What are the most common Ford E-Series problems?
According to Au7o's analysis of 560+ owner reports, the 2009 Ford E-Series has 10 documented issues. The most frequently reported are: 6.0L Power Stroke Head Gasket Failure from Insufficient Head Bolt Clamping, 6.0L Power Stroke Engine Oil Cooler Plugging (E-350/E-450 Diesel), 6.0L Power Stroke EGR Cooler Soot Clogging and Internal Rupture. Of these, 3 are rated critical and should be addressed promptly.
Is the Ford E-Series reliable?
The 2009 Ford E-Series has 10 known issues documented across 560+ owner reports. 3 issues are rated critical: 6.0L Power Stroke Head Gasket Failure from Insufficient Head Bolt Clamping and 6.0L Power Stroke Engine Oil Cooler Plugging (E-350/E-450 Diesel) and 6.0L Power Stroke EGR Cooler Soot Clogging and Internal Rupture. Prospective buyers should inspect for these issues and factor potential repair costs into their purchase decision. Regular maintenance following the manufacturer's schedule helps prevent many common problems.
How much does it cost to fix common Ford E-Series problems?
Repair costs for known Ford E-Series issues range from $20 to $8,000, depending on the specific problem and whether you choose DIY or professional repair. The most critical issue, 6.0L Power Stroke Head Gasket Failure from Insufficient Head Bolt Clamping, typically costs $3,500-$8,000 to repair. Au7o provides step-by-step DIY maintenance guides that can help reduce repair costs.
What is the 2004-2010 Ford E-Series 6.0L Power Stroke Head Gasket Failure from Insufficient Head Bolt Clamping?
The 6.0L Power Stroke in the 2004-2010 E-350/E-450 uses four torque-to-yield head bolts per cylinder. Under the high peak cylinder pressures this engine sees - especially once a plugged oil cooler and EGR cooler have raised combustion and coolant temperatures - the heads lift mom… Repairs typically run $3,500-$8,000. Severity: high.
What is the 2004-2010 Ford E-Series 6.0L Power Stroke Engine Oil Cooler Plugging (E-350/E-450 Diesel)?
The 2004-2010 E-350 and E-450 diesel vans use the 6.0L Power Stroke, whose engine oil cooler is a coolant-to-oil plate cooler with very small coolant passages. Casting sand left in the block and silicate dropout from degraded Ford Gold coolant progressively plug those passages. O… Repairs typically run $900-$2,200. Severity: high.
What is the 2004-2010 Ford E-Series 6.0L Power Stroke EGR Cooler Soot Clogging and Internal Rupture?
On the 2004-2010 E-350/E-450 6.0L Power Stroke the factory EGR cooler is a coolant-cooled tube bundle that both clogs with soot and carbon and cracks internally from thermal stress, dumping coolant into the intake. Van duty cycles (ambulance, shuttle, box truck idling) accelerate… Repairs typically run $800-$2,000. Severity: high.
What is the 2000-2014 Ford E-Series Transmission Cooler Line Rubber Hose Degradation and Leak?
E-Series vans use rubber transmission cooler hose sections that connect the steel lines to the radiator-mounted transmission cooler. These rubber sections harden, crack, and leak transmission fluid. The leak is often slow enough that the fluid level drops gradually, causing the t… Repairs typically run $50-$400. Severity: medium.
What is the 2000-2014 Ford E-Series Rear A/C Evaporator and Line Leaks?
Vans equipped with rear A/C suffer from refrigerant leaks in the rear evaporator core or the long refrigerant lines running under the body. Corrosion from road salt accelerates line deterioration. Repairs typically run $400-$1,200. Severity: medium.
What is the 2004-2010 Ford E-Series 5R110W TorqShift Solenoid Body Wear Causing Harsh Shifts and Limp Mode?
The 5R110W TorqShift, fitted behind the 6.0L Power Stroke E-350/E-450 (and behind gasoline V10 chassis in the same era), controls its shift sequence with seven solenoids in a single solenoid body. In high-idle, heavy-load van duty the solenoids and the valve body bores wear, so l… Repairs typically run $600-$1,800. Severity: medium.
What is the 1992-2016 Ford E-Series Rocker Panel, Wheel Arch and Rear Body Crossmember Rust-Through?
Econoline bodies trap water in the rocker panel, the lower cargo/side door openings, the wheel arches and - most seriously - the rear crossmember just ahead of the step bumper, behind the swing-out rear doors. Salt-belt vans rot from the inside out: the rocker perforates below th… Repairs typically run $600-$4,000. Severity: medium.
What is the 2004-2010 Ford E-Series 6.0L Power Stroke FICM Power Board Failure (Hard Start, Rough Run)?
The Fuel Injection Control Module on the 2004-2010 E-350/E-450 6.0L steps battery voltage up to about 48V to fire the injectors. Its DC-DC power board is damaged by low battery voltage during cranking - a chronic condition on vans with dual batteries where one battery is weak, an… Repairs typically run $250-$900. Severity: medium.
What is the 1997-2019 Ford E-Series Triton 2-Valve Exhaust Manifold Stud Breakage and Exhaust Tick?
The modular Triton gasoline engines fitted to the E-Series - 4.6L V8, 5.4L V8 and 6.8L V10, all 2-valve in this van (the E-Series never received the 3-valve heads used in F-Series trucks) - break their exhaust manifold studs where they thread into the aluminium head. Repeated hea… Repairs typically run $400-$1,600. Severity: medium.
What is the 2003-2014 Ford E-Series Front Door Hinge Pin Wear and Door Sagging?
E-Series cargo and passenger vans suffer from severe front door hinge pin wear, especially on the driver side due to frequency of use. The hinge pins and bushings wear to the point where the door sags noticeably, making it difficult to close and causing the door to strike the fen… Repairs typically run $20-$300. Severity: low.
