2009 Ford E-250

The 2009 Ford E-250 is a full-size cargo van, prized for its reliability and utility. It was available with two engine options: a 4.6L Triton V8 producing 225 horsepower and 286 lb-ft of torque, and a 5.4L Triton V8 producing 255 horsepower and 350 lb-ft of torque. Both engines were paired with a 4-speed automatic transmission. Owners typically appreciate the E-250’s robust build, large cargo capacity, and relatively simple mechanical design, making it easy to repair. Downsides often mentioned include relatively poor fuel economy and a somewhat dated interior.

Engine

4.6L Triton V8

• Spark Plug Thread Failure
  • Description/Symptoms: Spark plugs can become seized in the cylinder head, resulting in damaged threads during removal, or spark plugs ejected from the engine.
  • Solution: Installation of thread repair inserts such as Time-Sert.
  • Estimated Cost to Fix: $300 - $800+
  • Recalls: None Found

5.4L Triton V8

• Spark Plug Thread Failure
  • Description/Symptoms: Spark plugs can become seized in the cylinder head, resulting in damaged threads during removal, or spark plugs ejected from the engine.
  • Solution: Installation of thread repair inserts such as Time-Sert.
  • Estimated Cost to Fix: $300 - $800+
  • Recalls: None Found
• Cam Phaser Issues
  • Description/Symptoms: Ticking or rattling noise coming from the engine, especially at idle. Can also cause rough running and decreased performance.
  • Solution: Replacement of the cam phasers, timing chains, and potentially other related components.
  • Estimated Cost to Fix: $1500 - $3000+
  • Recalls: None Found

Transmission

4-Speed Automatic (4R75E or similar)

• Shift Flare/Slipping
  • Description/Symptoms: Delay or hesitation during gear changes, engine RPMs increasing without a corresponding increase in vehicle speed.
  • Solution: Valve body replacement or rebuild, transmission rebuild or replacement.
  • Estimated Cost to Fix: $500 - $3000+
  • Recalls: None Found

Suspension

• Leaf Spring Sagging/Failure
  • Description/Symptoms: Rear of the vehicle sitting lower than normal, especially when loaded. Can lead to poor handling and ride quality. Broken leaf springs are visually apparent.
  • Solution: Replacement of the leaf springs.
  • Estimated Cost to Fix: $400 - $1000+
  • Recalls: None Found
• Ball Joint Wear/Failure
  • Description/Symptoms: Clicking or popping noises from the front suspension, loose steering, uneven tire wear.
  • Solution: Replacement of the ball joints.
  • Estimated Cost to Fix: $200 - $600+
  • Recalls: None Found

Electrical

• Door Lock Actuator Failure
  • Description/Symptoms: Door locks not working, either intermittently or completely.
  • Solution: Replacement of the faulty door lock actuator.
  • Estimated Cost to Fix: $150 - $400+
  • Recalls: None Found
• Alternator Failure
  • Description/Symptoms: Battery light illumination, dimming headlights, difficulty starting, or complete electrical failure.
  • Solution: Replacement of the alternator.
  • Estimated Cost to Fix: $300 - $600+
  • Recalls: None Found

Exterior

• Rust on Lower Body Panels
  • Description/Symptoms: Rust forming on rocker panels, wheel wells, and lower doors, especially in areas exposed to road salt.
  • Solution: Rust repair, panel replacement, and repainting.
  • Estimated Cost to Fix: $300 - $1000+ per panel
  • Recalls: None Found

Interior

• Headliner Sagging
  • Description/Symptoms: The headliner fabric detaching from the backing and sagging down.
  • Solution: Headliner replacement.
  • Estimated Cost to Fix: $200 - $500+
  • Recalls: None Found

Summary

The 2009 Ford E-250, while a durable workhorse, has its share of common issues. The spark plug thread issue with both V8 engines is a well-known problem and can be costly. The 5.4L’s cam phaser issues are another potential high-cost repair. Suspension components like leaf springs and ball joints are prone to wear and can affect handling. Electrical issues, particularly with door lock actuators and alternators, can also arise. Rust is a concern, especially in colder climates. Overall, while the E-250 is generally reliable, potential buyers should be aware of these potential issues and factor in repair costs when evaluating a purchase. The severity of these issues ranges from minor inconveniences to major repairs costing several thousand dollars.