2004 Ford E-250
2004 Ford E-250
Overview
The 2004 Ford E-250 is a robust full-size van known for its utility and hauling capabilities. While generally reliable, like any vehicle of its age, it can experience specific issues. This analysis focuses on common mechanical and electrical concerns reported by owners, excluding routine maintenance. Understanding these potential problem areas can help owners anticipate and address repairs, ensuring the continued serviceability of their E-250.
Engine
4.2L V6
Intake Manifold Gasket Leaks
- Symptoms: Coolant leaks, rough idle, potential overheating.
- Solution: Replacement of intake manifold gaskets.
- Cost: $300 - $600
Spark Plug Blowout
- Symptoms: Loss of power, misfires, audible popping sound.
- Solution: Repair or replacement of spark plug threads, often requiring specialized tools.
- Cost: $400 - $800
5.4L V8 Triton
Spark Plug Blowout
- Symptoms: Loss of power, misfires, audible popping sound.
- Solution: Repair or replacement of spark plug threads, often requiring specialized tools.
- Cost: $400 - $800
Camshaft Position Sensor Failure
- Symptoms: Check Engine light, rough idle, stalling, difficulty starting.
- Solution: Replacement of the camshaft position sensor.
- Cost: $150 - $300
4.6L V8 Triton
Spark Plug Blowout
- Symptoms: Loss of power, misfires, audible popping sound.
- Solution: Repair or replacement of spark plug threads, often requiring specialized tools.
- Cost: $400 - $800
Camshaft Position Sensor Failure
- Symptoms: Check Engine light, rough idle, stalling, difficulty starting.
- Solution: Replacement of the camshaft position sensor.
- Cost: $150 - $300
6.8L V10 Triton
Spark Plug Blowout
- Symptoms: Loss of power, misfires, audible popping sound.
- Solution: Repair or replacement of spark plug threads, often requiring specialized tools.
- Cost: $400 - $800
Camshaft Position Sensor Failure
- Symptoms: Check Engine light, rough idle, stalling, difficulty starting.
- Solution: Replacement of the camshaft position sensor.
- Cost: $150 - $300
Transmission
4R70W (4-Speed Automatic)
Torque Converter Clutch (TCC) Issues
- Symptoms: Shuddering, slipping, failure to engage.
- Solution: Rebuild or replacement of the torque converter and potentially transmission.
- Cost: $800 - $1500
Overheating
- Symptoms: Delayed shifting, slipping, burning smell.
- Solution: Transmission fluid flush and cooler inspection/replacement.
- Cost: $200 - $500
4R100 (4-Speed Automatic)
Torque Converter Clutch (TCC) Issues
- Symptoms: Shuddering, slipping, failure to engage.
- Solution: Rebuild or replacement of the torque converter and potentially transmission.
- Cost: $800 - $1500
Overheating
- Symptoms: Delayed shifting, slipping, burning smell.
- Solution: Transmission fluid flush and cooler inspection/replacement.
- Cost: $200 - $500
Suspension
Standard Chassis
Ball Joint Wear
- Symptoms: Clunking noises over bumps, uneven tire wear, steering looseness.
- Solution: Replacement of worn ball joints.
- Cost: $300 - $600
Leaf Spring Sagging
- Symptoms: Rear end sag, reduced load capacity, rougher ride.
- Solution: Replacement of sagging leaf springs.
- Cost: $400 - $800
Electrical
General Electrical System
Alternator Failure
- Symptoms: Dimming lights, battery warning light, starting issues, dead battery.
- Solution: Replacement of the alternator.
- Cost: $300 - $600
Window Regulator Failure
- Symptoms: Power windows not working, slow operation, grinding noise.
- Solution: Replacement of the window regulator mechanism.
- Cost: $200 - $400
Exterior
Body and Trim
Rust on Body Panels
- Symptoms: Visible rust, bubbling paint, perforation of metal.
- Solution: Rust repair and repainting, or panel replacement.
- Cost: $200 - $1000+
Door Latch/Lock Actuator Issues
- Symptoms: Doors not locking/unlocking properly, difficulty opening/closing.
- Solution: Replacement of door latch or lock actuator.
- Cost: $150 - $350
Interior
Cabin Components
HVAC Blower Motor Failure
- Symptoms: No air coming from vents, or weak airflow, regardless of fan speed setting.
- Solution: Replacement of the blower motor.
- Cost: $150 - $300
Dashboard Cracking
- Symptoms: Visible cracks on the dashboard surface, especially in hot climates.
- Solution: Dashboard cover or replacement.
- Cost: $200 - $600
Summary Verdict
The 2004 Ford E-250 is a workhorse van that, while generally dependable, exhibits some common issues typical for its age and class. Engine concerns like spark plug blowout (especially on Triton V8/V10 engines) and intake manifold leaks on the 4.2L V6 are notable. Transmission issues, particularly with torque converter clutch engagement and overheating on the 4R70W and 4R100, require attention. Suspension components like ball joints and leaf springs can wear out, and electrical issues such as alternator failure are not uncommon. Exterior rust and interior wear, like HVAC blower motor problems, are also reported. Regular maintenance and proactive inspection of these areas are recommended for owners of the 2004 E-250.