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2002 Ford Econoline

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By Research the Car 6 min read

The 2002 Ford Econoline, also known as the Ford E-Series, is a full-size van renowned for its durability and cargo capacity. It was a popular choice for commercial use, conversions, and even as a family vehicle. Engine options for the 2002 model year included the 4.2L Essex V6 (200 hp and 260 lb-ft of torque), the 4.6L Triton V8 (225 hp and 290 lb-ft of torque), the 5.4L Triton V8 (235 hp and 335 lb-ft of torque) , and the 7.3L Power Stroke Turbo Diesel V8 (275 hp and 525 lb-ft of torque). Transmission options were primarily the 4R70W 4-speed automatic, with the E-350 Powerstroke variants getting the 4R100. Owners generally appreciate the Econoline’s reliability, simple design, and spacious interior. Common complaints often revolve around fuel economy (especially with the larger engines), handling characteristics due to its size, and age-related wear and tear issues typical of a vehicle of this vintage.

Engine

4.2L Essex V6

  • Intake Manifold Gasket Failure
    • Description/Symptoms: Coolant leaks, overheating, rough idle, loss of power, and white smoke from the exhaust.
    • Solution: Replace the intake manifold gaskets.
    • Estimated Cost to Fix: $300 - $600+
    • Recalls: None Found

4.6L Triton V8

  • Spark Plug Ejection
    • Description/Symptoms: Loud popping noise, loss of power, and spark plug being ejected from the cylinder head. This issue is more common on earlier 2-valve Triton engines due to fewer threads in the cylinder head.
    • Solution: Repair or replace the cylinder head, or use spark plug thread repair inserts.
    • Estimated Cost to Fix: $500 - $2000+ (depending on repair method and cylinder head replacement)
    • Recalls: None Found
  • Vacuum Leaks
    • Description/Symptoms: Whistling noise when driving, poor idling, and the engine will run lean.
    • Solution: Replace vacuum hoses and intake gaskets.
    • Estimated Cost to Fix: $100 - $500+ (depending on the shop and severity of the leaks)
    • Recalls: None Found

5.4L Triton V8

  • Spark Plug Ejection
    • Description/Symptoms: Loud popping noise, loss of power, and spark plug being ejected from the cylinder head. This issue is more common on earlier 2-valve Triton engines due to fewer threads in the cylinder head.
    • Solution: Repair or replace the cylinder head, or use spark plug thread repair inserts.
    • Estimated Cost to Fix: $500 - $2000+ (depending on repair method and cylinder head replacement)
    • Recalls: None Found
  • Vacuum Leaks
    • Description/Symptoms: Whistling noise when driving, poor idling, and the engine will run lean.
    • Solution: Replace vacuum hoses and intake gaskets.
    • Estimated Cost to Fix: $100 - $500+ (depending on the shop and severity of the leaks)
    • 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 (CPS). It’s recommended to use a genuine Ford/Motorcraft CPS to ensure proper operation.
    • Estimated Cost to Fix: $100 - $300+
    • Recalls: None Found
  • Under Valve Cover Harness (UVCH) Issues
    • Description/Symptoms: Rough running, misfires, and white smoke due to injector malfunction.
    • Solution: Replace the UVCH and glow plug harness.
    • Estimated Cost to Fix: $200 - $500+
    • Recalls: None Found

Transmission

4R70W 4-Speed Automatic

  • Soft or Delayed Shifts
    • Description/Symptoms: Noticeable delay when shifting gears, particularly between 1st and 2nd, and slipping or ‘soft’ shifts.
    • Solution: Typically requires a transmission rebuild or replacement if the issue is severe. Fluid and filter change may alleviate symptoms in milder cases.
    • Estimated Cost to Fix: $150 - $300 (Fluid and Filter Change); $1500 - $3500+ (Rebuild/Replacement)
    • Recalls: None Found
  • Torque Converter Failure
    • Description/Symptoms: Shuddering at low speeds, especially when accelerating, and possible stalling.
    • Solution: Replace the torque converter.
    • Estimated Cost to Fix: $500 - $1500+
    • Recalls: None Found

4R100 4-Speed Automatic

  • Hard Shifts
    • Description/Symptoms: Harsh or jerky shifts, particularly under load or when cold.
    • Solution: Replace the transmission control module (TCM)
    • Estimated Cost to Fix: $1500 - $3500+ (Rebuild/Replacement)
    • Recalls: None Found
  • Torque Converter Failure
    • Description/Symptoms: Shuddering at low speeds, especially when accelerating, and possible stalling.
    • Solution: Replace the torque converter.
    • Estimated Cost to Fix: $500 - $1500+
    • Recalls: None Found

Suspension

  • Worn Ball Joints
    • Description/Symptoms: Clunking or popping noises from the front suspension, especially when turning or going over bumps. Excessive tire wear.
    • Solution: Replace the ball joints. It’s often recommended to replace upper and lower ball joints at the same time.
    • Estimated Cost to Fix: $300 - $800+ per side (depending on the number of ball joints replaced)
    • Recalls: None Found
  • Worn Leaf Springs (Rear)
    • Description/Symptoms: Sagging rear end, reduced load capacity, and poor ride quality.
    • Solution: Replace the leaf springs.
    • Estimated Cost to Fix: $400 - $1000+ (per side)
    • Recalls: None Found

Electrical

  • Instrument Cluster Issues
    • Description/Symptoms: Intermittent or complete failure of gauges, flickering lights, and possible loss of odometer reading.
    • Solution: Repair or replace the instrument cluster.
    • Estimated Cost to Fix: $200 - $800+
    • Recalls: None Found
  • Window Motor Failure
    • Description/Symptoms: Window stops working, or only works intermittently.
    • Solution: Replace window motor.
    • Estimated Cost to Fix: $150 - $400
    • Recalls: None Found

Exterior

  • Rust (Especially around wheel wells and body seams)
    • Description/Symptoms: Visible rust on the body panels, particularly around the wheel wells, rocker panels, and seams.
    • Solution: Rust repair, which may involve patching, welding, and repainting.
    • Estimated Cost to Fix: $200 - $2000+ (depending on the severity and extent of the rust)
    • Recalls: None Found
  • Door Hinge Wear
    • Description/Symptoms: Doors sagging, difficult to close properly, and creaking noises when opening or closing.
    • Solution: Replace the door hinges or hinge pins.
    • Estimated Cost to Fix: $100 - $400+ per door
    • Recalls: None Found

Interior

  • Headliner Sagging
    • Description/Symptoms: Headliner fabric detaching from the backing and sagging down.
    • Solution: Replace the headliner.
    • Estimated Cost to Fix: $200 - $600+
    • Recalls: None Found
  • Broken Door Handles (Interior)
    • Description/Symptoms: Internal door handle breaks, making it impossible to open the door from the inside.
    • Solution: Replace the door handle.
    • Estimated Cost to Fix: $50 - $200+
    • Recalls: None Found

Summary

The 2002 Ford Econoline, while generally reliable, is prone to certain issues due to its age and high usage. Engine problems such as spark plug ejection and intake manifold leaks are common with the Triton engines, while the Power Stroke can suffer from CPS and UVCH failures. Transmission issues like hard or soft shifting can lead to costly repairs. Suspension wear and tear, particularly ball joints and leaf springs, will impact ride quality and safety. Electrical glitches and rust are other common areas of concern. Severity of the issues range from minor annoyances to major mechanical failures, and repair costs can vary widely depending on the specific problem and the repair shop. Prospective buyers should carefully inspect the vehicle for signs of these issues and factor in potential repair costs.

Ford, Econoline
Ford Econoline 2002
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