2006 Ford E-350 Super Duty

The 2006 Ford E-350 Super Duty is a full-size van known for its robust capabilities and versatility, often used for commercial purposes, conversion vans, and recreational vehicles. Engine options include the 5.4L Triton V8 (255 hp, 350 lb-ft torque), the 6.8L Triton V10 (305 hp, 420 lb-ft torque), and the 6.0L Power Stroke Turbo Diesel V8 (300 hp, 525 lb-ft torque). All engines were paired with a 4-speed automatic transmission. Owners generally appreciate the E-350’s spaciousness, towing capacity, and dependability, but some common complaints include fuel economy, ride quality, and certain engine/transmission issues, particularly with the diesel engine.

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 can cause a loud popping noise, misfires, and potential damage to the cylinder head.
  • Solution: Repairing the cylinder head with thread inserts or replacing the cylinder head.
  • Estimated Cost to Fix: $500 - $2000+ (depending on the extent of damage and repair method)
  • Recalls: None Found

6.0L Power Stroke Turbo Diesel V8

• EGR Cooler Failure
  • Description/Symptoms: The Exhaust Gas Recirculation (EGR) cooler can crack, allowing coolant to enter the engine. Symptoms include white smoke from the exhaust, coolant loss, and potential engine damage.
  • Solution: Replacing the EGR cooler. Upgraded aftermarket coolers are available and recommended for increased reliability.
  • Estimated Cost to Fix: $500 - $1500+
  • Recalls: None Found
• Fuel Injector Issues
  • Description/Symptoms: Injectors can fail leading to misfires, rough running, and black smoke from exhaust.
  • Solution: Replacing the faulty injectors.
  • Estimated Cost to Fix: $300 - $800+ per injector
  • Recalls: None Found
• Turbocharger Failure
  • Description/Symptoms: Turbocharger can fail from oil starvation, overspeed, and more.
  • Solution: Replacing the faulty turbocharger.
  • Estimated Cost to Fix: $1,500 - $3,000+
  • Recalls: None Found

Transmission

4R75E 4-Speed Automatic (All Engines)

• Torque Converter Failure
  • Description/Symptoms: Shuddering at highway speeds, stalling, or complete loss of drive.
  • Solution: Replacing the torque converter, and potentially rebuilding the transmission if damage has occurred.
  • Estimated Cost to Fix: $800 - $2500+
  • Recalls: None Found

Suspension

• Leaf Spring Sagging/Failure
  • Description/Symptoms: Rear of the van sitting lower than normal, especially when loaded. Rough ride, poor handling, and potential for bottoming out.
  • Solution: Replacing the leaf springs. Upgraded or heavy-duty springs may be recommended, especially for vans that are frequently used for towing or carrying heavy loads.
  • Estimated Cost to Fix: $400 - $1000+
  • Recalls: None Found
• Ball Joint Wear/Failure
  • Description/Symptoms: Loose steering, clunking noises from the front suspension, uneven tire wear.
  • Solution: Replacing the worn ball joints.
  • Estimated Cost to Fix: $200 - $600+ per side
  • Recalls: None Found

Electrical

• Alternator Failure
  • Description/Symptoms: Dimming headlights, battery warning light, difficulty starting, or stalling.
  • Solution: Replacing the alternator.
  • Estimated Cost to Fix: $200 - $500+
  • Recalls: None Found
• Window Regulator Failure
  • Description/Symptoms: Window rolls down very slowly or not at all. Window makes grinding sounds when attempting to roll down.
  • Solution: Replacing the window regulator.
  • Estimated Cost to Fix: $200 - $400+ per window
  • Recalls: None Found

Exterior

• Rust (Especially Around Wheel Wells and Body Seams)
  • Description/Symptoms: Visible rust developing on the body of the vehicle.
  • Solution: Rust repair.
  • Estimated Cost to Fix: $300 - $2,000+ (depending on the extent of rust)
  • Recalls: None Found

Interior

• HVAC Blower Motor Failure
  • Description/Symptoms: No air blowing from the vents, even when the fan is turned on.
  • Solution: Replacing the blower motor.
  • Estimated Cost to Fix: $150 - $400+
  • Recalls: None Found
• Door Latch Issues
  • Description/Symptoms: Difficult to open or close doors. Doors may not latch securely.
  • Solution: Replacing the door latch assembly.
  • Estimated Cost to Fix: $100 - $300+ per door
  • Recalls: None Found

Summary

The 2006 Ford E-350 Super Duty, while a workhorse, has several common issues to watch out for. Engine problems, especially with the 6.0L diesel, can be costly. The 5.4L V8’s spark plug issue is also a known concern. Suspension and electrical problems are less severe in terms of cost, but require attention. Overall, potential buyers should have a pre-purchase inspection performed to identify any existing or potential problems, especially with the engine and transmission. Repair costs can range from a few hundred dollars to several thousand, depending on the nature and severity of the issues.