2004 Ford E-250

Here is a breakdown of common issues and complaints associated with the 2004 Ford E-250, categorized and formatted as requested. The 2004 Ford E-250 is a popular work van known for its reliability, payload capacity, and spacious interior. It was available with several engine options, including the 4.2L Essex V6 (200 hp and 260 lb-ft of torque), the 4.6L Triton V8 (225 hp and 286 lb-ft of torque), and the 5.4L Triton V8 (255 hp and 350 lb-ft of torque). All engines were paired with a 4-speed automatic transmission. Owners often appreciate the van’s utility and cargo space, but common complaints include fuel economy and the age-related maintenance needs.

Engine

4.2L Essex V6

• Intake Manifold Gasket Failure
  • Description/Symptoms: Coolant leak, overheating, rough idle, white smoke from exhaust.
  • Solution: Replace the intake manifold gasket.
  • Estimated Cost to Fix: $300 - $600

4.6L Triton V8

• Spark Plug Blowout
  • Description/Symptoms: Loud popping noise, misfire, loss of power, damaged spark plug threads in the cylinder head.
  • Solution: Repair or replace the cylinder head, install thread repair inserts.
  • Estimated Cost to Fix: $500 - $2000+
• Idle Air Control Valve Issues
  • Description/Symptoms: Erratic idling, stalling, difficulty starting.
  • Solution: Clean or replace the idle air control (IAC) valve.
  • Estimated Cost to Fix: $100 - $300
• Fuel Injector Failure
  • Description/Symptoms: Misfire, rough running engine, poor fuel economy
  • Solution: Replace faulty fuel injectors.
  • Estimated Cost to Fix: $200 - $800
  • Recalls: None Found

5.4L Triton V8

• Spark Plug Blowout
  • Description/Symptoms: Loud popping noise, misfire, loss of power, damaged spark plug threads in the cylinder head.
  • Solution: Repair or replace the cylinder head, install thread repair inserts.
  • Estimated Cost to Fix: $500 - $2000+
• Idle Air Control Valve Issues
  • Description/Symptoms: Erratic idling, stalling, difficulty starting.
  • Solution: Clean or replace the idle air control (IAC) valve.
  • Estimated Cost to Fix: $100 - $300
• Fuel Injector Failure
  • Description/Symptoms: Misfire, rough running engine, poor fuel economy
  • Solution: Replace faulty fuel injectors.
  • Estimated Cost to Fix: $200 - $800
  • Recalls: None Found

Transmission

4-Speed Automatic (4R70W/4R75E)

• Shift Flare/Slipping
  • Description/Symptoms: Delayed engagement, slipping between gears, especially between 2nd and 3rd.
  • Solution: Transmission rebuild or replacement. Could also involve replacing solenoids or valve body repair.
  • Estimated Cost to Fix: $1500 - $3500+
• Harsh Shifting
  • Description/Symptoms: Abrupt or jerky shifts, especially when downshifting.
  • Solution: Fluid change, solenoid replacement, valve body repair.
  • Estimated Cost to Fix: $100 - $1000+
• Torque Converter Failure
  • Description/Symptoms: Shuddering at low speeds, stalling, poor acceleration.
  • Solution: Torque converter replacement.
  • Estimated Cost to Fix: $500 - $1500+

Suspension

• Worn Ball Joints
  • Description/Symptoms: Clunking or popping noises from the front end, especially when turning or going over bumps, uneven tire wear.
  • Solution: Ball joint replacement.
  • Estimated Cost to Fix: $200 - $600 per side
• Worn Leaf Springs
  • Description/Symptoms: Sagging rear end, poor ride quality, bottoming out
  • Solution: Leaf Spring Replacement
  • Estimated Cost to Fix: $400-$1000
  • Recalls: None Found

Electrical

• Alternator Failure
  • Description/Symptoms: Dimming lights, battery warning light, difficulty starting, dead battery.
  • Solution: Alternator replacement.
  • Estimated Cost to Fix: $200 - $500
• Battery Drain
  • Description/Symptoms: Battery repeatedly dying, requiring frequent jump starts.
  • Solution: Diagnose and repair parasitic drain. Common causes include faulty relays, aftermarket accessories, or a failing GEM (Generic Electronic Module).
  • Estimated Cost to Fix: $100 - $500+ (diagnosis can be time-consuming)
• Power Window/Door Lock Issues
  • Description/Symptoms: Intermittent or complete failure of power windows or door locks.
  • Solution: Repair or replace faulty switches, motors, or wiring.
  • Estimated Cost to Fix: $100 - $400 per component

Exterior

• Rust (Especially Around Wheel Wells and Body Seams)
  • Description/Symptoms: Visible rust, bubbling paint, corrosion.
  • Solution: Rust repair, body panel replacement.
  • Estimated Cost to Fix: $200 - $2000+ (depending on severity)

Interior

• Headliner Sagging
  • Description/Symptoms: Headliner fabric detaching from the roof.
  • Solution: Headliner replacement.
  • Estimated Cost to Fix: $200 - $500

Summary

The 2004 Ford E-250, while generally reliable, exhibits common issues related to its age and usage. Engine problems like spark plug blowouts and intake manifold leaks on the V8 engines can be moderately expensive. Transmission issues, particularly shift flares, can be costly to address, often requiring a rebuild or replacement. Suspension components like ball joints and leaf springs also wear out, impacting ride quality. Electrical issues, such as alternator failure and battery drain, are also typical. Rust can be a significant concern in certain climates. Overall, potential buyers should thoroughly inspect the vehicle, paying close attention to these common problem areas. Repair costs can range from a few hundred dollars for minor fixes to several thousand for major engine or transmission work.