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2002 Ford E-550 Econoline Super Duty

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By Research the Car 5 min read

Here’s a breakdown of common issues reported for the 2002 Ford E-550 Econoline Super Duty, categorized as requested. The 2002 Ford E-550 Econoline Super Duty is a heavy-duty work van appreciated for its robust chassis and significant towing capacity. Engine options include the 5.4L Triton V8 (255 hp, 350 lb-ft of torque), the 6.8L Triton V10 (310 hp, 425 lb-ft of torque), and the 7.3L Power Stroke Diesel V8 (275 hp, 525 lb-ft of torque). People often liked the E-550 for its utility, but disliked its age-related maintenance needs and fuel economy.

Engine

5.4L Triton V8

  • Spark Plug Blowout
    • Description/Symptoms: Spark plugs can eject from the cylinder head, often due to stripped threads in the aluminum head. This leads to a sudden loss of power and a loud popping noise.
    • Solution: Repairing the threads (e.g., using a Heli-Coil or Time-Sert) or replacing the cylinder head.
    • Estimated Cost to Fix: $500 - $2000+ (depending on the extent of damage and repair method)
    • Recalls: None Found
  • Intake Manifold Gasket Leak
    • Description/Symptoms: Coolant leak around the intake manifold can cause the engine to overheat, and oil can enter the intake tract causing rough running or misfires.
    • Solution: Replace the intake manifold gasket.
    • Estimated Cost to Fix: $300 - $800
    • Recalls: None Found

6.8L Triton V10

  • Exhaust Manifold Stud Breakage
    • Description/Symptoms: Broken exhaust manifold studs, typically on the rear cylinders, leading to exhaust leaks. These leaks can sound like a ticking noise that increases with engine speed.
    • Solution: Replacing the broken studs (often requires manifold removal).
    • Estimated Cost to Fix: $400 - $1200+ (depending on location and accessibility)
    • Recalls: None Found
  • Spark Plug Blowout
    • Description/Symptoms: Similar to the 5.4L, spark plugs can eject from the cylinder head due to stripped threads.
    • Solution: Repairing threads or replacing the cylinder head.
    • Estimated Cost to Fix: $500 - $2000+
    • Recalls: None Found

7.3L Power Stroke Diesel V8

  • Cam Position Sensor (CPS) Failure
    • Description/Symptoms: Intermittent stalling, rough running, or no-start condition.
    • Solution: Replacing the Cam Position Sensor (CPS).
    • Estimated Cost to Fix: $100 - $300
    • Recalls: None Found
  • Injector Issues
    • Description/Symptoms: Rough idle, excessive smoke, poor fuel economy, and loss of power.
    • Solution: Replacing faulty injectors.
    • Estimated Cost to Fix: $300 - $800+ per injector (can be a significant expense if multiple injectors are failing)
    • Recalls: None Found
  • High Pressure Oil Pump (HPOP) Failure
    • Description/Symptoms: Hard starting, stalling, or no-start condition, especially when hot.
    • Solution: Replacing or rebuilding the HPOP.
    • Estimated Cost to Fix: $500 - $1500+
    • Recalls: None Found

Transmission

  • 4R100 Automatic Transmission (Common to all engine options)

    • Torque Converter Failure
      • Description/Symptoms: Slipping, shuddering, or complete loss of drive, especially at higher speeds or under heavy load.
      • Solution: Replacing the torque converter.
      • Estimated Cost to Fix: $800 - $2000+ (includes transmission removal and fluid)
      • Recalls: None Found
    • Valve Body Issues
      • Description/Symptoms: Harsh or delayed shifting, slipping between gears, or failure to shift.
      • Solution: Replacing or rebuilding the valve body.
      • Estimated Cost to Fix: $500 - $1500+ (depending on the repair)
      • Recalls: None Found
    • Overdrive Issues
      • Description/Symptoms: Overdrive light flashing, transmission not shifting into overdrive, or harsh shifting.
      • Solution: Diagnosing and repairing the specific issue within the overdrive assembly. May require transmission rebuild.
      • Estimated Cost to Fix: $300 - $2500+ (wide range depending on complexity)
      • Recalls: None Found

Suspension

  • Leaf Spring Sagging/Cracking
    • Description/Symptoms: Rear end sagging, poor ride quality, reduced load capacity, and visible cracks in the leaf springs.
    • Solution: Replacing the leaf springs.
    • Estimated Cost to Fix: $500 - $1500+ per side
    • Recalls: None Found
  • Ball Joint Wear
    • Description/Symptoms: Clunking noises from the front suspension, loose steering, and uneven tire wear.
    • Solution: Replacing worn ball joints.
    • Estimated Cost to Fix: $200 - $800+ per side (depending on upper/lower and labor)
    • Recalls: None Found

Electrical

  • Alternator Failure
    • Description/Symptoms: Dimming lights, battery not charging, and eventual stalling of the vehicle.
    • Solution: Replacing the alternator.
    • Estimated Cost to Fix: $200 - $500
    • Recalls: None Found
  • Wiring Harness Issues
    • Description/Symptoms: Intermittent electrical problems, such as lights not working, sensors malfunctioning, or starting problems. Corrosion and damaged wiring are common.
    • Solution: Repairing or replacing damaged sections of the wiring harness.
    • Estimated Cost to Fix: $100 - $1000+ (highly variable depending on the extent of the damage)
    • Recalls: None Found

Exterior

  • Rust (Body and Frame)
    • Description/Symptoms: Rust on body panels, especially around wheel wells, door bottoms, and seams. Frame rust can compromise structural integrity.
    • Solution: Repairing or replacing rusted panels, and treating frame rust to prevent further corrosion. Frame replacement may be necessary in severe cases.
    • Estimated Cost to Fix: $200 - $5000+ (depends on the extent of rust damage)
    • Recalls: None Found

Interior

  • HVAC Blower Motor Failure
    • Description/Symptoms: Blower motor stops working, resulting in no heat or A/C.
    • Solution: Replacing the blower motor.
    • Estimated Cost to Fix: $150 - $400
    • Recalls: None Found
  • Instrument Cluster Issues
    • Description/Symptoms: Gauges not working properly, intermittent power loss to the cluster, or complete failure.
    • Solution: Repairing or replacing the instrument cluster.
    • Estimated Cost to Fix: $200 - $800+
    • Recalls: None Found

Summary

The 2002 Ford E-550 Econoline Super Duty, while a capable work vehicle, is prone to age-related issues. Engine problems, particularly spark plug blowout and exhaust manifold issues in the Triton engines and injector/HPOP issues in the 7.3L diesel, can be expensive. Transmission and suspension issues are also common. Rust is a significant concern. Electrical problems are fairly common but usually inexpensive to fix. The severity and cost of repairs can vary greatly depending on the specific issue and the extent of the damage. Regular maintenance and careful inspection are crucial for these vehicles.

Ford, E-550 Econoline Super Duty
Ford E-550 Econoline Super Duty 2002
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