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2002 Ford E-350 Club Wagon

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By Research the Car 5 min read

The 2002 Ford E-350 Club Wagon is a full-size passenger van known for its spaciousness and durability, making it a popular choice for large families and commercial use. The standard engine for the 2002 E-350 Club Wagon is the 5.4L Triton V8 engine that produces approximately 255 horsepower and 350 lb-ft of torque. Other engine options include the 7.3L Power Stroke Turbo Diesel V8 and the 6.8L Triton V10 engine. All engines are typically paired with a 4-speed automatic transmission. Owners often praise the van’s robust build and ample cargo/passenger space, but common complaints revolve around fuel economy, ride quality, and age-related mechanical issues.

Engine

5.4L Triton V8

  • Spark Plug Blowout
    • Description/Symptoms: The aluminum cylinder head threads are prone to stripping, causing spark plugs to be ejected from the engine. This results in a loud popping noise, misfire, and a significant loss of power.
    • Solution: Repairing the threads with a thread insert kit (like Time-Sert or Heli-Coil) is a common fix. Some opt for replacing the entire cylinder head.
    • Estimated Cost to Fix: $300 - $800+ (depending on repair method and labor)
    • Recalls: None Found
  • Intake Manifold Leaks
    • Description/Symptoms: Coolant leaks can develop at the intake manifold gasket, leading to overheating, coolant loss, and potential engine damage.
    • Solution: Replacing the intake manifold gasket.
    • Estimated Cost to Fix: $200 - $500
    • Recalls: None Found

7.3L Power Stroke Turbo Diesel V8

  • Cam Position Sensor Failure
    • Description/Symptoms: The cam position sensor can fail, causing stalling, hard starting, or a no-start condition.
    • Solution: Replacing the cam position sensor.
    • Estimated Cost to Fix: $50 - $200
    • Recalls: None Found
  • Glow Plug Relay Failure
    • Description/Symptoms: The glow plug relay can fail, leading to hard starting in cold weather.
    • Solution: Replacing the glow plug relay.
    • Estimated Cost to Fix: $100 - $300
    • Recalls: None Found
  • ICP (Injection Control Pressure) Sensor Failure
    • Description/Symptoms: Can cause stalling, rough running, or a no-start.
    • Solution: Replacing the ICP sensor.
    • Estimated Cost to Fix: $150 - $350
    • Recalls: None Found

6.8L Triton V10 * Spark Plug Blowout * Description/Symptoms: The aluminum cylinder head threads are prone to stripping, causing spark plugs to be ejected from the engine. This results in a loud popping noise, misfire, and a significant loss of power. * Solution: Repairing the threads with a thread insert kit (like Time-Sert or Heli-Coil) is a common fix. Some opt for replacing the entire cylinder head. * Estimated Cost to Fix: $300 - $800+ (depending on repair method and labor) * Recalls: None Found

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*   **Exhaust Manifold Leaks/Cracks**
    *   Description/Symptoms: Warped or cracked exhaust manifolds are common, especially on higher mileage vehicles, leading to exhaust leaks and a ticking noise, particularly when the engine is cold.
    *   Solution: Replacement of the exhaust manifold and gaskets.
    *   Estimated Cost to Fix: $400 - $1000+
    *   Recalls: None Found

Transmission

4R70W/4R100 4-Speed Automatic Transmission

  • Slipping/Harsh Shifting
    • Description/Symptoms: Transmission slipping between gears or experiencing harsh, delayed shifts. Often more pronounced when cold.
    • Solution: Could be due to worn clutches, valve body issues, or solenoid failure. Requires a transmission rebuild or replacement.
    • Estimated Cost to Fix: $1500 - $3500+ (rebuild or replacement)
    • Recalls: None Found
  • Torque Converter Failure
    • Description/Symptoms: Torque converter failure can cause shuddering, stalling, or a complete loss of drive.
    • Solution: Replacing the torque converter.
    • Estimated Cost to Fix: $500 - $1500
    • Recalls: None Found

Suspension

  • Worn Ball Joints/Tie Rod Ends
    • Description/Symptoms: Excessive play in the front end, clunking noises when going over bumps, and poor steering response.
    • Solution: Replacing the worn ball joints and tie rod ends.
    • Estimated Cost to Fix: $300 - $800 (per side)
    • Recalls: None Found
  • Sagging Leaf Springs
    • Description/Symptoms: Rear of the van sagging, especially when loaded. Affects ride height and handling.
    • Solution: Replacing the leaf springs or adding helper springs.
    • Estimated Cost to Fix: $400 - $1000
    • Recalls: None Found

Electrical

  • Instrument Cluster Issues
    • Description/Symptoms: Intermittent gauge failures, flickering lights, or complete loss of instrument cluster function.
    • Solution: Could be a faulty cluster or wiring issue. Replacing or repairing the instrument cluster.
    • Estimated Cost to Fix: $200 - $600
    • Recalls: None Found
  • Door Lock Actuator Failure
    • Description/Symptoms: Power door locks not working, either intermittently or completely.
    • Solution: Replacing the faulty door lock actuator.
    • Estimated Cost to Fix: $100 - $300 (per door)
    • Recalls: None Found
  • Alternator Failure
    • Description/Symptoms: Battery light on, dimming headlights, and eventually a no-start condition.
    • Solution: Replacing the alternator.
    • Estimated Cost to Fix: $200 - $500
    • Recalls: None Found

Exterior

  • Rust (especially around wheel wells and rocker panels)
    • Description/Symptoms: Rust forming on the body panels, particularly around the wheel wells, rocker panels, and undercarriage.
    • Solution: Rust repair involves cutting out the affected areas, welding in new metal, and repainting.
    • Estimated Cost to Fix: $500 - $2000+ (depending on severity)
    • Recalls: None Found
  • Sliding Door Issues
    • Description/Symptoms: Difficult to open or close the sliding door, often due to worn rollers or damaged tracks.
    • Solution: Replacing the sliding door rollers and/or repairing the tracks.
    • Estimated Cost to Fix: $200 - $500
    • Recalls: None Found

Interior

  • Headliner Sagging
    • Description/Symptoms: The headliner fabric detaches from the backing and sags down.
    • Solution: Replacing the headliner.
    • Estimated Cost to Fix: $200 - $500
    • Recalls: None Found
  • Power Window Regulator Failure
    • Description/Symptoms: Power windows not working or moving slowly.
    • Solution: Replacing the power window regulator.
    • Estimated Cost to Fix: $150 - $400 (per window)
    • Recalls: None Found

Summary

The 2002 Ford E-350 Club Wagon, while a reliable and spacious vehicle, is prone to certain age-related issues. The 5.4L Triton V8 is known for spark plug blowout problems. The 7.3L Powerstroke Diesel may have issues with the ICP sensor and glow plug relay, while the V10 can have exhaust manifold issues. The 4-speed automatic transmission can experience slipping and harsh shifting and torque converter failure. Suspension issues include worn ball joints and sagging leaf springs. Electrical problems often arise with the instrument cluster and door lock actuators. Rust, especially around the wheel wells and rocker panels, is a common concern. Interior issues include headliner sagging and power window regulator failure. The severity of these issues ranges from minor inconveniences to potentially costly repairs, with estimated repair costs varying widely depending on the specific problem and the chosen solution. Potential buyers should carefully inspect the vehicle for these common issues before purchasing.

Ford, E-350 Club Wagon
Ford E-350 Club Wagon 2002
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