and versatility. Engine options for this year included the 4.2L Essex V6 (200 hp, 260 lb-ft of torque), the 4.6L Triton V8 (225 hp, 290 lb-ft of torque), and the 5.4L Triton V8 (255 hp, 350 lb-ft of torque). The most common transmission was the 4R70W 4-speed automatic. Owners often appreciate the van’s robust build and utility, while common dislikes include its fuel economy and somewhat dated interior.

Engine

4.2L Essex V6

• Intake Manifold Gasket Failure
  • Description/Symptoms: Engine runs rough, coolant leaks externally, potential overheating.
  • Solution: Replace the intake manifold gasket.
  • Estimated Cost to Fix: $300 - $600+
  • Recalls: None Found

4.6L Triton V8

• Spark Plug Blowout
  • Description/Symptoms: Spark plug ejection from the cylinder head, loud popping noise, misfire. This is particularly common on early Triton engines with fewer threads in the cylinder head for the spark plugs.
  • Solution: Repair or replace the cylinder head, install thread inserts.
  • Estimated Cost to Fix: $500 - $2000+ depending on the severity and chosen repair.
  • Recalls: None Found
• Idle Air Control (IAC) Valve Failure
  • Description/Symptoms: Rough idle, stalling, especially when coming to a stop.
  • Solution: Replace the IAC valve.
  • Estimated Cost to Fix: $100 - $200
  • Recalls: None Found

5.4L Triton V8

• Spark Plug Blowout
  • Description/Symptoms: Spark plug ejection from the cylinder head, loud popping noise, misfire. This is particularly common on early Triton engines with fewer threads in the cylinder head for the spark plugs.
  • Solution: Repair or replace the cylinder head, install thread inserts.
  • Estimated Cost to Fix: $500 - $2000+ depending on the severity and chosen repair.
  • Recalls: None Found
• Idle Air Control (IAC) Valve Failure
  • Description/Symptoms: Rough idle, stalling, especially when coming to a stop.
  • Solution: Replace the IAC valve.
  • Estimated Cost to Fix: $100 - $200
  • Recalls: None Found
• EGR Valve Issues
  • Description/Symptoms: Rough idle, stalling, poor fuel economy, and possible check engine light.
  • Solution: Replace the EGR valve.
  • Estimated Cost to Fix: $200 - $400
  • Recalls: None Found

Transmission

4R70W 4-Speed Automatic

• Shifting Problems/Slipping
  • Description/Symptoms: Delayed shifting, harsh shifting, slipping between gears, or failure to shift.
  • Solution: Transmission rebuild or replacement. Could be related to worn friction plates, valve body issues, or torque converter failure.
  • Estimated Cost to Fix: $1500 - $3500+
  • Recalls: None Found
• Torque Converter Failure
  • Description/Symptoms: Shuddering at low speeds, especially during acceleration, and poor fuel economy.
  • Solution: Replace the torque converter.
  • Estimated Cost to Fix: $500 - $1000
  • Recalls: None Found

Suspension

• Ball Joint Wear/Failure
  • Description/Symptoms: Clunking noises from the front suspension, loose steering, uneven tire wear.
  • Solution: Replace worn ball joints.
  • Estimated Cost to Fix: $200 - $500+ per side
  • Recalls: None Found
• Leaf Spring Sagging/Broken
  • Description/Symptoms: Rear end sag, poor ride quality, potential loss of load-carrying capacity.
  • Solution: Replace leaf springs.
  • Estimated Cost to Fix: $400 - $1000+ per side, depending on parts and labor
  • Recalls: None Found

Electrical

• Power Window Issues
  • Description/Symptoms: Windows not functioning, slow operation, or intermittent operation.
  • Solution: Replace the window motor, regulator, or switch.
  • Estimated Cost to Fix: $150 - $400+ per window
  • Recalls: None Found
• Alternator Failure
  • Description/Symptoms: Dimming lights, battery warning light, difficulty starting, or stalling.
  • Solution: Replace the alternator.
  • Estimated Cost to Fix: $200 - $400
  • Recalls: None Found
• Fuse Box Corrosion
  • Description/Symptoms: Electrical components malfunctioning, intermittent electrical problems.
  • Solution: Clean or replace the fuse box.
  • Estimated Cost to Fix: $50 - $400+ depending on the extent of the damage.
  • Recalls: None Found

Exterior

• Door Hinge Wear
  • Description/Symptoms: Sagging doors, difficulty closing doors, popping noises when opening or closing.
  • Solution: Replace or repair door hinges and pins.
  • Estimated Cost to Fix: $100 - $300+ per door.
  • Recalls: None Found
• Rust (Especially around wheel wells and rocker panels)
  • Description/Symptoms: Visible rust, potentially leading to structural damage.
  • Solution: Rust repair or panel replacement.
  • Estimated Cost to Fix: $200 - $2000+ depending on severity
  • Recalls: None Found

Interior

• Door Lock Actuator Failure
  • Description/Symptoms: Power door locks not working, intermittent operation.
  • Solution: Replace the door lock actuator.
  • Estimated Cost to Fix: $100 - $300+ per door
  • Recalls: None Found
• Dashboard Cracks
  • Description/Symptoms: Cracks appearing on the dashboard surface.
  • Solution: Dash repair or replacement.
  • Estimated Cost to Fix: $100-$800+
  • Recalls: None Found

Summary

The 2002 Ford E-150 can be a reliable workhorse, but owners should be aware of some common issues. Engine problems such as spark plug blowout on the Triton engines and intake manifold leaks on the 4.2L are relatively common and can be costly to repair. Transmission issues, particularly with the 4R70W, can also be a significant concern. Suspension and electrical issues are also prevalent and should be inspected thoroughly. Rust is also a common issue and should be addressed to prevent further damage. The severity and cost of repairs can vary greatly depending on the specific problem and the extent of the damage.