The 2016 E-350 with the 6.8L V10 Triton is a workhorse van plagued by spark plug ejection issues and transmission cooler failures that can strand you. When maintained aggressively, it hauls reliably, but deferred maintenance leads to catastrophic engine damage.
Spark Plug Ejection from Aluminum Heads
Common · high severityTypical onset: 60,000-120,000 mi
Symptoms: Sudden misfire with loud popping sound, Loss of power under load, Check engine light with cylinder misfire codes, Hissing sound from engine bay
Fix: The 2-valve Triton V10 has inadequate thread engagement in the aluminum heads. Ejected plugs require HeliCoil or TimeSert thread repair (2-3 hours per cylinder if accessible). Severe cases damage the head requiring removal and machining (12-16 hours labor). Preventive installation of inserts on all cylinders runs 8-12 hours.
Estimated cost: $800-3,500
Transmission Oil Cooler Line Failure
Common · high severityTypical onset: 80,000-140,000 mi
Symptoms: Transmission fluid leaking at radiator connection, Pink fluid puddles under vehicle, Transmission overheating warning, Milky transmission fluid (coolant contamination)
Fix: The steel cooler lines rust through at the radiator quick-connect fittings or along the frame rail. Simple line replacement is 2-3 hours. If coolant mixes with ATF before you catch it, the transmission is toast—full rebuild or replacement (14-20 hours). Flush the cooling system and trans simultaneously if caught early.
Estimated cost: $400-6,500
Triton V10 Exhaust Manifold Stud Failure
Occasional · medium severityTypical onset: 90,000-150,000 mi
Symptoms: Ticking or tapping noise on cold start, Exhaust leak smell in cabin, Visible soot streaks on manifold, Loss of back pressure affects performance
Fix: Studs break off in the cylinder heads due to thermal cycling. Requires head removal to extract broken studs and retap threads (10-14 hours per side). Some techs attempt in-chassis extraction with mixed success (4-6 hours if lucky). Replace all studs with upgraded hardware during repair.
Estimated cost: $1,200-3,200
4R100 Transmission Hard Shifts and Slipping
Occasional · high severityTypical onset: 120,000-180,000 mi
Symptoms: Harsh 1-2 or 2-3 upshifts when cold, Delayed engagement into reverse, Slipping under heavy throttle in 3rd or 4th, Burnt ATF smell
Fix: The 4R100 behind the V10 suffers from worn intermediate clutches and hardened seals with age. Band adjustments buy time (1 hour) but most need a full rebuild with upgraded clutches and shift kit (14-18 hours). Towing and high GVWR accelerates wear significantly.
Estimated cost: $2,800-4,800
Fuel Pump Driver Module Failure
Occasional · medium severityTypical onset: 70,000-130,000 mi
Symptoms: No-start condition intermittently, Engine cranks but won't fire, Stalling at highway speed then restarts after cooling, No fuel pump prime sound on key-on
Fix: The FPDM mounted on the frame rail overheats and fails, cutting power to the fuel pump. Replacement is straightforward (1-1.5 hours) but diagnosis can be tricky if intermittent. Module is about $150-250. Some replace preemptively after 100k to avoid roadside breakdowns.
Estimated cost: $300-500
Rear Leaf Spring U-Bolt Loosening
Common · medium severitySymptoms: Clunking over bumps from rear suspension, Axle shifting side-to-side under load, Uneven tire wear on rear, Visible gap between spring pack and axle pad
Fix: U-bolts stretch and loosen over time, especially on vans that see loaded work or rough roads. Retorque to spec (30-45 minutes per side). If threads are damaged, replace U-bolts and check spring packs for separation (1.5-2 hours per side). Critical safety item that's often overlooked.
Estimated cost: $200-600
Integrated Trailer Brake Controller Malfunction (NHTSA Recall)
Occasional · high severitySymptoms: Trailer brakes activating without input, No trailer brake response when towing, Intermittent brake controller error messages, Brake controller display glitches
Fix: Ford issued recalls for faulty integrated trailer brake modules that fail internally. Covered under recall at dealer (2-3 hours labor, parts free). If you tow regularly and experience erratic trailer braking, check if your VIN is included and get it fixed immediately—major safety issue.
Estimated cost: $0 (recall)
Buy if you need the payload and can handle the spark plug time bomb—budget $3k-5k for preventive engine work or walk away from high-mileage examples.
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.