The 2000 E-350 with the 6.8L V10 Triton is a workhorse van plagued by catastrophic spark plug ejection issues and transmission cooler failures that can destroy the 4R100 transmission if ignored. These are serious, expensive problems that define ownership of this generation.
Spark Plug Ejection and Thread Failure
Common · high severity
Typical onset: 60,000-150,000 mi
Symptoms: Sudden loss of power with loud popping or hissing sound, Misfire codes (P0301-P0310), Visible spark plug blown out of cylinder head, Rough idle that wasn't there before
Fix: The two-piece spark plug design and inadequate thread engagement in the aluminum heads cause plugs to blow out under compression. Requires Heli-Coil or Time-Sert thread repair per cylinder (2-3 hours each), sometimes full head removal if damage is severe (12-16 hours). Some shops preemptively install inserts in all cylinders during plug changes. If caught early, single-cylinder repair runs 3-4 hours.
Estimated cost: $800-1,200 per cylinder, $4,000-6,000 for preventive all-cylinder inserts with head removal
Transmission Oil Cooler Line Failure and 4R100 Damage
Common · high severity
Typical onset: 80,000-140,000 mi
Symptoms: Transmission fluid in coolant or coolant in transmission (strawberry milkshake fluid), Erratic shifting or slipping after coolant contamination, External cooler line leaks at crimped fittings, Overheating transmission
Fix: The factory cooler lines rot from inside-out and the internal radiator cooler can fail, allowing cross-contamination that destroys the 4R100. Requires immediate cooler line replacement (2-3 hours), external cooler addition, and full fluid flush. If contamination occurred, transmission rebuild or replacement is mandatory (12-18 hours). This is THE killer of these transmissions.
Estimated cost: $400-700 for lines only, $2,800-4,500 for rebuild after contamination
Intake Manifold and Coolant Crossover Leaks
Common · medium severity
Typical onset: 70,000-130,000 mi
Symptoms: Coolant seepage at front of engine between cylinder banks, Sweet smell from engine bay, Slow coolant loss with no visible external leak, White residue on valley area of engine
Fix: The plastic crossover coolant tube under the intake manifold cracks, and intake gaskets fail. Requires upper intake removal to access (6-8 hours). Replace crossover, all intake gaskets, thermostat housing while in there. Not a roadside breakdown but leads to overheating if neglected.
Estimated cost: $900-1,400
Fuel Pump Driver Module Failure
Occasional · high severity
Typical onset: 90,000-160,000 mi
Symptoms: No-start condition, crank but won't fire, Intermittent stalling, especially when hot, Fuel pump runs constantly or not at all, Check engine light with fuel system codes
Fix: The fuel pump driver module (mounted on frame rail near tank) overheats and fails, cutting power to pump. Simple part replacement (0.8-1.2 hours) but difficult to diagnose if you don't know the quirk. Extended cranking kills the pump eventually, so replace both together if pump is original.
Estimated cost: $250-450 module only, $800-1,200 with pump
Front Suspension Ball Joint and Tie Rod Wear
Common · medium severity
Typical onset: 80,000-120,000 mi
Symptoms: Clunking over bumps from front end, Wandering steering or vague on-center feel, Uneven tire wear on front, Play in steering wheel
Fix: The Twin I-Beam front suspension eats ball joints and tie rods, especially on loaded vans. Both upper and lower ball joints should be done together (4-5 hours for both sides), tie rods add another 2 hours. Alignment mandatory afterward. Not sudden failure but safety-critical when loose.
Estimated cost: $800-1,400 for full front end refresh
DPFE Sensor and EGR System Issues
Occasional · low severity
Typical onset: 60,000-110,000 mi
Symptoms: Check engine light with P0401 or P0402 codes, Rough idle when warm, Failed emissions test, Surging at steady cruise
Fix: The DPFE (Delta Pressure Feedback EGR) sensor fails frequently, throwing EGR codes. It's a $60 part, 0.5 hours to replace on firewall. Sometimes the EGR valve itself is carboned up and needs cleaning or replacement (1.5 hours). Annoying but not a breakdown risk.
Estimated cost: $150-300 sensor, $350-550 with valve
Cruise Control Deactivator Switch Failure (Recall Related)
Occasional · medium severity
Symptoms: Cruise control won't engage or drops out randomly, Brake lights stay on or don't work properly, Speed control inoperative, Fluid leak under dash near brake pedal
Fix: Multiple recalls issued for speed control deactivator switch that can overheat or leak. If not already done, verify recall completion. Switch replacement is 1-1.5 hours. Not driving-critical but can cause electrical issues and brake light problems that fail inspection.
Estimated cost: $200-350 if not covered by recall
Owner tips
Install spark plug thread inserts preemptively if you plan to keep the van past 100k miles — it's cheaper than emergency repair
Replace transmission cooler lines and add external cooler before 100k miles, monitor fluid color religiously
Use Motorcraft spark plugs only and torque to exact spec (27-33 ft-lbs) — never overtighten on these heads
Flush cooling system every 30k miles — V10 runs hot and coolant breakdown accelerates manifold failures
Budget $1,500-2,000 annually for deferred maintenance items that will come due on any used example
Buy only if you need the V10's towing capacity and can budget for the spark plug and transmission cooler time bombs — these are $3k-5k problems waiting to happen, not 'ifs' but 'whens'.
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.
Fitment notes: High CCA required for 6.8L V10 engine; battery located under hood
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Every control module on the 1998-2003 Ford E-350 — where it lives, replacement time, and what it takes to program a replacement. Modules marked dealer / factory tool won't work after a part swap alone — budget for programming.
Anti-Lock Brake System Module (ABS)2.2 hr R&Rrelearn only +0.3 hrwith ABS (standard on most E-350s)▸ programming details
📍 Driver side frame rail forward of driver door, integrated with hydraulic control unit
🔧 Scan tool with ABS bleed function
⚠️ Requires brake system bleeding and sensor calibration after replacement. Module and HCU are one assembly.
📍 Behind driver side kick panel, left of steering column
🔧 Ford NGS or IDS
⚠️ Controls lighting, wipers, door locks, and numerous body functions. Configuration required for options like remote entry, autolamps, and trailer tow.
📍 Under center console between front seats, floor mounted
🔧 Ford NGS or IDS
⚠️ Requires crash data clear and system configuration. Battery must be disconnected 1+ minute before removal. Stores crash data.
Trailer Tow Module (TTM)1.0 hr R&Rno codingwith factory trailer tow package
📍 Behind driver side rear interior panel near rear door
⚠️ Controls trailer brake output and lighting interface. Plug-and-play replacement.
Air Suspension Control Module (ASCM)1.0 hr R&Rrelearn only +0.2 hrwith rear air suspension (optional on E-350 cutaway/motorhome chassis)▸ programming details
📍 Frame rail passenger side, mid-vehicle near fuel tank
🔧 Ford NGS or aftermarket scan tool
⚠️ Controls rear air springs and compressor. Height sensor calibration required after replacement. Not available on standard van body.
⚠️ PATS function is embedded in PCM. Key programming requires scan tool access. Transceiver ring is at ignition lock cylinder.
Aftermarket tool coverage varies by software version and vehicle build — treat "aftermarket tool" rows as "usually possible" and verify against your tool maker's coverage list before promising a customer. Spot a wrong location or hour? Tell us — corrections ship fast here.
FORD IS RECALLING MODEL YEARS 1995-2003 WINDSTAR, 2000-2003 EXCURSION DIESEL, 1993-1997 AND 1999-2003 F-250 SD THROUGH F-550 SD DIESEL, 1992-2003 E-150 THROUGH E-550, 1995-2002 EXPLORER, 1997 AND 2002 MERCURY MOUNTAINEER, 1995-1997 AND 2001-2003 RANGER, AND 1994 F53 VEHICLES EQUIPPED WITH THE TEXAS INSTRUMENTS SPEED CONTROL DEACTIVATION SWITCH (SCDS). THE SCDS MAY LEAK INTERNALLY AND THEN OVERHEAT, SMOKE, OR BURN.
Consequence: A VEHICLE FIRE COULD OCCUR WITH OR WITHOUT THE ENGINE RUNNING.
Remedy: FORD WILL NOTIFY OWNERS THAT DEALERS WILL INSTALL A FUSED WIRING HARNESS IN LINE WITH THE SCDS. ON 1999-2003 WINDSTAR VEHICLES WITH A LEAKING SCDS, DEALERS WILL ALSO INSPECT THE ABS CONTROL MODULE CONNECTOR AND REPAIR AS NECESSARY. REPAIRS WILL BE COMPLETED FREE OF CHARGE. THE SAFETY RECALL BEGAN ON OCTOBER 27, 2009. OWNERS MAY CONTACT FORD AT 1-888-222-2751.
VEHICLE SPEED CONTROL:CRUISE CONTROL · 08V051000
2008-02-04
FORD IS RECALLING 225,000 MY 1992-2003 ECONOLINE, MY 1993-1995 TAURUS SHO, MY 1992-1998 CROWN VICTORIA, MY 1993 BRONCO, F-SERIES, MY 1995-1997 F-SERIES SUPER DUTY STRIPPED CHASSIS, MY 1992-1998 MERCURY GRAND MARQUIS, AND MY 1992-1995 LINCOLN TOWN CAR VEHICLES. THE AFFECTED VEHICLES WERE PREVIOUSLY REPAIRED USING A WIRING HARNESS THAT IS NOT COMPATIBLE WITH THE VEHICLE CIRCUIT POLARITY.
Consequence: AS A RESULT, THE FUSE IS LOCATED IN THE OUTPUT CIRCUIT RATHER THAN IN THE INTENDED INPUT POWER FEED CIRCUIT, AND MAY NOT OFFER THE INTENDED PROTECTION IN THE EVENT OF AN ELECTRICAL SHORT TO GROUND.
Remedy: DEALERS WILL INSTALL A NEW WIRING HARNESS, OR REPLACE THE MATING ELECTRICAL COMPONENT. THE RECALL BEGAN ON FEBRUARY 18, 2008. OWNERS MAY CONTACT FORD AT 1-800-392-3673.
VEHICLE SPEED CONTROL · 07V336000
2007-08-03 · EA05005
ON CERTAIN PICKUP TRUCKS, PASSENGER VEHICLES, SPORT UTILITY VEHICLES, AND MOTOR HOMES CHASSIS, THE SPEED CONTROL DEACTIVATION SWITCH MAY, UNDER CERTAIN CONDITIONS, LEAK INTERNALLY AND THEN OVERHEAT, SMOKE, OR BURN.
Consequence: THIS COULD RESULT IN AN UNDERHOOD FIRE.
Remedy: DEALERS WILL INSTALL A FUSED WIRING HARNESS. OWNERS OF THE PASSENGER CARS INCLUDED IN THIS CAMPAIGN WILL BE INSTRUCTED TO RETURN THEIR VEHICLES TO THEIR DEALERS TO HAVE THE SPEED CONTROL DEACTIVATION SWITCH DISCONNECTED AS AN INTERIM REPAIR. AS SOON AS REPAIR PARTS ARE AVAILABLE (EXPECTED OCTOBER 2007), OWNERS WILL BE INSTRUCTED TO RETURN TO THE DEALERS FOR INSTALLATION OF A FUSED WIRING HARNESS. THE RECALL BEGAN ON AUGUST 13, 2007, AND MAILING COMPLETED BY SEPTEMBER 19, 2007. OWNERS MAY CONTACT FORD AT 1-888-222-2751.
VEHICLE DESCRIPTION: ON CERTAIN VANS WITH AMBULANCE PREP PACKAGES OR OTHER SEVERE-DUTY APPLICATIONS INVOLVING OPERATION AT OR NEAR THE GROSS VEHICLE WEIGHT WITH FREQUENT TWISTING OF THE VEHICLE BODY, SUCH AS OFF-ROAD, ROUGH ROAD OR SPEED BUMP EVENTS, THE 35 GALLON MID-SHIP FUEL TANK COULD DEVELOP A CRACK WHERE IT CONTACTS THE FRAME CROSS MEMBER. IF THE FUEL TANK CRACKS, FUEL LEAKAGE COULD OCCUR.
Consequence: FUEL LEAKAGE IN THE PRESENCE OF AN IGNITION SOURCE COULD RESULT IN A FIRE.
Remedy: DEALERS WILL INSPECT THE FUEL TANK AND, IF CRACKED, WILL REPLACE THE TANK. INSULATOR PADS WILL BE INSTALLED ON ALL VEHICLES TO REDUCE THE STRESS LEVELS IN THE FUEL TANK. OWNER NOTIFICATION BEGAN APRIL 19, 2001. OWNERS WHO TAKE THEIR VEHICLES TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND DO NOT RECEIVE THE FREE REMEDY WITHIN A REASONABLE TIME SHOULD CONTACT FORD AT 1-800-392-3673.
EQUIPMENT:OTHER:LABELS · 00V284000
2000-09-21
VEHICLE DESCRIPTION: BI-FUEL CNG PICKUP TRUCKS AND BI-FUEL CNG VANS, MODIFIED BY CFI CONTROL SYSTEMS, INC., FAIL TO CONFORM TO THE REQUIREMENTS OF FMVSS NO. 303, "FUEL SYSTEM INTEGRITY OF COMPRESSED NATURAL GAS VEHICLES." THE LABEL AFFIXED TO THE FUEL FILLER DOOR BY THE VEHICLE MODIFIER CONTAINS THE INSPECTION DATE AND EXPIRATION DATE OF THE CNG TANK. HOWEVER, IT DOES NOT CONTAIN THE STATEMENT "SEE INSTRUCTIONS ON THE FUEL CONTAINER FOR INSPECTION AND SERVICE LIFE."
Consequence: THESE VEHICLES DO NOT COMPLY WITH THE REQUIREMENTS.
Remedy: OWNERS WILL BE PROVIDED A LABEL WITH THE REQUIRED STATEMENT, ALONG WITH INSTRUCTIONS FOR AFFIXING THE LABEL AT THE FUEL FILLER DOOR. OWNER NOTIFICATION BEGAN NOVEMBER 2, 2000. OWNERS WHO TAKE THEIR VEHICLES TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND DO NOT RECEIVE THE FREE REMEDY WITHIN A REASONABLE TIME SHOULD CONTACT FORD AT 1-800-392-3673.
WHEELS:LUGS/NUTS/BOLTS/STUDS · 00V115000
2000-04-19
VEHICLE DESCRIPTION: CUTAWAYS AND STRIPPED CHASSIS WITH SINGLE REAR WHEELS. THE LUG NUTS CAN POTENTIALLY BOTTOM OUT ON A SHOULDER ON THE STUDS.
Consequence: IF THIS OCCURS, THERE CAN BE AN INADEQUATE CLAMP LOAD TO ATTACH THE WHEEL TO THE AXLE, RESULTING IN NOISE, DAMAGE TO THE WHEEL AND HUB, OR IN EXTREME CASES, LOSS OF A REAR WHEEL WHILE THE VEHICLE IS BEING DRIVEN.
Remedy: DEALERS WILL REPLACE THE REAR WHEEL ATTACHING STUDS.
Performance
Horsepower
305hp
Torque
420lb-ft
Capability & size
Towing capacity
10,000lb
Payload
4,080lb
Curb weight
6,100lb
Wiper blades
1992-2002 E-Series generation uses symmetrical 20-inch blades with standard hook attachments. No rear wiper.
Size-standard part numbers — verify your connector type before buying. Rear blades are model-specific; check the package's vehicle list.
Fuel economy figures are EPA data via fueleconomy.gov (median across matching trims). Performance figures are compiled estimates for the 2000 Ford E-350 6.8L V10 Triton and can vary by trim.
🔧 Database maintained under the daily editorial review of Chris Hackleman · Master Technician · 20+ years and Jeff Moore · Master Lexus & Toyota Mechanic · 20+ years.