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2002 Ford E-450 Econoline Super Duty

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By Research the Car 5 min read

The 2002 Ford E-450 Econoline Super Duty is a full-size van primarily used for commercial purposes, such as ambulances, shuttle buses, and delivery vehicles. This robust workhorse offered several engine options, including the 5.4L Triton V8 (255 hp, 350 lb-ft of torque), the 6.8L Triton V10 (305 hp, 420 lb-ft of torque), and the 7.3L Power Stroke Diesel V8 (215 hp, 425 lb-ft of torque). The vehicle is generally praised for its durability and cargo capacity, but disliked for its fuel economy and dated interior. All engine options are paired with a 4R100 4-speed automatic transmission.

Engine

5.4L Triton V8

  • Spark Plug Ejection
    • Description/Symptoms: Spark plugs can eject from the cylinder head due to insufficient threads. This can cause a loud popping noise, misfires, and engine damage.
    • Solution: Repair or replace the cylinder head with a Time Sert or Heli-coil repair.
    • Estimated Cost to Fix: $500 - $1500+
    • Recalls: None Found
  • Oil Leaks
    • Description/Symptoms: Oil leaks commonly occur from the valve cover gaskets and the oil pan gasket.
    • Solution: Replace the leaking gaskets.
    • Estimated Cost to Fix: $200 - $500
    • Recalls: None Found

6.8L Triton V10

  • Spark Plug Ejection
    • Description/Symptoms: Spark plugs can eject from the cylinder head due to insufficient threads. This can cause a loud popping noise, misfires, and engine damage.
    • Solution: Repair or replace the cylinder head with a Time Sert or Heli-coil repair.
    • Estimated Cost to Fix: $500 - $1500+
    • Recalls: None Found
  • Exhaust Manifold Leaks/Cracking
    • Description/Symptoms: Exhaust manifolds are prone to cracking, leading to exhaust leaks and a ticking noise, especially upon startup.
    • Solution: Replace the cracked exhaust manifold.
    • Estimated Cost to Fix: $300 - $800
    • Recalls: None Found

7.3L Power Stroke Diesel V8

  • Cam Position Sensor Failure
    • Description/Symptoms: Causes rough running, stalling, or no start condition.
    • Solution: Replace the cam position sensor.
    • Estimated Cost to Fix: $100 - $300
    • Recalls: None Found
  • Injector Issues
    • Description/Symptoms: Injectors can fail, causing poor performance, rough idle, and excessive smoke.
    • Solution: Replace faulty injectors.
    • Estimated Cost to Fix: $200 - $400 per injector
    • Recalls: None Found
  • CPS (Crank Position Sensor) Failure
    • Description/Symptoms: The truck will stall and die while driving, or not start at all. The sensor provides a critical signal to the engine computer for timing and fuel delivery.
    • Solution: Replace the crank position sensor.
    • Estimated Cost to Fix: $100 - $250
    • Recalls: None Found

Transmission

4R100 4-Speed Automatic

  • Torque Converter Failure
    • Description/Symptoms: Shuddering during acceleration, especially at highway speeds. Can also cause overheating and complete transmission failure.
    • Solution: Replace the torque converter.
    • Estimated Cost to Fix: $800 - $1500
    • Recalls: None Found
  • Shifting Problems/Slipping
    • Description/Symptoms: Difficulty shifting, slipping between gears, or harsh shifts.
    • Solution: Could be caused by low fluid, faulty solenoids, or worn clutches. Repair may involve fluid flush, solenoid replacement, or a complete transmission rebuild.
    • Estimated Cost to Fix: $100 (fluid flush) - $3000 (rebuild)
    • Recalls: None Found
  • Overdrive Issues
    • Description/Symptoms: Overdrive may fail to engage, resulting in higher RPMs at highway speeds and decreased fuel economy.
    • Solution: Repair or replace the overdrive servo or related components.
    • Estimated Cost to Fix: $500 - $1200
    • Recalls: None Found

Suspension

  • Leaf Spring Sagging/Breaking
    • Description/Symptoms: Rear end sag, reduced load capacity, and potential for dangerous handling.
    • Solution: Replace the leaf springs.
    • Estimated Cost to Fix: $500 - $1000 per side
    • Recalls: None Found
  • Ball Joint Wear
    • Description/Symptoms: Excessive play in the front end, clunking noises, and uneven tire wear.
    • Solution: Replace the worn ball joints.
    • Estimated Cost to Fix: $200 - $500 per side
    • Recalls: None Found

Electrical

  • Alternator Failure
    • Description/Symptoms: Dimming lights, battery not charging, and eventual stalling.
    • Solution: Replace the alternator.
    • Estimated Cost to Fix: $200 - $500
    • Recalls: None Found
  • Wiring Harness Issues
    • Description/Symptoms: Corrosion and damage to wiring harnesses can cause various electrical problems, including intermittent lights, sensor failures, and starting issues.
    • Solution: Repair or replace damaged wiring harnesses.
    • Estimated Cost to Fix: $200 - $1000+ (depending on severity)
    • Recalls: None Found
  • Instrument Cluster Problems
    • Description/Symptoms: Gauges may stop working or provide inaccurate readings.
    • Solution: Repair or replace the instrument cluster.
    • Estimated Cost to Fix: $200 - $600
    • Recalls: None Found

Exterior

  • Rust
    • Description/Symptoms: Rust is a common issue, especially in areas with harsh winters or coastal environments. Common locations include the rocker panels, door bottoms, and wheel wells.
    • Solution: Repair or replace rusted panels.
    • Estimated Cost to Fix: $200 - $2000+ (depending on severity)
    • Recalls: None Found
  • Door Hinge Wear
    • Description/Symptoms: Doors sagging and difficulty closing due to worn hinges.
    • Solution: Replace or repair door hinges.
    • Estimated Cost to Fix: $100 - $300 per door
    • Recalls: None Found

Interior

  • HVAC Blower Motor Failure
    • Description/Symptoms: The blower motor stops working, resulting in no heat or air conditioning.
    • Solution: Replace the blower motor.
    • Estimated Cost to Fix: $100 - $300
    • Recalls: None Found
  • Seat Frame Cracks
    • Description/Symptoms: The seat frames on high-mileage vehicles can crack, leading to discomfort and instability.
    • Solution: Weld or replace the seat frame.
    • Estimated Cost to Fix: $100 - $500
    • Recalls: None Found

Summary

The 2002 Ford E-450 Econoline Super Duty, while generally durable, is prone to several common issues. Engine problems like spark plug ejection and oil leaks are prevalent across the gasoline engine options. The 7.3L diesel can suffer from injector and sensor failures. The 4R100 transmission is known for torque converter and shifting problems. Suspension issues such as leaf spring sag and electrical problems like alternator failures are also frequent. Rust is a significant concern for the exterior. The severity and cost of repairs vary widely, but addressing these issues promptly is crucial for maintaining the vehicle’s reliability and safety.

Ford, E-450 Econoline Super Duty
Ford E-450 Econoline Super Duty 2002
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