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2004 Ford E-350 Club Wagon

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By Research the Car 5 min read

The 2004 Ford E-350 Club Wagon is a full-size van known for its spacious interior, robust towing capacity, and overall utility. Available engine options included a 5.4L Triton V8, a 6.8L Triton V10, and a 7.3L Power Stroke Diesel (early 2004 models). The 5.4L V8 produced around 255 horsepower and 350 lb-ft of torque. A common complaint among owners is the vehicle’s fuel economy, especially with the larger engines. Owners appreciate the E-350’s ability to haul large families and cargo, but some find the handling less refined compared to modern vans.

Engine

5.4L Triton V8

  • Spark Plug Thread Failure
    • Description/Symptoms: Spark plugs can eject from the cylinder head due to weak aluminum threads. This is often preceded by a ticking noise.
    • Solution: Installing thread repair inserts (Time-Sert or similar) into the cylinder head.
    • Estimated Cost to Fix: $500 - $1500+ (depending on the number of spark plugs affected and if DIY or professional repair)
    • Recalls: None Found
  • Oil Leaks
    • Description/Symptoms: Oil leaks often originate from the valve cover gaskets, oil pan gasket, or front crankshaft seal. Visible oil drips and a burning oil smell can be present.
    • Solution: Replacing the leaking gaskets or seals.
    • Estimated Cost to Fix: $150 - $600+ (depending on the location and complexity of the leak)
    • Recalls: None Found

6.8L Triton V10

  • Exhaust Manifold Bolts Breaking
    • Description/Symptoms: Exhaust manifold bolts corrode and break, leading to exhaust leaks. This results in a ticking or hissing sound, especially when the engine is cold.
    • Solution: Replacing the broken exhaust manifold bolts. In some cases, the exhaust manifold itself may need to be replaced if it’s warped or damaged.
    • Estimated Cost to Fix: $300 - $1000+ (depending on the extent of the damage and if DIY or professional repair)
    • Recalls: None Found
  • Fuel Injector Issues
    • Description/Symptoms: Rough idling, misfires, poor fuel economy, and a check engine light can indicate failing fuel injectors.
    • Solution: Replacing the faulty fuel injectors.
    • Estimated Cost to Fix: $200 - $800+ (depending on the number of injectors replaced and if DIY or professional repair)
    • Recalls: None Found

7.3L Power Stroke Diesel

  • Cam Position Sensor Failure
    • Description/Symptoms: Stalling, rough running, and difficulty starting.
    • Solution: Replacing the cam position sensor.
    • Estimated Cost to Fix: $50 - $200+
    • Recalls: None Found
  • Injector O-rings
    • Description/Symptoms: Can fail which will result in hard starts, poor fuel economy, and black or white smoke from the exhaust.
    • Solution: Replacing the injector o-rings.
    • Estimated Cost to Fix: $200 - $800+
    • Recalls: None Found

Transmission

4R100 (Automatic)

  • Torque Converter Issues
    • Description/Symptoms: Shuddering during lockup, slipping, or failure to lock up. This can also cause the transmission to overheat.
    • Solution: Replacing the torque converter.
    • Estimated Cost to Fix: $800 - $2000+ (including labor and parts)
    • Recalls: None Found
  • Shifting Problems
    • Description/Symptoms: Harsh or delayed shifting, slipping between gears, or failure to shift at all.
    • Solution: Could be related to valve body issues, solenoid failures, or worn clutches. Diagnosis and repair may require a transmission rebuild or replacement.
    • Estimated Cost to Fix: $500 - $3000+ (depending on the severity of the problem)
    • Recalls: None Found

Suspension

  • Sagging Leaf Springs (Rear)
    • Description/Symptoms: The rear of the van sits lower than normal, especially when loaded. This can affect ride quality and handling.
    • Solution: Replacing the leaf springs. Adding helper springs or air suspension can provide additional support.
    • Estimated Cost to Fix: $300 - $1000+ (depending on the replacement option)
    • Recalls: None Found
  • Worn Ball Joints
    • Description/Symptoms: Clunking noises from the front suspension, especially when going over bumps or turning. Uneven tire wear can also occur.
    • Solution: Replacing the worn ball joints.
    • Estimated Cost to Fix: $200 - $600+ (depending on the extent of the damage and labor costs)
    • Recalls: None Found

Electrical

  • Door Lock Actuators
    • Description/Symptoms: Intermittent or complete failure of the power door locks.
    • Solution: Replacing the faulty door lock actuators.
    • Estimated Cost to Fix: $100 - $300+ per door (depending on if DIY or professional repair)
    • Recalls: None Found
  • Instrument Cluster Problems
    • Description/Symptoms: Gauges malfunctioning or not working, flickering lights, or the entire cluster going dark.
    • Solution: Repairing or replacing the instrument cluster.
    • Estimated Cost to Fix: $200 - $800+ (depending on the repair needed)
    • Recalls: None Found

Exterior

  • Rust
    • Description/Symptoms: Rust commonly forms on the rocker panels, wheel wells, and around the door seams, especially in areas with road salt exposure.
    • Solution: Rust repair, which can involve patching, welding, and repainting.
    • Estimated Cost to Fix: $200 - $2000+ (depending on the extent of the rust)
    • Recalls: None Found

Interior

  • Headliner Sagging
    • Description/Symptoms: The headliner material detaches from the backing and sags down.
    • Solution: Replacing or re-gluing the headliner.
    • Estimated Cost to Fix: $150 - $500+ (depending on the method and if DIY or professional repair)
    • Recalls: None Found
  • Blower Motor Resistor Failure
    • Description/Symptoms: The climate control fan only works on certain speeds or not at all.
    • Solution: Replacing the blower motor resistor.
    • Estimated Cost to Fix: $50 - $200+ (depending on if DIY or professional repair)
    • Recalls: None Found

Summary

The 2004 Ford E-350 Club Wagon, while a capable and versatile vehicle, can experience a range of issues. Engine problems like spark plug thread failure (5.4L) and exhaust manifold bolt breakage (6.8L) can be costly to address. Transmission issues, especially with the 4R100, may require significant repairs or even a rebuild. Suspension wear and electrical glitches are also common concerns. Rust can be a major issue, depending on the vehicle’s location and history. Overall, potential buyers should thoroughly inspect the vehicle, paying close attention to these common problem areas, and factor in the potential for future repairs when considering the purchase price. The severity and cost of these issues can range from relatively minor to substantial, making a pre-purchase inspection highly recommended.

Ford, E-350 Club Wagon
Ford E-350 Club Wagon 2004
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