2003 Ford E-450 Super Duty

Here is a breakdown of common issues and complaints associated with the 2003 Ford E-450 Super Duty. This vehicle was a popular choice for shuttle buses, ambulances, and other commercial applications due to its robust build and spacious interior. The 2003 E-450 offered a few engine choices including the 5.4L Triton V8, the 6.8L Triton V10, and the 7.3L Power Stroke Turbo Diesel (early production) or the 6.0L Power Stroke Turbo Diesel (late production). Horsepower and torque varied based on the engine, with the 6.8L V10 producing around 305 horsepower and 420 lb-ft of torque. Owners often praise the E-450 for its reliability and workhorse capabilities, but common complaints include fuel economy, ride quality, and some specific issues related to the engine and transmission.

Engine

5.4L Triton V8

• Spark Plugs Blowing Out
  • Description/Symptoms: Spark plugs are ejected from the cylinder head, often stripping the threads in the process. This results in a loud popping noise, misfire, and loss of power.
  • Solution: Repairing the cylinder head by installing thread inserts. Sometimes, if damage is extensive, replacing the cylinder head is necessary. Using correct torque specifications when reinstalling plugs is important.
  • Estimated Cost to Fix: $500 - $1500+
  • Recalls: None Found
• Cooling Fan Clutch Failure
  • Description/Symptoms: The cooling fan clutch fails, leading to overheating, especially under heavy loads or in hot weather.
  • Solution: Replacing the fan clutch with a new unit.
  • Estimated Cost to Fix: $200 - $400
  • Recalls: None Found

6.8L Triton V10

• Spark Plugs Blowing Out
  • Description/Symptoms: Spark plugs are ejected from the cylinder head, often stripping the threads in the process. This results in a loud popping noise, misfire, and loss of power.
  • Solution: Repairing the cylinder head by installing thread inserts. Sometimes, if damage is extensive, replacing the cylinder head is necessary. Using correct torque specifications when reinstalling plugs is important.
  • Estimated Cost to Fix: $500 - $1500+
  • Recalls: None Found
• Exhaust Manifold Leaks
  • Description/Symptoms: Exhaust manifold studs break, causing exhaust leaks. These leaks can be noisy and reduce fuel efficiency.
  • Solution: Replacing the broken exhaust manifold studs, often requiring removal of the manifold. Sometimes the manifold itself needs to be replaced if warped or damaged.
  • Estimated Cost to Fix: $400 - $1000+
  • Recalls: None Found
• Cooling Fan Clutch Failure
  • Description/Symptoms: The cooling fan clutch fails, leading to overheating, especially under heavy loads or in hot weather.
  • Solution: Replacing the fan clutch with a new unit.
  • Estimated Cost to Fix: $200 - $400
  • Recalls: None Found

7.3L Power Stroke Turbo Diesel (Early Production)

• Cam Position Sensor (CPS) Failure
  • Description/Symptoms: Sudden stalling, rough running, or difficulty starting.
  • Solution: Replacing the Cam Position Sensor (CPS).
  • Estimated Cost to Fix: $100 - $250
  • Recalls: None Found
• Injector Driver Module (IDM) Failure
  • Description/Symptoms: Engine misfires, rough running, and potential no-start conditions.
  • Solution: Replacing the Injector Driver Module (IDM).
  • Estimated Cost to Fix: $300 - $600
  • Recalls: None Found

6.0L Power Stroke Turbo Diesel (Late Production)

• EGR Cooler Failure
  • Description/Symptoms: Coolant loss, white smoke from the exhaust, and potential engine overheating. The EGR cooler is prone to cracking.
  • Solution: Replacing the EGR cooler, often upgrading to an aftermarket version designed for improved durability.
  • Estimated Cost to Fix: $800 - $1500+
  • Recalls: None Found
• Oil Cooler Failure
  • Description/Symptoms: Oil and coolant mixing, leading to potential engine damage. This is typically located below the oil filter.
  • Solution: Replacing the oil cooler.
  • Estimated Cost to Fix: $600 - $1200+
  • Recalls: None Found
• Fuel Injector Issues
  • Description/Symptoms: Rough running, misfires, white smoke, and hard starting.
  • Solution: Replacing faulty fuel injectors, which often requires specialized tools and knowledge.
  • Estimated Cost to Fix: $300 - $600 per injector (can be more depending on labor)
  • Recalls: None Found

Transmission

• 4R100 (Typically Paired with V8 and V10 Engines)

  • Shift Flare
    • Description/Symptoms: Delayed or erratic shifting between gears. Especially noticeable between 2nd and 3rd gear.
    • Solution: Replacing worn valve body components or performing a transmission rebuild.
    • Estimated Cost to Fix: $500 - $3000+ depending on the extent of the damage.
    • Recalls: None Found
  • Torque Converter Failure
    • Description/Symptoms: Shuddering or vibration at highway speeds, poor acceleration, and potential stalling.
    • Solution: Replacing the torque converter.
    • Estimated Cost to Fix: $500 - $1500
    • Recalls: None Found

• E4OD (Typically Paired with 7.3L Diesel)

  • Harsh Shifting
    • Description/Symptoms: Abrupt and harsh shifts between gears.
    • Solution: Addressing valve body issues, solenoid issues, or worn internal components.
    • Estimated Cost to Fix: $400 - $2000+
    • Recalls: None Found
  • Complete Failure
    • Description/Symptoms: Transmission stops working completely.
    • Solution: Replacing the transmission or doing a complete rebuild.
    • Estimated Cost to Fix: $2000 - $4500+
    • Recalls: None Found

Suspension

• Leaf Spring Sagging/Breakage
  • Description/Symptoms: Vehicle sagging, poor ride quality, and potential instability.
  • Solution: Replacing the leaf springs, possibly upgrading to heavier-duty springs.
  • Estimated Cost to Fix: $500 - $1200+ per spring set
  • Recalls: None Found
• Ball Joint Wear
  • Description/Symptoms: Loose steering, clunking noises from the front end, and uneven tire wear.
  • Solution: Replacing worn ball joints.
  • Estimated Cost to Fix: $200 - $600+ per side
  • Recalls: None Found

Electrical

• Alternator Failure
  • Description/Symptoms: Dimming lights, battery not charging, and eventual stalling.
  • Solution: Replacing the alternator.
  • Estimated Cost to Fix: $200 - $500
  • Recalls: None Found
• Window Motor Failure
  • Description/Symptoms: Window not going up or down.
  • Solution: Replacing the window motor.
  • Estimated Cost to Fix: $150 - $400
  • Recalls: None Found

Exterior

• Rust (Especially around Wheel Wells and Rocker Panels)
  • Description/Symptoms: Visible rust on the body panels.
  • Solution: Rust repair by cutting out and welding in new metal or using rust converter products.
  • Estimated Cost to Fix: $300 - $2000+ depending on severity.
  • Recalls: None Found

Interior

• Dashboard Cracking
  • Description/Symptoms: Cracks appearing on the dashboard, especially in areas exposed to direct sunlight.
  • Solution: Replacing the dashboard (expensive) or using a dashboard cover.
  • Estimated Cost to Fix: $100 (for a cover) to $1000+ (for a replacement)
  • Recalls: None Found
• Seat Frame Issues
  • Description/Symptoms: Broken seat frames causing instability and discomfort.
  • Solution: Welding and repairing the frame or replacing the entire seat.
  • Estimated Cost to Fix: $100 - $500+
  • Recalls: None Found

Summary

The 2003 Ford E-450 Super Duty is a generally reliable vehicle, but owners should be aware of common issues. Engine issues, particularly with the spark plugs on the Triton engines and the EGR/oil cooler on the 6.0L diesel, can be expensive to fix. Transmission problems, especially with the 4R100 and E4OD can also be costly. Suspension components wear out over time, and rust can be a concern in certain climates. While some issues are relatively minor, others can lead to significant repair bills. Performing regular maintenance and addressing problems early can help extend the life of this workhorse vehicle.