2002 Ford E-350 Super Duty

The 2002 Ford E-350 Super Duty is a full-size van renowned for its durability and workhorse capabilities. Engine options include the 5.4L Triton V8 (255 hp and 350 lb-ft of torque), the 6.8L Triton V10 (310 hp and 425 lb-ft of torque), and the 7.3L Power Stroke Turbo Diesel V8 (275 hp and 525 lb-ft of torque). A 4-speed automatic transmission was the standard option for all engines. Owners often praise the E-350 for its spaciousness and towing capacity but criticize its fuel economy and aging design.

Engine

5.4L Triton V8

• Spark Plug Blowout
  • Description/Symptoms: Spark plugs can eject from the cylinder head, causing a loud popping noise and engine misfire. This is due to insufficient threads in the aluminum cylinder head.
  • Solution: Repairing the threads with a thread insert kit (e.g., Time-Sert or Heli-Coil) is the most common solution.
  • Estimated Cost to Fix: $300 - $800+ depending on the number of spark plugs that need repairing.
  • Recalls: None Found
• Intake Manifold Cracking
  • Description/Symptoms: Cracks can develop in the plastic intake manifold, leading to vacuum leaks, rough idling, and potentially a check engine light.
  • Solution: Replacement of the intake manifold.
  • Estimated Cost to Fix: $400 - $700
  • Recalls: None Found

6.8L Triton V10

• Spark Plug Blowout
  • Description/Symptoms: Similar to the 5.4L, spark plugs can eject from the cylinder head due to insufficient threads.
  • Solution: Repairing the threads with a thread insert kit.
  • Estimated Cost to Fix: $300 - $800+
  • Recalls: None Found
• Exhaust Manifold Leaks
  • Description/Symptoms: Exhaust manifold studs can break, leading to exhaust leaks, a hissing sound, and reduced engine performance.
  • Solution: Replacing the broken studs or the entire exhaust manifold.
  • Estimated Cost to Fix: $200 - $600+ depending on the severity and repair approach.
  • Recalls: None Found

7.3L Power Stroke Turbo Diesel V8

• Cam Position Sensor Failure
  • Description/Symptoms: The engine may stall, run rough, or not start. A check engine light is common.
  • Solution: Replacement of the Cam Position Sensor.
  • Estimated Cost to Fix: $100 - $200
  • Recalls: None Found
• ICP (Injection Control Pressure) Sensor Failure
  • Description/Symptoms: Rough idling, stalling, poor performance, and hard starting are common symptoms.
  • Solution: Replacement of the ICP sensor.
  • Estimated Cost to Fix: $150 - $300
  • Recalls: None Found
• CPS (Crank Position Sensor) Failure
  • Description/Symptoms: Hard starting, stalling, and engine misfires.
  • Solution: Replacement of the CPS.
  • Estimated Cost to Fix: $100 - $200
  • Recalls: None Found

Transmission

4R100 4-Speed Automatic Transmission (All Engines)

• Hard Shifting/Slipping
  • Description/Symptoms: Delayed or harsh shifts between gears, slipping out of gear, and a general lack of smooth operation. This is often due to worn-out clutches and valve body issues.
  • Solution: Transmission rebuild or replacement.
  • Estimated Cost to Fix: $2,000 - $4,000+
  • Recalls: None Found
• Torque Converter Failure
  • Description/Symptoms: Shuddering at low speeds, especially during acceleration. Can also lead to transmission overheating.
  • Solution: Replacement of the torque converter.
  • Estimated Cost to Fix: $800 - $1500+
  • Recalls: None Found

Suspension

• Worn Ball Joints and Tie Rod Ends
  • Description/Symptoms: Loose steering, clunking noises from the front end, and uneven tire wear.
  • Solution: Replacement of the worn ball joints and/or tie rod ends.
  • Estimated Cost to Fix: $300 - $800+ per side, depending on the extent of the damage.
  • Recalls: None Found
• Leaf Spring Sagging/Cracking
  • Description/Symptoms: The rear of the van sits lower than normal, ride quality is poor, and there may be visible cracks in the leaf springs.
  • Solution: Replacement of the leaf springs.
  • Estimated Cost to Fix: $500 - $1,000+ per side.
  • Recalls: None Found

Electrical

• Alternator Failure
  • Description/Symptoms: Dimming headlights, warning lights on the dashboard, and eventually a dead battery.
  • Solution: Replacement of the alternator.
  • Estimated Cost to Fix: $200 - $500
  • Recalls: None Found
• Window Motor Failure
  • Description/Symptoms: Window not moving up or down
  • Solution: Replacement of the window motor.
  • Estimated Cost to Fix: $150 - $400
  • Recalls: None Found

Exterior

• Rust (Body and Undercarriage)
  • Description/Symptoms: Rust forming on body panels, especially around wheel wells and rocker panels. Severe rust can affect the structural integrity of the van.
  • Solution: Rust repair, body panel replacement, and rust prevention treatments.
  • Estimated Cost to Fix: $200 - $2000+, depending on severity.
  • Recalls: None Found

Interior

• Headliner Sagging
  • Description/Symptoms: The headliner fabric detaches from the backing board and sags down.
  • Solution: Replacement of the headliner.
  • Estimated Cost to Fix: $200 - $500
  • Recalls: None Found
• Door Handle Breakage
  • Description/Symptoms: Interior door handles can break, making it difficult to open the doors.
  • Solution: Replacement of the door handle.
  • Estimated Cost to Fix: $50 - $200
  • Recalls: None Found

Summary

The 2002 Ford E-350 Super Duty has some common issues, particularly related to the engine (spark plug blowouts, sensor failures) and transmission (hard shifting, slipping). Suspension components like ball joints and leaf springs also tend to wear out with age and use. Rust is a major concern for vehicles of this age, particularly in regions with harsh winters. While some repairs are relatively inexpensive (sensor replacements, door handles), others like transmission rebuilds or rust repair can be quite costly. Potential buyers should carefully inspect the vehicle for these common issues and factor in potential repair costs.