The 2011 E-150 is a proven workhorse van built on Ford's last-generation full-size platform, sharing the Triton V8 engines with F-Series trucks. The 4.6L is generally more reliable, while the 5.4L suffers from catastrophic spark plug and piston failures that can grenade the engine.
5.4L Triton Spark Plug Ejection and Thread Stripping
Common · high severity
Typical onset: 60,000-120,000 mi
Symptoms: sudden misfire with Check Engine Light, loud popping or hissing sound from engine bay, loss of power, spark plug literally blown out of cylinder head
Fix: Early 3-valve 5.4L engines had inadequate spark plug threads that strip or blow out. If caught early with just stripped threads, HeliCoil thread repair runs 2-3 hours per hole. If the plug blows out violently, you're looking at cylinder head removal or replacement—12-16 hours labor. Some engines experience multiple plug failures over time.
Estimated cost: $400-1,200 per plug for thread repair, $3,000-5,000 for head removal/repair
5.4L Triton Piston and Ring Failure (Two-Piece Design)
Occasional · high severity
Typical onset: 100,000-180,000 mi
Symptoms: excessive oil consumption (quart per 1,000 mi or worse), blue smoke on startup or acceleration, loss of compression, eventual catastrophic engine failure with knocking
Fix: The two-piece piston design in 2004-2010 5.4L 3V engines allows the crown to separate from the skirt, destroying the engine. Once oil consumption starts accelerating, you need rings at minimum (engine-out, 18-24 hours), but usually pistons too. Many shops recommend short block or reman engine because cam phasers and timing components are often worn by this point—30-40 hours total.
Estimated cost: $5,000-8,500 for short block or reman engine with labor
4R75E/4R75W Transmission Oil Cooler Line Failure
Common · medium severity
Typical onset: 80,000-150,000 mi
Symptoms: transmission fluid leak under vehicle, pink fluid pooling, transmission overheating, harsh shifting or slipping if fluid level drops
Fix: The steel cooler lines rust through at the frame pass-through points or at crimp fittings, especially in salt belt states. This is the subject of multiple NHTSA recalls but not all VINs were covered. Replacing both lines preventively is smart—lines run along frame rails to radiator-mounted cooler. 2-3 hours labor, includes fluid refill.
Estimated cost: $350-650
Intake Manifold Runner Control Stuck or Failed
Occasional · low severity
Typical onset: 90,000-140,000 mi
Symptoms: P2004/P2005/P2006 codes (IMRC malfunction), rough idle, reduced power at low RPM, Check Engine Light
Fix: The IMRC actuator motor or the plastic flapper valves inside the intake manifold stick due to carbon buildup or actuator motor failure. Sometimes you can clean it (3-4 hours to remove intake, walnut blast runners, reinstall). If actuator motor is bad or plastic tabs broken inside manifold, you need a new intake manifold assembly—5-7 hours labor on the 5.4L.
Estimated cost: $400-900 for cleaning/actuator, $1,200-1,800 for manifold replacement
Cam Phaser Failure (5.4L 3-Valve)
Common · medium severity
Typical onset: 80,000-150,000 mi
Symptoms: loud rattling/knocking on cold startup that quiets after 10-30 seconds, P0012/P0022 codes (cam timing over-advanced/retarded), Check Engine Light, eventually won't start or runs rough
Fix: The variable cam timing phasers wear out and rattle on startup due to oil pressure bleed-down or internal failure. Requires both phasers, timing chains, guides, tensioners, and updated oil pump drive—it's a full timing job. 12-16 hours labor. Always use 5W-20 oil and change every 5,000 mi to extend phaser life.
Estimated cost: $2,200-3,800
Transmission Mount Collapse
Common · low severity
Typical onset: 70,000-120,000 mi
Symptoms: clunk when shifting into Drive or Reverse, vibration at idle in gear, excessive driveline movement felt through floor
Fix: The rear transmission mount deteriorates and the rubber separates from the metal frame. It's a heavy transmission in a heavy vehicle, so the mount works hard. Replacement is straightforward—support trans with jack, unbolt mount, swap—1.5 hours labor.
Estimated cost: $200-350
Owner tips
If buying a 5.4L 3V engine, verify spark plugs were replaced with updated Motorcraft SP-515/SP-546 plugs and anti-seize—never exceed 27 ft-lbs torque spec
Change transmission fluid every 50,000 mi with Mercon V (not LV)—these transmissions run hot in van duty and fluid degrades faster
Inspect frame-mounted trans cooler lines annually for rust perforation, especially if you're in the rust belt—replace proactively around 100k mi
Use only 5W-20 synthetic oil and change every 5,000 mi to keep cam phasers alive on the 5.4L—cheap insurance
The 4.6L 2V engine (if optioned) avoids most of the 5.4L drama—significantly more reliable long-term
Buy the 4.6L version if you can find one; avoid the 5.4L unless you can verify recent engine work or budget $5k-8k for inevitable engine replacement after 120k miles.
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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MobilityWorks (WMK Inc.) is recalling certain model year 2006-2014 Ford E-150, E-250, and E-350 vans modified by MobilityWorks to be equipped with certain model S2005, S2010, S5005, S5010, S5505, and S5510 wheelchair lifts manufactured by Ricon Corporation. The affected lifts are equipped with folding link arms that may have pivot holes that are too big, allowing the bearings to move out of position.
Consequence: If the bearings move out of position, the stowed platform may have excessive movement resulting in failure of the platform mounting. This failure could cause the wheel chair lift platform to fall out of the vehicle when the doors are opened, increasing the risk of injury for the lift operator.
Remedy: MobilityWorks will notify owners, and Ricon dealers will inspect the link arms for damage or for displaced bearings. The platform will be inspected for cracks. Any damaged parts will be replaced, free of charge. The recall began on December 15, 2015. Owners may contact MobilityWorks customer service at 1-800-769-8267, or Ricon Customer Service at 1-800-322-2884. Note: These vehicles and wheelchair lifts were subject to a similar recall in 2014. All vehicles that received that recall remedy are still affected by this recall as well.
EQUIPMENT ADAPTIVE/MOBILITY · 14V706000
2014-11-05 · EQ14013
Cummings Mobility Conversion & Supply (Cummings) is recalling certain model year 2006-2014 Ford E-150, E-250, E-350, Chevrolet Express, 2006-2008 Dodge Sprinter, and 2009-2014 Mercedes-Benz Sprinter, and 2013 Ford Transit Connect vehicles manufactured January 1, 2006, to October 8, 2014, equipped with certain model S2005, S2010, S5005, S5010, S5505, and S5510 wheelchair lifts manufactured by Ricon Corporation after January 1, 2006. The platform side plate of the affected wheelchair lifts may crack.
Consequence: If the platform side plates crack, the lift platform can separate from the lift and come to rest against the vehicle's lift door. When the doors are opened, the platform may fall out, increasing the risk of injury to the lift operator.
Remedy: Cummings will notify owners to take buses to a Ricon dealer or service center who will install supplemental platform support bumpers. Any platform that has already started cracking will be replaced, free of charge. The recall began January 13, 2015. Owners may contact Cumming's customer service at 1-800-639-5438 or Ricon customer service at 1-800-322-2884. Cumming's number for this recall is 14E-041.
EQUIPMENT ADAPTIVE/MOBILITY · 14V584000
2014-09-23
National Van Builders, Inc. (National Van) is recalling certain 2007-2014 Ford E-150 and E-250 vehicles manufactured February 26, 2007, to August 19, 2014, and equipped with certain model S2005, S2010, S5005, S5010, S5505, and S5510 wheelchair lifts manufactured by Ricon Corporation. The platform side plate of the affected wheelchair lifts may crack.
Consequence: If the platform side plates crack, the lift platform can separate from the lift and come to rest against the vehicle's lift door. When the doors are opened, the platform may fall out, increasing the risk of injury to the lift operator.
Remedy: National Van will notify owners to take buses to a Ricon dealer or service center who will install supplemental platform support bumpers. Any platform that has already started cracking will be replaced, free of charge. The recall began on October 3, 2014. Owners may contact National Van customer service at 1-800-527-7477. National Van's number for this recall is Ricon2014.
FUEL SYSTEM, OTHER:DELIVERY:HOSES, LINES/PIPING, AND FITTINGS · 14V426000
2014-07-10
Roush Performance Products, Inc. (Roush) is recalling certain model year 2010-2012 Ford E-150 Wagons and Cargo Vans, E-250 Cargo Vans and Extended Cargo Vans, E-350 Wagons, Extended Wagons, Cargo Vans, and Extended Vans, and E-450 Cutaway models. These models were modified by Roush to be equipped with certain propane fuel system conversion kits manufactured January 2011 to August 2012 with an aluminum fuel line fitting. Due to a reaction between the different metals, the affected kits may develop a propane leak where the aluminum fuel line fitting contacts the brass supply valve housing.
Consequence: A propane leak in the presence of an ignition source increases the risk of a fire.
Remedy: Roush will notify owners and will replace the aluminum fuel line fittings with new stainless steel fittings, free of charge. The recall began on September 1, 2014. Owners may contact Roush customer service at 1-800-597-6874.
FUEL SYSTEM, OTHER:STORAGE · 14V097000
2014-03-04
Landi Renzo USA is recalling certain model year 2011-2014 Ford E-150, E-250, and E-350 vehicles modified January 2, 2011, through February 24, 2014 to operate on compressed natural gas (CNG). In the affected vehicles, the left and right rear brackets that support the rear CNG cylinder may fail, allowing the cylinder to dislodge from the vehicle.
Consequence: If the cylinder dislodges, a CNG leak may result, increasing the risk of a fire.
Remedy: Landi Renzo USA will notify owners, and dealers will inspect and replace the side arm brackets, as necessary, free of charge. The recall began on March 27, 2014. Owners may contact Landi Renzo USA at 1-855-526-3400.
EQUIPMENT · 13V261000
2013-06-21 · EQ13003
Mobility Works is recalling certain model year 2006-2012 Ford E-150, E-250 and E-350 vehicles manufactured August 2006 through August 2012. The vehicles are equipped with certain Ricon S series and K Series wheelchair lifts with an optional armored pendant cable. The armored cable may be positioned such that it does not clear the wheelchair lift.
Consequence: If the cable does not clear the wheel chair lift it may contact the power lug and, if it does not have a nonconductive cover, or it has an improperly installed non-conductive cover, a short circuit may occur that could result in a fire.
Remedy: Mobility Works will notify owners and Ricon will provide a supplemental cover kit and instructions, free of charge. This recall campaign is expected to begin July 15, 2013. Owners may contact Mobility Works at 1-877-275-4912 and Ricon at 1-818-267-3000.
FUEL SYSTEM, OTHER:FUEL INJECTION SYSTEM · 11E033000
2011-08-31
ROUSH IS RECALLING CERTAIN AFTERMARKET ROUSH CLEAN TECH LIQUID PROPANE AUTOGAS FUEL SYSTEM KITS USED FOR INSTALLATION ON THE FOLLOWING VEHICLES: MODEL YEAR 2007 AND 2008 FORD E-350 (DUEL REAR WHEEL), MY 2009-2011 FORD E- 150, E-250, AND E-350, AND MY 2009-2011 FORD E-450 CUTAWAYS. THE FUEL RAILS INCLUDED IN THE KITS CONTAIN IMPROPERLY SEATED INJECTOR RETENTION CLIPS. THIS COULD RESULT IN LEAKAGE OF PROPANE AUTOGAS. THE PART NUMBERS OF THE AFFECTED KITS ARE: P07C2-176KIT-AB, P10C2-RCOMMKIT-AB, P10C2-R150KIT-AA, P10C2-R150KIT-AC, P10C2-R350KIT-AC, P11C2-R150KIT-AA, P11C2-R150KIT-AB, P11C2-R350KIT-AA, P11C2-R350KIT-AB, P10-SO-RKIT-BA, PBC2-RKIT158-AB, PBC2-RKIT176-AB, AND PBC2-RKITMB-AC.
Consequence: A GAS LEAK IN THE PRESENCE OF AN IGNITION SOURCE CAN RESULT IN A FIRE.
Remedy: ROUSH WILL NOTIFY OWNERS OF THE VEHICLES OF WHICH THE KITS WERE INSTALLED ON IN ORDER TO ARRANGE FOR FREE REPLACEMENT OF THE INJECTOR RETENTION CLIPS. THE SAFETY RECALL BEGAN ON SEPTEMBER 29, 2011. OWNERS MAY CONTACT ROUSH AT 1-800-59-ROUCH (1-800-597-6874.
FUEL SYSTEM, OTHER:FUEL INJECTION SYSTEM · 11V450000
2011-08-31
ROUSH IS RECALLING CERTAIN MODEL YEAR 2009-2011 FORD E-150, E-250, AND E-350 5.4L ENGIN VANS/WAGONS/CUTAWAYS, AND MODEL YEAR 2010-2011 FORD E-450 6.8L ENGINE CUTAWAY VEHICLES ALTERED BY ROUCH TO OPERATE USING THE ROUSH BRANDED CLEANTECH PROPANE AUTOGAS FUEL SYSTEM. THE FUEL RAILS INCLUDED IN THE KITS CONTAIN IMPROPERLY SEATED INJECTOR RETENTION CLIPS. THIS COULD RESULT IN LEAKAGE OF PROPANE AUTOGAS.
Consequence: A PROPANE LEAK IN THE PRESENCE OF AN IGNITION SOURCE CAN RESULT IN A FIRE.
Remedy: ROUSH WILL NOTIFY OWNERS OF THE VEHICLES OF WHICH THE KITS WERE INSTALLED IN ORDER TO ARRANGE FOR FREE REPLACEMENT OF THE INJECTOR RETENTION CLIPS. THE SAFETY RECALL BEGAN ON SEPTEMBER 26, 2011. OWNERS MAY CONTACT ROUSH AT 1-734-466-6255.
VISIBILITY:WINDSHIELD · 11V445000
2011-08-26
Ford Motor Company (Ford) is recalling certain model year 2011 Ford E-150, E-250, E-350, and E-450 vehicles built from May 12, 2011, through May 26, 2011. Due to improper manufacturing conditions, some of the windshields may form bubbles after an extended time in hot temperatures. As such, these vehicles fail to conform to the requirements of Federal Motor Vehicle Safety Standard No. 205, "Glazing Materials."
Consequence: The presence of bubbles may hinder driver's visibility thereby increasing the risk of a crash.
Remedy: Ford will notify owners, and dealers will inspect and replace the windshield if bubbles are present, free of charge. The recall began in January 2014. Owners may contact the Ford customer relationship center at 1-866-436-7332. Ford's recall campaign number is 11C20.
FUEL SYSTEM, OTHER:DELIVERY:HOSES, LINES/PIPING, AND FITTINGS · 11E019000
2011-05-31
ROUSH IS RECALLING CERTAIN AFTERMARKET ROUSH CLEAN TECH LIQUID PROPANE AUTOGAS FUEL SYSTEM KITS PRODUCED BETWEEN DECEMBER 17, 2010, AND MAY 6, 2011, USED FOR INSTALLATION ON FLEET VEHICLES MODEL YEAR 2009 THROUGH 2011 FORD E-SERIES VANS/WAGONS/SHUTTLES/CUTAWAY (150, 250 AND 350) WITH 5.4L ENGINES ("E-SERIES"), AND MY 2011 FORD E-450 CUTAWAYS. THE VALVES INSTALLED IN THE SERVICE PORT OF THE FUEL RAILS OF THE KIT WERE UNDER MINIMUM SPECIFICATION FOR THE DIAMETER. THIS LED TO INSUFFICIENT COMPRESSION OF THE O-RING, ALLOWING LEAKAGE OF PROPANE AUTOGAS. THE PART NUMBERS OF THE AFFECTED KITS ARE: P10C2-R150KIT-AA, P10C2-R150KIT-AC, P10C2-R350KIT-AC, P11C2-R150KIT-AA, P11C2-R150KIT-AB, P11C2-R350KIT-AA, P11C2-R350KIT-AB, P-10-SO-RKIT-BA, PBC2-RKIT158-AB, PBC2-RKIT176-AB, AND PBC2-RKITMB-AC.
Consequence: A GAS LEAK IN THE PRESENCE OF AN IGNITION SOURCE CAN RESULT IN A FIRE.
Remedy: AS OF MAY 27, 2011, ROUSH HAD NOTIFIED ALL OWNERS OF RECORD BY TELEPHONE AND SHIPPED TO THEM REPLACEMENT VALVES FREE OF CHARGE. OWNERS MAY CONTACT ROUSH AT 1-734-466-6255.
FUEL SYSTEM, OTHER:DELIVERY:HOSES, LINES/PIPING, AND FITTINGS · 11V307000
2011-05-31
ROUSH PERFORMANCE PRODUCTS IS RECALLING CERTAIN 2011 FORD E-SERIES VANS EQUIPPED WITH 5.4 OR 6.8 LITER ENGINES THAT HAVE BEEN ALTERED BY ROUSH TO OPERATE USING THE ROUSH LIQUID PROPANE AUTOGAS FUEL SYSTEM. A VALVE IN THE SYSTEM MAY HAVE BEEN MISMACHINED ALLOWING A PROPANE LEAK.
Consequence: A PROPANE LEAK IN THE PRESENCE OF AN IGNITION SOURCE MAY RESULT IN A VEHICLE FIRE.
Remedy: ROUSH WILL REPLACE THE DEFECTIVE VALVE WITH A CORRECTLY MACHINED ONE. ALL THE AFFECTED VEHICLES HAVE BEEN REPAIRED, THEREFORE, AN OWNER NOTIFICATION LETTER WILL NOT BE ISSUED FOR THIS CAMPAIGN. OWNERS MAY CONTACT ROUSH AT 1-734-466-6255.
SEATS:FRONT ASSEMBLY:POWER ADJUST · 11V246000
2011-04-20
FORD IS RECALLING CERTAIN MODEL YEAR 2011 E-150, E-250, E-350 AND E-450 TRUCKS FOR FAILING TO COMPLY WITH THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 207, "SEATING SYSTEMS." IT MAY BE POSSIBLE THAT UNDER UNUSUALLY HIGH LOADS, SUCH AS DURING A CRASH, THE DRIVER POWER SEAT TRACK WORM GEAR MAY FRACTURE.
Consequence: IN THE EVENT OF A CRASH OR OTHER CIRCUMSTANCES OF SEVERE LOADING, THE WORM GEAR COULD FRACTURE AND ALLOW THE SEAT TO SHIFT UNRESTRAINED FORWARD OR BACKWARD INCREASING THE RISK AND/OR SEVERITY OF INJURIES TO THE DRIVER.
Remedy: DEALERS WILL INSPECT THE DRIVER'S SEAT TRACK ASSEMBLY, AND IF NECESSARY, REPLACE IT FREE OF CHARGE. THE SAFETY RECALL BEGAN ON MAY 4, 2011. OWNERS MAY CONTACT FORD MOTOR COMPANY CUSTOMER RELATIONSHIP CENTER AT 1-866-436-7332.
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