2002 Ford E-250 Econoline
The 2002 Ford E-250 Econoline is a popular full-size van known for its durability and versatility. It’s often used for commercial purposes, such as cargo hauling and passenger transport. Common praises include its spaciousness, powerful engine options, and relatively simple mechanics making it easier to repair. Criticisms often center on its fuel economy, outdated interior, and handling characteristics compared to more modern vans. The 2002 E-250 offered several engine choices including a 4.2L Essex V6 producing around 200 horsepower and 260 lb-ft of torque, a 4.6L Triton V8 producing around 225 horsepower and 290 lb-ft of torque, and a 5.4L Triton V8 producing around 255 horsepower and 350 lb-ft of torque. These engines were primarily paired with a 4-speed automatic transmission.
Engine
4.2L Essex V6
- Intake Manifold Gasket Leak
- Description/Symptoms: Engine may misfire, run rough, or have poor fuel economy. You might also hear a hissing sound and see coolant leaks around the intake manifold.
- Solution: Replace the intake manifold gasket.
- Estimated Cost to Fix: $200 - $400+
- Recalls: None Found
4.6L Triton V8
- Spark Plug Blowout
- Description/Symptoms: A spark plug can be ejected from the cylinder head due to weak threads. This results in a loud popping noise, a severe misfire, and a loss of power. This issue is prevalent in earlier 2-valve Triton engines.
- Solution: Repair or replace the cylinder head with a revised design or use a thread repair kit (e.g., Time-Sert).
- Estimated Cost to Fix: $500 - $1500+ depending on the repair method.
- Recalls: None Found
- Idle Air Control (IAC) Valve Failure
- Description/Symptoms: Rough idling, stalling, or difficulty starting.
- Solution: Replace the IAC valve.
- Estimated Cost to Fix: $100 - $250+
- Recalls: None Found
5.4L Triton V8
- Spark Plug Blowout
- Description/Symptoms: A spark plug can be ejected from the cylinder head due to weak threads. This results in a loud popping noise, a severe misfire, and a loss of power. This issue is prevalent in earlier 2-valve Triton engines.
- Solution: Repair or replace the cylinder head with a revised design or use a thread repair kit (e.g., Time-Sert).
- Estimated Cost to Fix: $500 - $1500+ depending on the repair method.
- Recalls: None Found
- Fuel Injector Failure
- Description/Symptoms: Engine misfires, rough idling, poor fuel economy, and a check engine light with codes related to specific injectors.
- Solution: Replace the faulty fuel injector(s).
- Estimated Cost to Fix: $150 - $400+ per injector.
- Recalls: None Found
Transmission
4R70W 4-Speed Automatic
- Slipping or Harsh Shifting
- Description/Symptoms: The transmission slips between gears, shifts harshly, or fails to shift at all. This can be caused by worn clutches, valve body issues, or low fluid levels.
- Solution: Perform a transmission service (fluid and filter change). If the problem persists, further diagnostics are needed, potentially leading to a valve body repair or a complete transmission rebuild/replacement.
- Estimated Cost to Fix: $150 - $300 for service, $500 - $1200+ for valve body, $2000 - $4000+ for rebuild/replacement.
- Recalls: None Found
- Torque Converter Failure
- Description/Symptoms: Shuddering or vibrations at certain speeds, especially under light acceleration. This can also cause stalling when coming to a stop.
- Solution: Replace the torque converter.
- Estimated Cost to Fix: $500 - $1500+
- Recalls: None Found
Suspension
- Worn Ball Joints
- Description/Symptoms: Clunking or popping noises from the front suspension, especially when going over bumps or turning. Loose or wobbly steering.
- Solution: Replace the worn ball joints.
- Estimated Cost to Fix: $200 - $500+ per side.
- Recalls: None Found
- Worn Leaf Springs
- Description/Symptoms: Sagging rear suspension, especially when loaded. Reduced load-carrying capacity.
- Solution: Replace the leaf springs or add-a-leaf springs.
- Estimated Cost to Fix: $300 - $800+ per side.
- Recalls: None Found
Electrical
- Alternator Failure
- Description/Symptoms: Dimming headlights, a battery that won’t stay charged, and a warning light on the dashboard.
- Solution: Replace the alternator.
- Estimated Cost to Fix: $200 - $400+
- Recalls: None Found
- Wiring Harness Issues
- Description/Symptoms: Intermittent electrical problems, such as malfunctioning lights, power windows, or sensors. These can be caused by corrosion or damaged wiring.
- Solution: Repair or replace the damaged wiring harness.
- Estimated Cost to Fix: $100 - $1000+ depending on the extent of the damage.
- Recalls: None Found
Exterior
- Rust on Rocker Panels and Wheel Arches
- Description/Symptoms: Rust formation on the lower body panels.
- Solution: Repair or replace rusted panels.
- Estimated Cost to Fix: $300 - $1500+ per panel depending on the severity and repair method.
- Recalls: None Found
Interior
- Dashboard Cracking
- Description/Symptoms: Cracks appearing in the dashboard plastic, especially in warmer climates.
- Solution: Replace the dashboard or use a dashboard cover.
- Estimated Cost to Fix: $200 - $800+ for replacement, $30 - $100 for a cover.
- Recalls: None Found
- Door Handle Breakage (Interior and Exterior)
- Description/Symptoms: Door handles breaking or becoming loose, making it difficult to open the doors.
- Solution: Replace the broken door handles.
- Estimated Cost to Fix: $50 - $200+ per handle.
- Recalls: None Found
Summary
The 2002 Ford E-250 Econoline, while a reliable workhorse, does have its share of common issues. Engine problems like spark plug blowouts and intake manifold leaks are prevalent, with repair costs potentially reaching into the thousands. Transmission issues, particularly with slipping or harsh shifting, can also be costly. Suspension problems, rust, and electrical issues add to the potential ownership expenses. While some issues may be minor and relatively inexpensive to fix, others can be quite significant, so a thorough inspection before purchase is highly recommended.