The 2004 E-350 with the 6.8L V10 Triton is a workhorse van/cutaway that's built tough but has two catastrophic weak points: spark plug ejection from the heads and transmission cooler failures that can kill the 4R100/TorqShift. When maintained, these vans rack up serious miles, but neglect or bad luck with these issues ends careers early.
Spark Plug Ejection from Cylinder Head (2V Triton engines)
Common · high severity
Typical onset: 60,000-150,000 mi
Symptoms: Sudden loss of power and loud hissing or popping from engine bay, Check engine light with misfire codes (P0301-P0310), Metal spark plug threads found on plug during removal, Rough idle and reduced power under load
Fix: The 2V Triton heads have inadequate spark plug thread engagement—only 4 threads versus 8+ on most engines. Plugs blow out, stripping the aluminum threads. Requires HeliCoil or TimeSert thread insert kit (proper fix), or in severe cases, cylinder head removal and machining. DIY with insert kit: 3-4 hours for one cylinder. Shop repair with head off: 8-12 hours labor plus machine work. Some shops pre-emptively install inserts on all cylinders during any head work.
Estimated cost: $800-1,200 per cylinder with insert kit; $3,000-5,000 if head removal required
Symptoms: Transmission slipping, delayed engagement, or no movement, Milky or strawberry-colored transmission fluid (coolant mixing), Engine overheating or coolant loss with no external leaks, Gray or foamy engine coolant in reservoir
Fix: The factory transmission cooler inside the radiator develops internal leaks, allowing coolant into the trans and vice versa. Coolant destroys clutch packs and torque converter within days. Requires new radiator, transmission flush (or rebuild if contamination went far), external cooler install recommended. If caught early (milky fluid, no slip): flush, radiator, cooler. If delayed: full transmission rebuild. Labor: 6-8 hours for cooler/radiator/flush; 18-24 hours for rebuild.
Estimated cost: $1,200-2,000 if caught early; $3,500-5,500 with transmission rebuild
Exhaust Manifold Stud Failure and Leaks
Common · medium severity
Typical onset: 70,000-120,000 mi
Symptoms: Loud ticking or tapping noise from engine bay, especially on cold start, Exhaust smell in cabin or under hood, Visible soot streaks on manifold or head, Check engine light with O2 sensor codes (P0151, P0171, etc.)
Fix: Studs corrode and snap, or threads strip from the aluminum head. Manifolds warp from heat cycles. Requires manifold removal, broken stud extraction (often requires drilling and EZ-outs), retapping threads, new studs/bolts, and new manifolds or resurfacing. Both sides often done together. 8-12 hours labor for both sides with stud extraction.
Estimated cost: $1,800-3,200 for both sides with new manifolds
Fuel Pump Driver Module (FPDM) Failure
Occasional · high severity
Symptoms: No start or stalling, especially when fuel tank is 1/4 to 1/2 full, Intermittent stalling that gets worse over time, Engine cranks but won't fire, or starts then dies immediately, No fuel pump prime sound when key turned to 'on'
Fix: The FPDM (mounted on the frame rail near the fuel tank) overheats and fails, cutting power to the fuel pump. Common Ford issue across platforms. Replacement is straightforward: 1-1.5 hours labor. Part is $150-250. Some techs add heat shielding or relocate to cooler spot as preventive.
Estimated cost: $300-500
Intake Manifold Gasket Coolant Leaks
Occasional · medium severity
Typical onset: 90,000-150,000 mi
Symptoms: Coolant seepage at front or rear of intake manifold, Slow coolant loss with no visible external puddles, Sweet smell from engine bay, White residue or crusty buildup on intake valley
Fix: Composite intake gaskets deteriorate from heat cycles. Requires intake removal, gasket set, and coolant flush. On V10, it's a big job due to manifold size and coil-pack removal. 6-8 hours labor. Good time to do spark plugs and coil boots while in there.
Estimated cost: $1,200-1,800
Rear Differential Pinion Seal Leak (Dana or Ford 10.5" axles)
Occasional · low severity
Typical onset: 80,000-130,000 mi
Symptoms: Gear oil dripping from front of differential or on driveshaft, Oil spots under center of vehicle when parked, Whining noise from rear axle under load (if fluid level drops significantly)
Fix: Pinion seal hardens and leaks. Requires driveshaft removal, pinion nut torque spec verification (critical for bearing preload), seal replacement, fluid refill. 2-3 hours labor. If bearing preload was lost, may need full pinion bearing setup (longer job). Most common on high-mileage work vans.
Estimated cost: $400-700
Owner tips
Install aftermarket external transmission cooler immediately—bypass or supplement the factory in-radiator cooler to prevent fluid cross-contamination
Use Motorcraft spark plugs ONLY and replace every 60k mi; torque to 27 lb-ft and never over-torque, which increases ejection risk
Check transmission fluid color monthly; any pink or milky appearance means immediate shutdown and cooler inspection
Have a shop inspect exhaust manifold studs and spark plug thread condition during any head work or timing job—preventive HeliCoil install on all cylinders is cheap insurance
Replace fuel filter every 30k mi; clogged filters stress the pump and FPDM
Buy one if you need towing/payload and can budget $2-3k for preventive trans cooler and potential spark plug thread repairs—solid platform once those landmines are cleared, but neglected examples are grenades.
AI-assisted summary drawn from NHTSA recall data, our labor-times database, and platform knowledge. Not a substitute for a pre-purchase inspection on a specific vehicle.
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FORD IS RECALLING CERTAIN REPLACEMENT FUEL TANKS THAT COULD BE INSTALLED INTO MODEL YEAR 2004 THROUGH 2008 E-150, E-250, AND E-350 VANS AND WAGONS. THE AFFECTED FUEL TANKS HAVE AN EXTRA OBDII SENSOR HOLE ON THE TOP OF THE TANK THAT MAY NOT BE PROPERLY SEALED AND MAY LEAK FUEL.
Consequence: A FUEL LEAK IN THE PRESENCE OF AN IGNITION SOURCE MAY RESULT IN A FIRE.
Remedy: FORD WILL NOTIFY OWNERS, AND DEALERS WILL REPLACE THE FUEL TANKS FREE OF CHARGE. THE SAFETY RECALL BEGAN ON NOVEMBER 28, 2011. OWNERS MAY CONTACT FORD MOTOR COMPANY CUSTOMER RELATIONSHIP CENTER AT 1-800-232-5952.
EQUIPMENT ADAPTIVE/MOBILITY · 09V100000
2009-03-27 · EQ08011
VAN CONVERSIONS IS RECALLING 52 MY 2004-2007 FORD E-150, E-250 E-350 AND MY 2006 GM SAVANNA 3500 VANS BUILT ON FORD AND GM CHASSIS AND EQUIPPED WITH RICON PLATFORM STYLE WHEELCHAIR LIFTS. THESE LIFTS FAIL TO COMPLY WITH THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 403, "PLATFORM LIFT SYSTEM ACCESSIBLE FOR MOTOR VEHICLES," THE ANTI-STOW INTERLOCK MAY NOT DETECT THE PRESENCE OF A WHEELCHAIR OR MOBILITY AID USER. THE PRESSURE SENSING SWITCH THAT DETECTS THE PRESENCE OF WEIGHT ON THE PLATFORM WAS NOT ADJUSTED TO THE NECESSARY SENSITIVITY LEVEL. THE LIFT COULD STOW EVEN THOUGH SOMEONE OR SOMETHING IS STILL ON THE LIFT.
Consequence: A LIFT OCCUPANT CAN BE INJURED SHOULD THE LIFT BEGIN TO STOW UNINTENTIONALLY.
Remedy: VAN CONVERSIONS IS WORKING WITH RICON TO CORRECT THE WHEELCHAIR LIFTS FREE OF CHARGE (PLEASE SEE 07E097). OWNERS MAY CONTACT RICON AT 1-818-267-3000 OR VAN CONVERSIONS AT 610-837-0707.
EQUIPMENT ADAPTIVE/MOBILITY · 09V102000
2009-03-27 · EQ08011
VAN CONVERSIONS IS RECALLING 74 MY 2004-2007 FORD E-150, E-250 E-350 AND MY 2006 GM SAVANNA 3500 VANS BUILT ON FORD AND GM CHASSIS AND EQUIPPED WITH RICON PLATFORM STYLE WHEELCHAIR LIFTS. THESE VEHICLES FAIL TO COMPLY WITH THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 404, "PLATFORM LIFT INSTALLATIONS IN MOTOR VEHICLES." THE THRESHOLD WARNING SYSTEM MAY NOT DETECT THE PRESENCE OF A WHEELCHAIR OR MOBILITY AID USER IN A CERTAIN SPOT WITHIN THE DEFINED THRESHOLD AREA.
Consequence: THE USER OF THE LIFT COULD BE INJURED SHOULD THE LIFT MOVE UNINTENTIONALLY.
Remedy: VAN CONVERSIONS IS WORKING WITH RICON TO CORRECT THE WHEELCHAIR LIFTS FREE OF CHARGE (PLEASE SEE 07E095). OWNERS MAY CONTACT RICON AT 1-818-267-3000 OR VAN CONVERSIONS AT 610-837-0707.
EQUIPMENT ADAPTIVE/MOBILITY · 08V518000
2008-10-06 · EQ08011
MOBILITYWORKS IS RECALLING 224 MY 2007-2008 FORD E150, MY 2006-2008 E250, MY 2004-2007 E350, MY 2006 E450, MY 2005-2007 CHEVROLET 2500, MY 2007 CHEVROLET 1500, AND MY 2006 DODGE 2500 VANS EQUIPPED WITH RICON PLATFORM STYLE WHEELCHAIR LIFTS. THESE VEHICLES FAIL TO COMPLY WITH THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 404, "PLATFORM LIFT INSTALLATIONS IN MOTOR VEHICLES." THE THRESHOLD WARNING SYSTEM MAY NOT DETECT THE PRESENCE OF A WHEELCHAIR OR MOBILITY AID USER IN A CERTAIN SPOT WITHIN THE DEFINED THRESHOLD AREA.
Consequence: THE USER OF THE LIFT COULD BE INJURED SHOULD THE LIFT MOVE UNINTENTIONALLY.
Remedy: MOBILITYWORKS IS WORKING WITH RICON TO CORRECT THE WHEELCHAIR LIFTS FREE OF CHARGE (PLEASE SEE 07E095). OWNERS MAY CONTACT RICON AT 1-818-267-3000 OR MOBILITY WORKS AT 1-800-769-8267.
EQUIPMENT ADAPTIVE/MOBILITY · 08V519000
2008-10-06 · EQ08011
MOBILITYWORKS IS RECALLING 133 MY 2005-2006 FORD E250, MY 2000, 2004-2006 E350, MY 2000, 2005 E450, MY 2005-2006 GMC 2500, GMC 3500, AND MY 2006 DODGE 2500 VANS EQUIPPED WITH RICON PLATFORM STYLE WHEELCHAIR LIFTS. THESE LIFTS FAIL TO COMPLY WITH THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 403, "PLATFORM LIFT SYSTEMS FOR MOTOR VEHICLES." THE ANTI-STOW INTERLOCK MAY NOT DETECT THE PRESENCE OF A WHEELCHAIR OR MOBILITY AID USER. THE PRESSURE SENSING SWITCH THAT DETECTS THE PRESENCE OF WEIGHT ON THE PLATFORM WAS NOT ADJUSTED TO THE NECESSARY SENSITIVITY LEVEL. THE LIFT COULD STOW EVEN THOUGH SOMEONE OR SOMETHING IS STILL ON THE LIFT.
Consequence: A LIFT OCCUPANT CAN BE INJURED SHOULD THE LIFT BEGIN TO STOW UNINTENTIONALLY.
Remedy: MOBILITYWORKS IS WORKING WITH RICON TO CORRECT THE WHEELCHAIR LIFTS FREE OF CHARGE (PLEASE SEE 07E097). OWNERS MAY CONTACT RICON AT 1-818-267-3000 OR MOBILITYWORKS AT 1-800-769-8267.
FUEL SYSTEM, GASOLINE · 06E056000
2006-06-13
CERTAIN AFTERMARKET FUEL FILTERS SOLD UNDER THE PUROLATOR BRAND NAME, P/N F65277, SHIPPED FROM JANUARY 16 THROUGH JUNE 2, 2006, FOR USE ON THE ABOVE LISTED PASSENGER VEHICLES. DUE TO INCORRECT DESIGN, THE QUICK CONNECTORS MAY NOT FULLY SEAT WITH THE TUBE INTERFACE, EVEN THOUGH THE PERSON MAKING THE CONNECTION MAY BELIEVE THAT THE QUICK CONNECTOR IS FULLY ATTACHED.
Consequence: FAILURE OF THIS CONNECTION COULD LEAD TO FUEL SPILLAGE AND, IN THE PRESENCE OF AN IGNITION SOURCE, A FIRE COULD OCCUR.
Remedy: UFI WILL NOTIFY OWNERS AND REPLACE THE FILTERS FREE OF CHARGE. THE RECALL BEGAN ON AUGUST 4, 2006. OWNERS MAY CONTACT UFI FILTERS USA AT 800-230-5876.
ELECTRICAL SYSTEM:WIRING · 05V270000
2005-06-10 · EA05003
CERTAIN PICKUP TRUCKS, SPORT UTILITY VEHICLES AND VANS EQUIPPED WITH 6.0L DIESEL ENGINES MAY EXPERIENCE STALLING WITHOUT WARNING WHILE DRIVING AND MAY OR MAY NOT RESTART.
Consequence: SHOULD THE ENGINE STALL, A VEHICLE CRASH COULD OCCUR.
Remedy: DEALERS WILL UPGRADE THE FUEL INJECTION CONTROL MODULE (FICM) WIRE HARNESS OR REPLACED, AND/OR HAVE A NEW INJECTION CONTROL PRESSURE (ICP)) SENSOR CONNECTOR INSTALLED FREE OF CHARGE. THE RECALL BEGAN ON JULY 22, 2005. OWNERS MAY CONTACT FORD AT 1-800-392-3673.
EQUIPMENT ADAPTIVE/MOBILITY · 04V589000
2004-12-15
ON CERTAIN VANS BUILT ON FORD E250/E350 CHASSIS AND EQUIPPED WITH SURE-LOK WHEELCHAIR SECUREMENT SYSTEMS, THE SPROCKET TEETH OF THE RETRACTOR ASSEMBLY IS OUT OF ALIGNMENT.
Consequence: IN THE EVENT OF A VEHICLE CRASH, THE WHEELCHAIR MAY NOT BE ADEQUATELY SECURED POSSIBLY RESULTING IN INJURIES TO A WHEELCHAIR OCCUPANT.
Remedy: DEALERS WILL INSPECT AND REPLACE THE WHEELCHAIR SECUREMENT RETRACTORS AS NECESSARY. SURE-LOK IS CONDUCTING THE OWNER NOTIFICATION AND REMEDY FOR THIS CAMPAIGN. OWNERS SHOULD CONTACT SURE-LOCK AT 1-908-231-1804 OR ACCUBUILT AT 419-222-1501.
EQUIPMENT ADAPTIVE/MOBILITY · 04V562000
2004-11-26
ON CERTAIN VANS EQUIPPED WITH SURE-LOK WHEELCHAIR SECUREMENT SYSTEMS, THE SPROCKET TEETH OF THE RETRACTOR ASSEMBLY IS OUT OF ALIGNMENT.
Consequence: IN THE EVENT OF A VEHICLE CRASH, THE WHEELCHAIR MAY NOT BE ADEQUATELY SECURED POSSIBLY RESULTING IN INJURIES TO A WHEELCHAIR OCCUPANT.
Remedy: DEALERS WILL INSPECT AND REPLACE THE WHEELCHAIR SECUREMENT RETRACTORS AS NECESSARY. SURE-LOK WILL HANDLE THE REPAIRS FOR THIS CAMPAIGN. OWNERS SHOULD CONTACT SURE-LOCK AT 1-908-231-1804 OR MOBILITYWORKS AT 1-800-769-8267.
ELECTRICAL SYSTEM:WIRING · 04V444000
2004-09-13
ON CERTAIN VANS, A DIODE IN THE ANTI-LOCK BRAKING SYSTEM (ABS) MODULE MAY EXPERIENCE AN ELECTRICAL SHORT.
Consequence: THE ELECTRICAL SHORT MAY CAUSE AN ABS MALFUNCTION THAT WOULD ILLUMINATE THE ABS WARNING LIGHT, OR THE MODULE MAY OVERHEAT RESULTING IN A BURNING ODOR, SMOKE, AND/OR FIRE. THIS CONDITION MAY OCCUR WHILE THE VEHICLE IS BEING DRIVEN OR UNATTENDED.
Remedy: DEALERS WILL INSTALL A NEW FUSE IN THE ABS CIRCUIT AND INSTALL A HEAT SHIELD OVER THE ABS MODULE. THE RECALL BEGAN ON OCTOBER 15, 2004. OWNERS SHOULD CONTACT FORD AT 1-800-392-3673.
ALSO FORD IS EXTENDING THE LIMITED WARRANTY (FOR A ONE TIME REPLACEMENT) OF THE ABS MODULE FOR A TOTAL OF 10 YEARS OR 150,000 MILES FROM THE WARRANTY START DATE, WHICHEVER OCCURS FIRST. IF YOUR VEHICLE HAS ALREADY ACCUMULATED MORE THAN 150,000 MILES, THIS COVERAGE WILL LAST UNTIL SEPTEMBER 30, 2005.
ENGINE AND ENGINE COOLING · 04V445000
2004-09-13
ON CERTAIN VANS, THE AIR FILTER ELEMENT MATERIAL PROCESS RESULTED IN AN AIR FILTER PAPER ELEMENT THAT CAN SMOLDER OR BURN. THIS CHANGE IN FILTER PAPER COMPOSITION COMBINED WITH THE CONFIGURATION OF THE AIR INDUCTION SYSTEM, MAY ALLOW HOT CARBON PARTICLES TO CONTACT THE AIR FILTER ELEMENT DURING CERTAIN DRIVING CONDITIONS THAT CREATE HOT PARTICLES.
Consequence: THESE HOT PARTICLES MAY IGNITE THE AIR FILTER ELEMENT WITH THE POTENTIAL FOR AIR INDUCTION SYSTEM DAMAGE OR UNDERHOOD FIRE.
Remedy: DEALERS WILL INSPECT AND REPLACE THE AIR FILTER ELEMENT. THE RECALL BEGAN SEPTEMBER 27, 2004. OWNERS SHOULD CONTACT FORD AT 1-800-392-3673.
ALSO FORD IS EXTENDING THE LIMITED WARRANTY (FOR A ONE TIME REPLACEMENT) OF THE ABS MODULE FOR A TOTAL OF 10 YEARS OR 150,000 MILES FROM THE WARRANTY START DATE, WHICHEVER OCCURS FIRST. IF YOUR VEHICLE HAS ALREADY ACCUMULATED MORE THAN 150,000 MILES, THIS COVERAGE WILL LAST UNTIL SEPTEMBER 30, 2005.
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