2002 FORD E-350

Typical onset: 60,000-150,000 mi

Symptoms: Sudden loud pop or bang from engine bay, loss of power, Misfire codes, rough idle on one or more cylinders, Visible spark plug threads stripped or blown out of head, Coolant or compression loss if head cracks

Fix: The 2-valve Triton V10 has inadequate spark plug thread engagement (4 threads). Plugs can blow out under load, stripping aluminum threads. Requires HeliCoil insert or TimeSert repair per hole (2-3 hours per plug), or cylinder head replacement if cracked (12-16 hours labor for both heads). Preventive: replace plugs every 60k with anti-seize, torque to EXACT spec (27-33 lb-ft).

Estimated cost: $400-800 per hole for insert repair, $3,500-5,500 for dual head replacement if catastrophic

Typical onset: 120,000-200,000 mi

Symptoms: Heavy blue smoke on startup or acceleration, Oil consumption 1+ quart per 500-1,000 miles, Loss of compression on leak-down test, Metallic rattling or knocking from lower end, Check engine light with misfire or fuel trim codes

Fix: Early Triton V10s (through 2004) suffer from weak ring land design on pistons—rings can break or groove walls under stress, especially if overheated or run low on oil. Requires complete tear-down: pistons, rings, bore honing or sleeving, main/rod bearings. Budget 30-40 shop hours for full rebuild, or 20-25 for short block swap.

Estimated cost: $4,500-7,500 for in-chassis rebuild with machine work, $3,500-5,000 for reman short block plus installation

Typical onset: 80,000-140,000 mi

Symptoms: Pink milkshake in coolant reservoir (ATF in coolant), Transmission slipping, erratic shifts, or delayed engagement, Overheating transmission, burnt smell, Coolant in transmission pan (strawberry milkshake)

Fix: The 4R100 transmission cooler inside the radiator can rupture, mixing coolant and ATF—kills both systems fast. Requires radiator replacement, transmission flush (or rebuild if contaminated internally), all cooler lines. If caught early (coolant side only), 4-6 hours. If trans is damaged, add 12-18 hours for rebuild.

Estimated cost: $800-1,500 if caught early (radiator, flush, lines), $2,800-4,200 if transmission rebuild needed

Symptoms: Cruise control inoperative, no response to buttons, Brake pedal feels spongy or has excess travel, Brake fluid reservoir low without visible leaks, Rarely: brake fluid seeping at firewall near pedal assembly

Fix: The speed control deactivator switch (brake pedal-mounted) can leak brake fluid and fail. Ford issued recalls (02S17, 04V138) but many vehicles missed coverage or degraded afterward. Replace switch assembly and bleed brakes. 1.5-2 hours labor.

Estimated cost: $180-320

Typical onset: 70,000-130,000 mi

Symptoms: Clunk or thud when shifting from park to drive/reverse, Excessive vibration at idle, smooths out at speed, Visible sag or tearing of rubber mount under transmission

Fix: The rear transmission mount (crossmember-mounted) fatigues from the heavy 4R100's weight and torque cycling. Requires jack support and 4-6 bolts. DIY-friendly. 1-1.5 hours labor.

Estimated cost: $150-280

Typical onset: 100,000-160,000 mi

Symptoms: Rough idle, especially when cold, Small coolant weep visible at manifold corners, Slight coolant smell, reservoir slowly drops, Minor misfire codes that come and go

Fix: The two-piece plastic intake manifold on the V10 can develop gasket leaks at the block or between upper/lower halves. Not as catastrophic as the V8 versions, but annoying. Replace all gaskets, check for warping. 6-8 hours labor (tight quarters).

Estimated cost: $650-1,100