2002 Ford E-350 Econoline Club Wagon

The 2002 Ford E-350 Econoline Club Wagon is a full-size van known for its durability and practicality, making it a popular choice for commercial use, families, and conversion vans. Engine options included a 5.4L Triton V8, a 6.8L Triton V10, and a 7.3L Power Stroke Turbo Diesel V8. The 5.4L Triton V8 produced around 255 horsepower and 350 lb-ft of torque. Most models were equipped with a 4-speed automatic transmission. Owners generally appreciate the van’s spaciousness, towing capacity, and reliability; however, they commonly complain about fuel economy, ride quality, and potential rust issues.

Engine

5.4L Triton V8

• Spark Plug Blowout
  • Description/Symptoms: Spark plugs ejecting from the cylinder head, often accompanied by a loud popping noise and engine misfire. This is due to insufficient threads in the aluminum cylinder head.
  • Solution: Install thread inserts (e.g., Time-Sert or Heli-Coil) to repair the damaged threads.
  • Estimated Cost to Fix: $500 - $1500+ depending on the number of spark plugs that need to be repaired and if any damage was caused.
  • Recalls: None Found
• Idle Air Control (IAC) Valve Failure
  • Description/Symptoms: Rough idling, stalling, especially when coming to a stop, or erratic RPMs at idle.
  • Solution: Replace the IAC valve.
  • Estimated Cost to Fix: $100 - $300
  • Recalls: None Found
• PCV Valve
  • Description/Symptoms: Can cause vacuum leaks.
  • Solution: Replace the PCV valve.
  • Estimated Cost to Fix: $50 - $150
  • Recalls: None Found

6.8L Triton V10

• Spark Plug Blowout
  • Description/Symptoms: Similar to the 5.4L V8, spark plugs can eject from the cylinder head due to insufficient threads.
  • Solution: Install thread inserts.
  • Estimated Cost to Fix: $500 - $2000+ depending on the damage and the number of spark plugs that need to be repaired.
  • Recalls: None Found

7.3L Power Stroke Turbo Diesel V8

• Cam Position Sensor (CPS) Failure
  • Description/Symptoms: Stalling, rough running, no-start condition.
  • Solution: Replace the Cam Position Sensor.
  • Estimated Cost to Fix: $100 - $300
  • Recalls: None Found
• Fuel Injector Issues
  • Description/Symptoms: Rough idle, white smoke, poor fuel economy, lack of power.
  • Solution: Diagnose and replace faulty fuel injectors.
  • Estimated Cost to Fix: $200 - $400+ per injector (parts and labor).
  • Recalls: None Found
• Glow Plug Problems
  • Description/Symptoms: Hard starting, especially in cold weather, excessive white smoke on startup.
  • Solution: Replace faulty glow plugs and/or the glow plug relay.
  • Estimated Cost to Fix: $200 - $600+ depending on the number of glow plugs that need replacing.
  • Recalls: None Found

Transmission

• 4R100 4-Speed Automatic Transmission
  • Erratic Shifting/Slipping
    • Description/Symptoms: Harsh or delayed shifts, slipping between gears, or failure to shift.
    • Solution: Could be due to low fluid, faulty solenoids, or worn clutches/bands. Requires transmission service, valve body repair, or complete rebuild.
    • Estimated Cost to Fix: $200 (fluid change) - $3000+ (rebuild) depending on the cause.
    • Recalls: None Found
  • Torque Converter Failure
    • Description/Symptoms: Shuddering, vibration, or stalling at low speeds, especially when starting from a stop.
    • Solution: Replace the torque converter.
    • Estimated Cost to Fix: $800 - $1500+
    • Recalls: None Found

Suspension

• Worn Ball Joints
  • Description/Symptoms: Clunking or popping noises when turning or going over bumps, loose steering.
  • Solution: Replace worn ball joints (upper and/or lower).
  • Estimated Cost to Fix: $300 - $800+ per side.
  • Recalls: None Found
• Sagging Leaf Springs
  • Description/Symptoms: Rear of the van sitting low, poor ride quality, reduced load-carrying capacity.
  • Solution: Replace or add-a-leaf to the rear leaf springs.
  • Estimated Cost to Fix: $400 - $1000+
  • Recalls: None Found

Electrical

• Alternator Failure
  • Description/Symptoms: Dimming headlights, battery light on, battery not charging, stalling.
  • Solution: Replace the alternator.
  • Estimated Cost to Fix: $200 - $500
  • Recalls: None Found
• Window Motor Failure
  • Description/Symptoms: Window failing to raise or lower, grinding noises from the door.
  • Solution: Replace the window motor and/or regulator.
  • Estimated Cost to Fix: $150 - $400 per window.
  • Recalls: None Found

Exterior

• Rust (Body Panels and Frame)
  • Description/Symptoms: Rust formation on rocker panels, wheel wells, door panels, and frame components. This is especially common in areas with road salt use.
  • Solution: Rust repair, panel replacement, frame reinforcement. Prevention includes rustproofing treatments.
  • Estimated Cost to Fix: $200 - $5000+ depending on the severity and extent of the rust.
  • Recalls: None Found

Interior

• Headliner Sagging
  • Description/Symptoms: The fabric headliner detaching from the backing board and sagging down.
  • Solution: Replace the headliner.
  • Estimated Cost to Fix: $200 - $500+
  • Recalls: None Found
• Door Handle Breakage
  • Description/Symptoms: Interior door handles breaking or becoming loose.
  • Solution: Replace the door handle.
  • Estimated Cost to Fix: $50 - $200
  • Recalls: None Found

Summary

The 2002 Ford E-350 Econoline Club Wagon is generally a reliable van, but owners should be aware of potential issues like spark plug blowouts (especially on the Triton V8 and V10 engines), transmission problems, and rust. While some repairs are relatively inexpensive (e.g., replacing the CPS or IAC valve), others, like spark plug thread repair, transmission rebuilds, and rust remediation, can be quite costly. Regular maintenance and addressing problems early can help extend the life of the vehicle and prevent more expensive repairs down the road.