2002 Ford E-150 Econoline

Introduction: The 2002 Ford E-150 Econoline is a full-size van offered with two engine options: a 4.6L V8 and a 5.4L V8. It comes with three transmission options: a 4-speed automatic (4R70W), a 5-speed manual (NV3500), and a 5-speed automatic (5R110W). People appreciate the van’s spacious interior, reliability, and affordability. However, it has known issues in several areas, as outlined below.

Engine 4.6L V8

• Intake manifold gasket failure: Oil leaking from the front of the engine, coolant loss, overheating
• Solution: Replace intake manifold gasket
• Estimated Cost to Fix: $500 - $800+
• Recalls: 02V116000, 02V201000

5.4L V8

• Cam phaser failure: Engine knocking, rattling, or ticking noises, reduced engine power
• Solution: Replace cam phasers and timing components
• Estimated Cost to Fix: $2,000 - $3,000+
• Recalls: 07V321000, 08V282000

Transmission 4-speed automatic (4R70W)

• Torque converter shudder: Vibration during acceleration, especially at low speeds
• Solution: Replace torque converter
• Estimated Cost to Fix: $800 - $1,200+
• Recalls: None Found

5-speed manual (NV3500)

• Clutch failure: Difficulty shifting gears, slipping, or grinding noises
• Solution: Replace clutch assembly
• Estimated Cost to Fix: $500 - $700+
• Recalls: None Found

5-speed automatic (5R110W)

• Overheating: Transmission slipping, delayed gear engagement, burnt transmission fluid
• Solution: Replace transmission cooler, flush transmission fluid
• Estimated Cost to Fix: $1,000 - $1,500+
• Recalls: None Found

Suspension

• Leaf spring failure: Sagging rear end, reduced load capacity
• Solution: Replace leaf springs
• Estimated Cost to Fix: $500 - $800+
• Recalls: None Found

Electrical

• Alternator failure: Dimming lights, battery warning light illuminated, loss of electrical power
• Solution: Replace alternator
• Estimated Cost to Fix: $300 - $500+
• Recalls: None Found

Exterior

• Rust on body panels: Rust spots and holes in the metal, especially on the undercarriage
• Solution: Rust repair or replacement of affected panels
• Estimated Cost to Fix: $500 - $2,000+
• Recalls: None Found

Interior

• Power window failure: Windows not working or moving slowly
• Solution: Replace window motor or switch
• Estimated Cost to Fix: $200 - $400+
• Recalls: None Found

Other

• Fuel pump failure: Engine stalling, hard starting, loss of power
• Solution: Replace fuel pump
• Estimated Cost to Fix: $500 - $800+
• Recalls: 04V043000, 09V053000

Summary: The 2002 Ford E-150 Econoline has a range of known issues, particularly in its engine, transmission, and suspension components. While the van offers a spacious interior and reliability, potential repairs can be costly. Engine issues, such as intake manifold gasket failure and cam phaser failure, are significant concerns that can lead to high expenses. Transmission issues can also be problematic, especially with the 5-speed automatic transmission overheating. Other issues, like rust on body panels and fuel pump failure, are less severe but can still require attention.