2004 Ford E-Series Problems: 12 Known Issues

On the 1997-2004 Ford E-Series, nHTSA reviewed complaints that a spark plug detached from the cylinder threads or ejected from the engine on 1997-2004 Ford vehicles with Triton V-8 and V-10 engines. Most complainants reported a loud pop while driving or on start-up followed by a repetitive clicking or popping sound, often with some loss of power; in nearly all cases damage was limited to the engine. ODI's 2007 review counted 652 complaints, mostly on 1997-2002 models (17 on 2003 and 2 on 2004).

On the 2004-2009 Ford E-Series 6.0L Power Stroke V8 diesel, ford's 6.0L coolant-loss bulletin includes a road test for leaking head gaskets: cooling-system pressure rising above the cap's holding pressure, or the degas cap venting continuously under load. It says a turbocharger over-boost condition, from irregular variable-geometry turbo response or a biased exhaust back-pressure sensor signal, causes excessive cylinder pressure that may lead to head gasket failure. Applies to: 2004-2009 E-Series with the 6.0L Power Stroke diesel V8 (Ford TSB 09-8-3). Not the gasoline E-Series engines.

On the 1997-2004 Ford E-Series, the IAC valve becomes clogged with carbon deposits, causing erratic idle speed, stalling at stops, and surging idle. Particularly common on 5.4L and 4.6L Triton engines in fleet vehicles with frequent stop-and-go use.

On the 1999-2004 Ford E-Series, e-250, E-350 and E-450 vans built roughly 1999-2004 behind the 5.4L, 6.8L V10 and 7.3L Power Stroke use the 4R100, the heavy-duty evolution of the E4OD. In loaded van and cutaway service the one-way (sprag) clutch and the direct/forward clutch packs fail, so the transmission will not shift correctly out of first, or shifts appear only in some ranges. Related documented complaints on the same unit include a start-up ticking in Park or Neutral caused by the overdrive clutch steel separator plates striking the case spline (TSB 98-20-9) and a torque converter dust plug that falls out under severe duty (TSB 02-21-1, applicable to E-Series from 1989).

On the 1992-2014 Ford E-Series, owners report transmission fluid leaks at the front of the van from the cooler lines: at the short rubber hose sections and clamps where the lines meet the coolers, and where the steel cooler lines have rusted through near the external filter housing. Applies to: 1992-2014 E-Series vans with automatic transmissions; the owner reports linked here are from a 2000 E-250 (5.4L, 4R70W) and a 2005 E-350 Super Duty (5.4L). Mileage when it happened, as stated in the linked owner reports: 160,000 miles on a 2000.

On the 2004-2009 Ford E-Series 6.0L Power Stroke V8 diesel, ford's bulletin says some 6.0L diesel E-Series vans may vent coolant from the degas bottle cap, lose coolant, blow white smoke from the tailpipe, lose power from overheating or lose cabin heat, typically under load such as towing or climbing hills. A leaking EGR cooler can cause white smoke and internal coolant loss that may hydro-lock the engine, and can push exhaust gas into the cooling system so it looks like a leaking head gasket. Applies to: 2004-2009 E-Series with the 6.0L Power Stroke diesel V8 (Ford TSB 09-8-3, which supersedes 08-11-3). Not the gasoline E-Series engines.

On the 2004-2009 Ford E-Series 6.0L Power Stroke V8 diesel, ford's 6.0L coolant-loss bulletin tests the engine oil cooler for coolant-flow restriction: engine oil temperature 15°F (8.4°C) or more above coolant temperature on a loaded road test means the cooler is restricted. The bulletin says coolant degraded by combustion gases, low system pressure or overheating drops silicate and loses corrosion protection, and that rust flakes and silicate can collect in the oil cooler. Applies to: 2004-2009 E-Series with the 6.0L Power Stroke diesel V8 (Ford TSB 09-8-3). Not the gasoline E-Series engines.

On the 1992-2014 Ford E-Series, owners report rust on the floor and on the body reinforcing members welded under it, which turned out deeper than it looked once it was wire-brushed and ground. They blame moisture held against the floor by the factory carpet or mat backing, and water and road spray getting in from underneath. Applies to: 1992-2014 E-Series vans (fourth-generation body); the owner reports linked here are from a 2003 E-350 and a 2007 E-350 extended van.

On the 1992-2014 Ford E-Series, owners report play in the front door hinge pins and bushings that lets the driver's door contact the body or rub the fender. One owner reports replacement brass bushings breaking again after a pin-and-bushing kit. Applies to: 1992-2014 E-Series vans (fourth-generation body); the owner reports linked here are from a 1997 E-350 and a 1999 E-350.

On the 1992-2014 Ford E-Series, owners of vans with factory rear A/C report refrigerant leaks at the rear evaporator and along the long lines that run to it, so the A/C stops blowing cold. They report the lines leaking around the brackets that hold them and above the rear tire, from corrosion or rock damage. Applies to: 1992-2014 E-Series vans with factory rear (auxiliary) A/C; the owner reports linked here are from a 2007 E-350 and a 2012 E-350 wagon.

On the 1999-2010 Ford E-Series, ford's bulletin says some E-Series vans with the 5.4L or 6.8L 2-valve engine may have broken exhaust manifold studs. Applies to: 1999-2010 E-Series with the 5.4L 2-valve V8 or 6.8L 2-valve V10, non-supercharged (Ford TSB 09-22-8, Oct 28, 2009, which supersedes 5-5-4). The 4.6L is not listed in the bulletin.

On the 2004-2010 Ford E-Series 6.0L Power Stroke V8 diesel, ford's bulletin says some 6.0L diesel E-350 and E-450 vans may run rough, lack power, start hard or not start, with or without code P0611 or injector circuit codes. The cause may be the DC-DC converter in one half of the fuel injection control module (FICM), which boosts battery voltage to 48 volts for the injectors, or the main circuit board in the other half; low FICM supply voltage increases its load and can damage it or shorten its life. Applies to: 2004-2010 E-350 and E-450 with the 6.0L Power Stroke diesel V8 (Ford TSB 10-12-6, June 11, 2010). Not the gasoline E-Series engines.