2003 Ford E-250

The 2003 Ford E-250 is a popular full-size van known for its versatility and durability. Engine options include the 4.2L Essex V6, the 4.6L Triton V8, and the 5.4L Triton V8. The 5.4L Triton V8 produced 255 horsepower and 350 lb-ft of torque. The transmission options were primarily a 4-speed automatic. Owners often praise the E-250 for its cargo capacity and reliability, but common complaints include issues related to age, such as rust, worn suspension components, and electrical problems.

Engine

4.2L Essex V6

• Intake Manifold Gasket Failure
  • Description/Symptoms: Coolant leak, rough running engine, overheating.
  • Solution: Replace the intake manifold gasket.
  • Estimated Cost to Fix: $300 - $600+
  • Recalls: None Found

4.6L Triton V8

• Spark Plug Blowout
  • Description/Symptoms: Loud popping noise from the engine, misfire, loss of power. Primarily affects early Triton engines (1997-2003) with cylinder heads having fewer threads for spark plugs.
  • Solution: Repair or replace cylinder head, install spark plug thread repair kit.
  • Estimated Cost to Fix: $500 - $2000+ depending on the severity and repair method.
  • Recalls: None Found

5.4L Triton V8

• Spark Plug Blowout
  • Description/Symptoms: Loud popping noise from the engine, misfire, loss of power. Primarily affects early Triton engines (1997-2003) with cylinder heads having fewer threads for spark plugs.
  • Solution: Repair or replace cylinder head, install spark plug thread repair kit.
  • Estimated Cost to Fix: $500 - $2000+ depending on the severity and repair method.
  • Recalls: None Found
• Exhaust Manifold Bolts Breaking
  • Description/Symptoms: Ticking noise from the engine, especially when cold. Exhaust leak.
  • Solution: Replace broken exhaust manifold bolts and potentially the exhaust manifold itself.
  • Estimated Cost to Fix: $300 - $800+
  • Recalls: None Found

Transmission

4-Speed Automatic (4R70W/4R75W)

• Slipping/Erratic Shifting
  • Description/Symptoms: Transmission slips between gears, harsh or delayed shifts, difficulty engaging gears.
  • Solution: Transmission rebuild or replacement, valve body repair, solenoid replacement.
  • Estimated Cost to Fix: $1500 - $3500+
  • Recalls: None Found
• Torque Converter Failure
  • Description/Symptoms: Shuddering at highway speeds, stalling, difficulty engaging gears.
  • Solution: Replace the torque converter.
  • Estimated Cost to Fix: $500 - $1200+
  • Recalls: None Found

Suspension

• Ball Joint Wear
  • Description/Symptoms: Clunking noise from the front suspension, especially over bumps. Loose steering.
  • Solution: Replace worn ball joints.
  • Estimated Cost to Fix: $200 - $600+ per side.
  • Recalls: None Found
• Leaf Spring Sagging/Broken
  • Description/Symptoms: Rear end sagging, poor ride quality, reduced load capacity.
  • Solution: Replace leaf springs.
  • Estimated Cost to Fix: $400 - $1000+ per side.
  • Recalls: None Found

Electrical

• Alternator Failure
  • Description/Symptoms: Dimming headlights, battery warning light, stalling.
  • Solution: Replace 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 issues. Often found in areas prone to corrosion or damage.
  • Solution: Repair or replace damaged wiring harness sections.
  • Estimated Cost to Fix: $100 - $1000+ depending on the severity and location.
  • Recalls: None Found

Exterior

• Rust on Rocker Panels and Wheel Wells
  • Description/Symptoms: Visible rust on rocker panels, wheel wells, and around seams.
  • Solution: Rust repair and panel replacement.
  • Estimated Cost to Fix: $500 - $2000+ per affected area, depending on the severity.
  • Recalls: None Found

Interior

• Headliner Sagging
  • Description/Symptoms: The headliner fabric detaches from the backing and sags down.
  • Solution: Replace the headliner.
  • Estimated Cost to Fix: $200 - $500+
  • Recalls: None Found

Summary

The 2003 Ford E-250, while generally reliable, is prone to issues common with older vehicles, such as rust, worn suspension components, and electrical problems. Engine-specific issues, like spark plug blowout and exhaust manifold bolt breakage on the Triton engines, can be costly to repair. Transmission issues can also be significant. Overall, potential buyers should inspect the vehicle thoroughly, especially for rust and signs of engine or transmission problems. The severity and cost of repairs can range from relatively minor fixes to major overhauls.