2002 Ford E-150 Econoline

The 2002 Ford E-150 Econoline is a popular full-size van known for its versatility and utility, often used for commercial purposes, family transportation, and conversion into recreational vehicles. Engine options included a 4.2L Essex V6 (around 200 horsepower and 260 lb-ft of torque), a 4.6L Triton V8 (around 225 horsepower and 290 lb-ft of torque), and a 5.4L Triton V8 (around 235-255 horsepower and 330-350 lb-ft of torque). All engine options were paired with a 4-speed automatic transmission. Owners often praise the E-150 for its spacious interior, towing capacity, and relatively simple mechanical design. Common complaints include issues related to age, such as rust, worn suspension components, and electrical gremlins.

Engine

4.2L Essex V6

• Intake Manifold Gasket Failure
  • Description/Symptoms: Coolant leaks externally, often pooling near the rear of the engine or internally causing white smoke from exhaust and/or milkshake oil. Overheating may also occur.
  • Solution: Replace the intake manifold gasket.
  • Estimated Cost to Fix: $300 - $600
  • Recalls: None Found

4.6L Triton V8

• Spark Plug Thread Damage/Ejection
  • Description/Symptoms: Spark plugs can loosen and be ejected from the cylinder head, especially in engines with higher mileage. This is due to the relatively few threads in the aluminum cylinder head. Causes a loud popping noise, misfire, and loss of power.
  • Solution: Repair or replace the cylinder head. Thread repair kits (e.g., Time-Sert) can be used if the damage is not too severe.
  • Estimated Cost to Fix: $200 (thread repair kit) - $1500+ (cylinder head replacement)
  • Recalls: None Found
• Idle Air Control (IAC) Valve Failure
  • Description/Symptoms: Rough idle, stalling, especially when the engine is cold or 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 Thread Damage/Ejection
  • Description/Symptoms: Spark plugs can loosen and be ejected from the cylinder head, especially in engines with higher mileage. This is due to the relatively few threads in the aluminum cylinder head. Causes a loud popping noise, misfire, and loss of power.
  • Solution: Repair or replace the cylinder head. Thread repair kits (e.g., Time-Sert) can be used if the damage is not too severe.
  • Estimated Cost to Fix: $200 (thread repair kit) - $1500+ (cylinder head replacement)
  • Recalls: None Found
• Idle Air Control (IAC) Valve Failure
  • Description/Symptoms: Rough idle, stalling, especially when the engine is cold or when coming to a stop.
  • Solution: Replace the IAC valve.
  • Estimated Cost to Fix: $100 - $200
  • Recalls: None Found

Transmission

4R70W 4-Speed Automatic (All Engines)

• Harsh Shifting/Slipping
  • Description/Symptoms: Erratic or delayed shifting, slipping between gears, or harsh engagement. Can be caused by worn clutches, valve body issues, or low fluid level.
  • Solution: Transmission fluid flush and filter change, valve body repair or replacement, or transmission rebuild/replacement.
  • Estimated Cost to Fix: $150 (fluid flush) - $3000+ (transmission rebuild/replacement)
  • Recalls: None Found

Suspension

• Worn Ball Joints/Tie Rod Ends
  • Description/Symptoms: Clunking noises from the front end, loose steering, uneven tire wear.
  • Solution: Replace worn ball joints and/or tie rod ends.
  • Estimated Cost to Fix: $200 - $600 per side (depending on components replaced)
  • Recalls: None Found
• Sagging Leaf Springs
  • Description/Symptoms: Rear of the vehicle sags, especially when loaded. Reduced ride quality and handling.
  • Solution: Replace leaf springs, add-a-leaf, or install helper springs.
  • Estimated Cost to Fix: $300 - $1000+ (depending on the solution)
  • Recalls: None Found

Electrical

• Door Ajar Light Issues
  • Description/Symptoms: The “door ajar” light stays on even when all doors are closed, leading to battery drain.
  • Solution: Clean or replace the door jamb switches.
  • Estimated Cost to Fix: $50 - $200
  • Recalls: None Found
• Instrument Cluster Malfunctions
  • Description/Symptoms: Gauges stop working, erratic readings, or complete failure of the instrument cluster.
  • Solution: Repair or replace the instrument cluster.
  • Estimated Cost to Fix: $200 - $600
  • Recalls: None Found

Exterior

• Rust on Body Panels/Frame
  • Description/Symptoms: Rust formation, especially in areas prone to salt exposure (e.g., wheel wells, rocker panels, frame).
  • Solution: Rust repair (patching, welding), rust removal and painting.
  • Estimated Cost to Fix: $200 - $2000+ (depending on severity)
  • Recalls: None Found

Interior

• Headliner Sagging
  • Description/Symptoms: The headliner fabric detaches from the backing and sags down.
  • Solution: Replace or re-glue the headliner fabric.
  • Estimated Cost to Fix: $150 - $400
  • Recalls: None Found
• Broken Door Handles
  • Description/Symptoms: Interior or exterior door handles break, making it difficult or impossible to open the door.
  • Solution: Replace the broken door handle.
  • Estimated Cost to Fix: $50 - $200
  • Recalls: None Found

Summary

The 2002 Ford E-150 Econoline, while generally reliable, exhibits issues typical of vehicles of its age. Engine problems, particularly spark plug thread issues in the 4.6L and 5.4L engines and intake manifold gasket failure in the 4.2L, can be costly to repair. Transmission issues, such as harsh shifting, may require a simple fluid flush or a complete rebuild. Suspension components like ball joints, tie rod ends, and leaf springs wear out over time. Electrical gremlins, such as door ajar light problems and instrument cluster malfunctions, can be frustrating. Rust is a common issue, especially in areas with road salt. The severity and cost of these issues vary significantly depending on the vehicle’s condition and maintenance history, but potential buyers should be aware of these common problems when considering a 2002 E-150.