2004 Ford E-150

2004 Ford E-150

Overview

The 2004 Ford E-150 is a full-size van known for its utility and workhorse capabilities. While generally considered a robust vehicle, like any model, it has specific areas that have seen more attention from owners regarding reliability. This analysis focuses on common reported issues beyond routine maintenance, examining its powertrain, suspension, electrical systems, and other key areas. Understanding these potential problem points can help owners anticipate and address issues proactively, ensuring the longevity and performance of their E-150.

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Engine

4.2L V6

Intake Manifold Gasket Leaks

• Symptoms: Coolant leaks, engine misfires, rough idle, overheating.
• Solution: Replacement of intake manifold gaskets.
• Cost: $400 - $800

Spark Plug Blowout

• Symptoms: Loss of power, rough running, ticking noise from engine, check engine light.
• Solution: Repair or replacement of spark plug threads, often requiring specialized tools or inserts.
• Cost: $300 - $700

4.6L V8

Intake Manifold Gasket Leaks

• Symptoms: Coolant leaks, engine misfires, rough idle, overheating.
• Solution: Replacement of intake manifold gaskets.
• Cost: $400 - $800

Spark Plug Blowout

• Symptoms: Loss of power, rough running, ticking noise from engine, check engine light.
• Solution: Repair or replacement of spark plug threads, often requiring specialized tools or inserts.
• Cost: $300 - $700

5.4L V8

Intake Manifold Gasket Leaks

• Symptoms: Coolant leaks, engine misfires, rough idle, overheating.
• Solution: Replacement of intake manifold gaskets.
• Cost: $400 - $800

Spark Plug Blowout

• Symptoms: Loss of power, rough running, ticking noise from engine, check engine light.
• Solution: Repair or replacement of spark plug threads, often requiring specialized tools or inserts.
• Cost: $300 - $700

Camshaft Position Sensor Failure

• Symptoms: Check engine light, rough idle, poor acceleration, stalling.
• Solution: Replacement of the camshaft position sensor.
• Cost: $150 - $300

Transmission

4R70W (4-Speed Automatic)

Torque Converter Issues

• Symptoms: Shuddering, slipping, delayed engagement, overheating transmission fluid.
• Solution: Replacement of the torque converter and potentially transmission fluid flush.
• Cost: $800 - $1500

Overdrive Clutch Pack Failure

• Symptoms: Inability to engage overdrive gear, slipping in higher gears.
• Solution: Rebuild or replacement of the transmission.
• Cost: $1800 - $3500

5R55E (5-Speed Automatic)

Solenoid Pack Failure

• Symptoms: Harsh shifting, delayed engagement, transmission fault codes.
• Solution: Replacement of the transmission solenoid pack.
• Cost: $400 - $700

Torque Converter Issues

• Symptoms: Shuddering, slipping, delayed engagement, overheating transmission fluid.
• Solution: Replacement of the torque converter and potentially transmission fluid flush.
• Cost: $800 - $1500

Suspension

Standard Chassis

Ball Joint Wear

• Symptoms: Clunking noises over bumps, uneven tire wear, wandering steering.
• Solution: Replacement of worn ball joints.
• Cost: $300 - $600

Leaf Spring Sagging/Breakage

• Symptoms: Rear end sag, reduced load capacity, rattling noises.
• Solution: Replacement of leaf springs.
• Cost: $400 - $800

Electrical

General Electrical System

Alternator Failure

• Symptoms: Dimming headlights, battery warning light, electrical components malfunctioning, dead battery.
• Solution: Replacement of the alternator.
• Cost: $400 - $700

Window Regulator Failure

• Symptoms: Power windows not operating, slow window movement, grinding noises.
• Solution: Replacement of the window regulator assembly.
• Cost: $200 - $400

Exterior

Body Panels and Trim

Rust on Body Panels

• Symptoms: Visible rust, bubbling paint, perforation of metal, especially around wheel wells and rocker panels.
• Solution: Rust repair and repainting, or replacement of affected panels.
• Cost: $500 - $2000+

Interior

Interior Components

HVAC Blower Motor Failure

• Symptoms: No air coming from vents, or air only coming from certain vents, intermittent fan speed.
• Solution: Replacement of the HVAC blower motor and resistor.
• Cost: $200 - $400

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Summary Verdict

The 2004 Ford E-150 is a capable work van with a generally solid reputation, but it’s not without its common issues. The gasoline V6 and V8 engines can experience intake manifold gasket leaks and spark plug blowouts, while the automatic transmissions, particularly the 4R70W, may develop torque converter or clutch pack problems. Suspension components like ball joints and leaf springs are also noted for wear. Electrical issues such as alternator failure and window regulator problems are not uncommon. Rust can be a concern on exterior body panels, especially in certain climates. Interiorly, the HVAC blower motor is a component that may require replacement. Despite these potential issues, many E-150s continue to serve reliably with proper maintenance and timely repairs.