2004 Ford E-150 Club Wagon

The 2004 Ford E-150 Club Wagon is a popular choice for large families and those needing a versatile vehicle for cargo and passenger transport. Available engine options include a 4.2L Essex V6 producing 200 hp and 260 lb-ft of torque, a 4.6L Triton V8 producing 225 hp and 286 lb-ft of torque, and a 5.4L Triton V8 producing 255 hp and 350 lb-ft of torque. All engines were paired with a 4-speed automatic transmission. Owners often appreciate the E-150’s spacious interior and towing capability, while some dislike its fuel economy and handling.

Engine

4.2L Essex V6

• Intake Manifold Gasket Failure
  • Description/Symptoms: Engine may run rough, misfire, or have a vacuum leak. Check Engine Light may illuminate. Coolant may leak externally.
  • Solution: Replace the intake manifold gasket.
  • Estimated Cost to Fix: $200 - $500
  • Recalls: None Found

4.6L Triton V8

• Spark Plug Blowout
  • Description/Symptoms: Spark plug ejects from the cylinder head, often damaging the threads. Loud popping noise, loss of power, and engine misfire.
  • Solution: Repair or replace the cylinder head. Thread repair kits (like Time-Sert) can be used.
  • Estimated Cost to Fix: $300 - $1500+ (depending on the extent of the damage and repair method)
  • Recalls: None Found
• Oil Leaks
  • Description/Symptoms: Oil leaks can occur from various locations, including the valve cover gaskets, oil pan gasket, and rear main seal. Visible oil drips and a burning oil smell.
  • Solution: Replace the leaking gasket or seal.
  • Estimated Cost to Fix: $100 - $500+ per leak location
  • Recalls: None Found

5.4L Triton V8

• Spark Plug Blowout
  • Description/Symptoms: Spark plug ejects from the cylinder head, often damaging the threads. Loud popping noise, loss of power, and engine misfire.
  • Solution: Repair or replace the cylinder head. Thread repair kits (like Time-Sert) can be used.
  • Estimated Cost to Fix: $300 - $1500+ (depending on the extent of the damage and repair method)
  • Recalls: None Found
• Oil Leaks
  • Description/Symptoms: Oil leaks can occur from various locations, including the valve cover gaskets, oil pan gasket, and rear main seal. Visible oil drips and a burning oil smell.
  • Solution: Replace the leaking gasket or seal.
  • Estimated Cost to Fix: $100 - $500+ per leak location
  • Recalls: None Found

Transmission

4R70W 4-Speed Automatic Transmission (All Engines)

• Shift Flare/Slipping
  • Description/Symptoms: Delayed or harsh shifts, transmission slipping between gears, and generally poor shift quality.
  • Solution: Valve body issues could be the cause, in which case valve body replacement/rebuild is necessary, or complete transmission rebuild.
  • Estimated Cost to Fix: $500 - $3000+
  • Recalls: None Found

Suspension

• Ball Joint Failure
  • Description/Symptoms: Clicking or popping noises from the front suspension, loose steering, uneven tire wear.
  • Solution: Replace the worn ball joints.
  • Estimated Cost to Fix: $200 - $600 per side
  • Recalls: None Found
• Leaf Spring Sagging/Breaking (Rear)
  • Description/Symptoms: Rear of the vehicle sits lower than normal, reduced load-carrying capacity, rough ride. In extreme cases, leaf springs can break.
  • Solution: Replace the leaf springs.
  • Estimated Cost to Fix: $300 - $800 per side
  • Recalls: None Found

Electrical

• Door Ajar Light Stays On
  • Description/Symptoms: The “Door Ajar” light remains illuminated even when all doors are closed properly. Could be caused by a faulty door jamb switch.
  • Solution: Replace the faulty door jamb switch.
  • Estimated Cost to Fix: $50 - $200
  • Recalls: None Found
• ABS Sensor Failure
  • Description/Symptoms: ABS light is illuminated, ABS system may not function properly, reduced braking performance.
  • Solution: Replace the faulty ABS sensor.
  • Estimated Cost to Fix: $100 - $300 per sensor
  • Recalls: None Found

Exterior

• Rust on Rocker Panels and Wheel Arches
  • Description/Symptoms: Visible rust forming on the lower body panels.
  • Solution: Remove the rust and repaint, or replace the affected body panels.
  • Estimated Cost to Fix: $300 - $1000+ per panel, depending on severity and repair method
  • Recalls: None Found
• Door Handle Breakage
  • Description/Symptoms: Exterior door handles, especially on side and rear doors, can break due to age and wear.
  • Solution: Replace the broken door handle.
  • Estimated Cost to Fix: $50 - $200 per handle
  • Recalls: None Found

Interior

• Power Window Regulator Failure
  • Description/Symptoms: Window moves slowly, erratically, or not at all.
  • Solution: Replace the power window regulator.
  • Estimated Cost to Fix: $150 - $400 per window
  • Recalls: None Found
• Blend Door Actuator Failure
  • Description/Symptoms: Inconsistent temperature control, clicking noises behind the dashboard, inability to control airflow direction.
  • Solution: Replace the blend door actuator.
  • Estimated Cost to Fix: $150 - $500+ (depending on location and accessibility)
  • Recalls: None Found

Summary

The 2004 Ford E-150 Club Wagon has a mix of common issues, some of which can be quite expensive to repair. Engine-related problems like spark plug blowout on the 4.6L and 5.4L Triton V8 engines can be a major concern. Transmission issues, such as shift flare, can also be costly. Suspension components like ball joints and leaf springs are prone to wear and tear, while electrical problems with door ajar sensors and ABS sensors are also common. Rust on the exterior and interior issues like power window and blend door actuator failures are also found. Overall, prospective buyers should be aware of these potential problems and have the vehicle thoroughly inspected before purchasing. Repair costs can range from relatively minor to significant, depending on the issue.