2004 Ford E-450 Super Duty

Introduction:

The 2004 Ford E-450 Super Duty is a heavy-duty passenger van with impressive towing and hauling capabilities. It comes equipped with a robust 5.4L V8 engine that generates 255 horsepower and 350 lb-ft of torque. The vehicle is available with a 4-speed automatic transmission or a 5-speed manual transmission. Its spacious interior and versatile seating configurations make it a popular choice for families, businesses, and transportation services. Despite its strengths, the E-450 Super Duty has experienced several issues over the years.

Engine

5.4L V8 Engine

• Intake Manifold Runner Control Valve Failure:
  • Description/Symptoms: Engine hesitation, rough idle, decreased fuel economy
  • Solution: Replace intake manifold runner control valve
  • Estimated Cost to Fix: $500 - $800
  • Recalls: #08V203000, #07V333000
• Oil Pressure Sensor Failure:
  • Description/Symptoms: Low oil pressure warning light illuminates, potential engine damage
  • Solution: Replace oil pressure sensor
  • Estimated Cost to Fix: $150 - $250
  • Recalls: None Found
• Head Gasket Failure:
  • Description/Symptoms: Coolant leaks, overheating, engine performance issues
  • Solution: Replace head gasket
  • Estimated Cost to Fix: $2,000 - $3,000+
  • Recalls: None Found

Transmission

4-Speed Automatic Transmission:

• Transmission Slipping:
  • Description/Symptoms: Transmission hesitates or slips during gear changes
  • Solution: Overhaul or replace transmission
  • Estimated Cost to Fix: $2,000 - $5,000+
  • Recalls: None Found
• Torque Converter Failure:
  • Description/Symptoms: Transmission shuddering, overheating, slipping
  • Solution: Overhaul or replace torque converter
  • Estimated Cost to Fix: $800 - $1,500
  • Recalls: None Found

5-Speed Manual Transmission:

• Clutch Master Cylinder Failure:
  • Description/Symptoms: Clutch pedal spongy or difficult to engage
  • Solution: Replace clutch master cylinder
  • Estimated Cost to Fix: $300 - $500
  • Recalls: None Found
• 5th Gear Syncro Failure:
  • Description/Symptoms: Difficulty or grinding noise when shifting into 5th gear
  • Solution: Replace 5th gear syncro
  • Estimated Cost to Fix: $800 - $1,200
  • Recalls: None Found

Suspension

• Front Coil Spring Failure:
  • Description/Symptoms: Sagging front end, reduced ride height
  • Solution: Replace front coil springs
  • Estimated Cost to Fix: $500 - $800
  • Recalls: None Found
• Rear Leaf Spring Failure:
  • Description/Symptoms: Sagging rear end, reduced load capacity
  • Solution: Replace rear leaf springs
  • Estimated Cost to Fix: $800 - $1,200
  • Recalls: None Found

Electrical

• Alternator Failure:
  • Description/Symptoms: Electrical system not charging, dim headlights, battery warning light
  • Solution: Replace alternator
  • Estimated Cost to Fix: $500 - $800
  • Recalls: None Found
• Battery Drain:
  • Description/Symptoms: Battery goes dead quickly after being left parked
  • Solution: Diagnose and repair source of battery drain
  • Estimated Cost to Fix: $150 - $500+
  • Recalls: None Found

Exterior

• Rust on Frame:
  • Description/Symptoms: Excessive corrosion and rust on metal frame
  • Solution: Clean and treat rust, apply undercoating
  • Estimated Cost to Fix: $1,000 - $2,000+
  • Recalls: None Found
• Window Regulator Failure:
  • Description/Symptoms: Power windows inoperable
  • Solution: Replace window regulator
  • Estimated Cost to Fix: $300 - $500
  • Recalls: None Found

Interior

• HVAC Blower Motor Failure:
  • Description/Symptoms: No airflow from HVAC system
  • Solution: Replace blower motor
  • Estimated Cost to Fix: $300 - $500
  • Recalls: None Found
• Dashboard Cracking:
  • Description/Symptoms: Cracks appearing on dashboard
  • Solution: Replace dashboard
  • Estimated Cost to Fix: $1,000 - $2,000+
  • Recalls: None Found

Summary:

While the 2004 Ford E-450 Super Duty offers impressive capabilities and versatility, it has experienced several issues over the years. Engine issues, particularly involving the intake manifold runner control valve and oil pressure sensor, are common. Transmission problems, such as slipping and torque converter failure, affect both automatic and manual transmissions. Suspension issues, including coil and leaf spring failure, can compromise ride quality and handling. Electrical concerns range from alternator failure to battery drain. Exterior problems include rust on the frame and window regulator issues. Interior issues are limited to HVAC blower motor failure and dashboard cracking. The severity and cost of these issues vary depending on the specific problem and whether it is covered by a recall.