2003 Ford E-350 Club Wagon
The 2003 Ford E-350 Club Wagon is a full-size passenger van known for its spacious interior and robust build, making it popular for large families and commercial use. Engine options included the 5.4L Triton V8 (255 hp, 350 lb-ft torque), the 6.8L Triton V10 (310 hp, 425 lb-ft torque), and the 7.3L Power Stroke Turbo Diesel V8 (275 hp, 525 lb-ft torque). The 2003 E-350 came standard with a 4-speed automatic transmission (4R100 for the gas engines, and E4OD for the diesel). Owners often praise the E-350 for its reliability and towing capacity, but common complaints include fuel economy and age-related issues affecting various components.
Engine
5.4L Triton V8
- Spark Plug Issues
- Description/Symptoms: Spark plugs breaking upon removal due to a two-piece design and corrosion inside the cylinder head. This can lead to misfires, rough idling, and reduced engine power.
- Solution: Use penetrating oil before attempting removal. Special extraction tools may be needed if the spark plug breaks. Installation of updated one-piece spark plugs is recommended.
- Estimated Cost to Fix: $300 - $800+ depending on the number of broken plugs and whether professional extraction is needed.
- Recalls: None Found
- Intake Manifold Cracks
- Description/Symptoms: Cracks in the plastic intake manifold, leading to vacuum leaks, poor engine performance, and illuminated check engine light.
- Solution: Replacement of the intake manifold with an updated composite or aluminum version.
- Estimated Cost to Fix: $300 - $600
- Recalls: None Found
6.8L Triton V10
- Exhaust Manifold Leaks
- Description/Symptoms: Broken exhaust manifold studs causing exhaust leaks, noticeable hissing sound, and reduced fuel economy.
- Solution: Removal of broken studs and replacement with new, stronger studs. May require welding or specialized tools if studs are seized.
- Estimated Cost to Fix: $400 - $1000+ depending on the number of broken studs and labor involved.
- Recalls: None Found
7.3L Power Stroke Turbo Diesel V8
- Cam Position Sensor Failure
- Description/Symptoms: Sudden stalling, rough running, or difficulty starting the engine. Diagnostic trouble codes related to the cam position sensor.
- Solution: Replacement of the cam position sensor.
- Estimated Cost to Fix: $100 - $200
- Recalls: None Found
- Glow Plug Issues
- Description/Symptoms: Hard starting, especially in cold weather, and excessive white smoke upon startup. Can also lead to damaged glow plug relay.
- Solution: Replacement of faulty glow plugs and inspection/replacement of the glow plug relay.
- Estimated Cost to Fix: $200 - $500+ depending on the number of glow plugs needing replacement and relay condition.
- Recalls: None Found
Transmission
4R100 (Gas Engines)
- Torque Converter Failure
- Description/Symptoms: Shuddering or vibration during acceleration, particularly at lower speeds. Transmission slipping or failing to engage gears.
- Solution: Replacement of the torque converter and fluid flush. Inspection of the transmission for further damage.
- Estimated Cost to Fix: $800 - $1500+ depending on the shop and extent of the damage.
- Recalls: None Found
E4OD (Diesel Engine)
- Forward Clutch Failure
- Description/Symptoms: Failure to move in forward gears. Slipping between gears.
- Solution: Full Transmission rebuild
- Estimated Cost to Fix: $1500-$3000+
- Recalls: None Found
Suspension
- Leaf Spring Sagging/Broken Leaves
- Description/Symptoms: Rear end sagging, poor ride quality, and clunking noises from the rear suspension.
- Solution: Replacement of the leaf springs, either with new springs or adding helper springs.
- Estimated Cost to Fix: $400 - $1000+ depending on the extent of damage and the quality of replacement springs.
- Recalls: None Found
- Ball Joint Wear
- Description/Symptoms: Steering play, clunking noises over bumps, and uneven tire wear.
- Solution: Replacement of the worn ball joints.
- Estimated Cost to Fix: $300 - $800+
- Recalls: None Found
Electrical
- ABS Sensor Failure
- Description/Symptoms: ABS light illuminated, loss of ABS function, and potential issues with the speedometer.
- Solution: Diagnosis to identify the faulty sensor and replacement of the sensor.
- Estimated Cost to Fix: $150 - $400+
- Recalls: None Found
- Window Motor Failure
- Description/Symptoms: Slow or non-functional power windows.
- Solution: Replacement of the window motor.
- Estimated Cost to Fix: $150 - $300+
- Recalls: None Found
Exterior
- Door Hinge Wear
- Description/Symptoms: Sagging doors, difficulty closing, and noisy hinges.
- Solution: Replacement of worn hinge pins and bushings, or replacement of the entire hinge assembly.
- Estimated Cost to Fix: $100 - $400+ per door.
- Recalls: None Found
Interior
- Headliner Sagging
- Description/Symptoms: The headliner fabric detaches from the backing board and sags down.
- Solution: Replacement of the headliner material.
Estimated Cost to Fix: $200 - $500+
- Recalls: None Found
- Blend Door Actuator Failure
- Description/Symptoms: Clicking noises from behind the dashboard, inability to control temperature properly, and inconsistent airflow.
- Solution: Replacement of the faulty blend door actuator.
Estimated Cost to Fix: $200 - $500+
- Recalls: None Found
Summary
The 2003 Ford E-350 Club Wagon, while a capable and spacious vehicle, does exhibit some common issues, primarily due to its age and mileage. Engine issues, such as spark plug problems and intake manifold cracks in the 5.4L V8, or glow plug problems in the 7.3L diesel, can be costly to repair. Transmission problems, while less frequent, can also lead to significant expenses. Suspension wear and electrical glitches are also common areas of concern. The severity of these issues ranges from relatively minor fixes to more extensive repairs, and the associated costs can vary widely depending on the specific problem and the repair shop. Buyers should carefully inspect the vehicle and address any identified problems to ensure long-term reliability.