2004 Ford E-150

Introduction:

The 2004 Ford E-150 is a full-size van available in various configurations, including cargo, passenger, and chassis cab. It offers a range of engine and transmission options to suit different needs. Despite its popularity, the E-150 has encountered some common issues reported by owners.

Engine

5.4L V8 Triton

• Cam Phaser Failure:
  • Description/Symptoms: Rough idle, reduced engine power, check engine light
  • Solution: Replace cam phasers
  • Estimated Cost to Fix: $1,000 - $2,000+
• Spark Plug Blowout:
  • Description/Symptoms: Misfiring, rough running, engine noise
  • Solution: Replace spark plugs, repair cylinder head threads
  • Estimated Cost to Fix: $500 - $1,500+
• Intake Manifold Gasket Leak:
  • Description/Symptoms: Coolant leak, overheating, rough idle
  • Solution: Replace intake manifold gasket
  • Estimated Cost to Fix: $300 - $600+
• Timing Chain Tensioner Failure:
  • Description/Symptoms: Engine rattle on startup, loss of power
  • Solution: Replace timing chain tensioner
  • Estimated Cost to Fix: $500 - $1,000+

4.6L V8 Modular

• Ignition Coil Failure:
  • Description/Symptoms: Misfiring, rough running, reduced engine power
  • Solution: Replace ignition coils
  • Estimated Cost to Fix: $200 - $400+

Transmission

4-Speed Automatic (4R70W):

• Torque Converter Shudder:
  • Description/Symptoms: Vibration or shudder when accelerating from a stop
  • Solution: Replace torque converter
  • Estimated Cost to Fix: $800 - $1,200+
• Transmission Slipping:
  • Description/Symptoms: Difficulty shifting gears, loss of power
  • Solution: Replace transmission
  • Estimated Cost to Fix: $2,000 - $3,000+

Suspension

• Front Ball Joint Failure:
  • Description/Symptoms: Noise when turning, excessive tire wear
  • Solution: Replace ball joints
  • Estimated Cost to Fix: $200 - $400+
• Rear Leaf Spring Breakage:
  • Description/Symptoms: Sagging rear end, rough ride
  • Solution: Replace leaf springs
  • Estimated Cost to Fix: $300 - $600+
• Strut Mount Failure:
  • Description/Symptoms: Clunking noise when hitting bumps, reduced handling
  • Solution: Replace strut mounts
  • Estimated Cost to Fix: $150 - $300+

Electrical

• Alternator Failure:
  • Description/Symptoms: Battery light on, electrical system problems
  • Solution: Replace alternator
  • Estimated Cost to Fix: $400 - $700+
• Battery Terminal Corrosion:
  • Description/Symptoms: Difficulty starting, electrical system issues
  • Solution: Clean battery terminals, replace cables if necessary
  • Estimated Cost to Fix: $50 - $150+
• Headlight Switch Failure:
  • Description/Symptoms: Headlights not working, intermittent operation
  • Solution: Replace headlight switch
  • Estimated Cost to Fix: $100 - $200+

Exterior

• Rust:
  • Description/Symptoms: Rust spots on body panels, especially around wheel wells
  • Solution: Preventative measures (undercoating), rust repair as needed
  • Estimated Cost to Fix: $500 - $1,500+ depending on severity

Interior

• Door Panel Sagging:
  • Description/Symptoms: Door panels sagging or loose
  • Solution: Reattach door panels, reinforce behind the panels
  • Estimated Cost to Fix: $100 - $300+
• Dash Panel Cracking:
  • Description/Symptoms: Cracks in the dashboard
  • Solution: No known solution, replacement of the dash may be necessary
  • Estimated Cost to Fix: $500 - $1,000+ for replacement

Summary:

The 2004 Ford E-150 is a popular vehicle, but it has encountered some common issues, particularly with its engine and transmission. The severity of these issues can vary, and some may be more costly to fix than others. Potential owners should be aware of these potential issues and consider them when making a purchase decision.