2005 Ford E-350 Problems
RepairPal has identified the most common problems with the 2005 Ford E-350 based on complaints from actual vehicle owners. We'll tell you what the problem is and what it'll take to fix it.
The Check Engine Light may illuminate, the engine may run rough and have misfires on acceleration. Commonly the ignition coils and/or the ignition coil boots are the cause of this problem. The rubber boot that insulates the coil to the spark plug can dry and crack allowing arcing. Inspect the coils and boots, and replace them as needed. Our technicians also recommend replacing the coil boots any time the spark plugs are replaced.
Appropriate cooling system maintenance is very important for this engine. Coolant should be inspected for nitrite levels at each service, and use of an additive, or replacement of coolant, should be done as needed. Deteriorated coolant can lead to EGR cooler and / or engine oil cooler failure. Failure of either can cause coolant loss and overheating, prolonged overheating can cause head gasket failure. White smoke may also be emitted from the tailpipe from the burning of coolant. The cooling system should be thoroughly inspected, and replace the EGR cooler and components as needed. With extended overheating, the head gaskets should be inspected for damage. If the cooling system is especially contaminated with oil, flushing agents and a degreaser like Simple Green may be needed to effectively flush the contaminants.
The spark plugs may become dislodged from the cylinder heads. A loud popping noise can be heard and a subsequent misfire experienced. The threads on the spark plug ports in the cylinder head(s) can become stripped or missing when the spark plug is dislodged. The threads in cylinder heads may be replaced using “Lock-N-Stitch” aluminum inserts. Our technicians tell us thread replacement is performed when the vehicle is out of base warranty. Vehicles under base warranty receive a new cylinder head.
Damage to the fan clutch wire harness and / or erratic fan clutch operation can cause the engine cooling to not turn on. A new fan clutch assembly will be needed to fix this problem.
The engine may stall and not restart. There is a recall to replace the camshaft position sensor, found to be defective. Replace the camshaft position sensor if that is found to be the problem.
Electrolysis can cause repeated failures of the heater core and radiator. The diagnosing technician should check for voltage present in the coolant, with the battery disconnected, because electrical current in the coolant causes electrolysis. Corroded or deteriorated parts should be replaced, and the coolant should be flushed. Ground straps can be added to help prevent future corrosion of components.
If the slip yoke in the driveshaft is binding, it can make a clunking noise when pulling away from a stop. The slip yoke will need to be lubricated.
Leaking exhaust manifold gaskets can cause exhaust fumes to enter the vehicle. The exhaust manifold gaskets should be replaced as needed.
The front end may make a rattle noise over bumps. There may be handling issues, and play in the front wheels on inspection. If there is up and down movement on the front wheels while the lower control arms are being supported, inspect the upper and lower ball joints for excessive play. These are prone to failure from moisture entry and lack of lubrication. The ball joints should be replaced as needed.
Engine oil may leak externally from the cylinder head gasket. The gaskets were contaminated with metal debris from the factory – between the block and gasket and/or the head and gasket. To correct, the head gasket must be replaced and the mating surfaces on the cylinder head and block need to be inspected for chips or damage. In some cases the cylinder head will not be repairable and will need replacement.
The Check Engine Light may come on with codes in engine computer memory for P0401, P0402, P0404, and P1335. In addition white or black smoke will be emitted from the tailpipe and the engine will feel down on power. This is most commonly caused by build up of black sludge and other solid deposits in the Exhaust Gas Recirculation (EGR) System (EGR Valve, EGR Cooler, Exhaust Back Pressure (EBP) Sensor, and EBP tube), intake manifold, turbocharger and the EGR throttle plate. Regularly adding a cetane booster to the fuel will aid in a more complete combustion and the engine oil should be replaced at the proper intervals to avoid sludge build up. Installing an EGR baffle kit also helps to prevent future EGR valve contamination.
A lack of power and possible Check Engine Light may be experienced with codes P0238, P0299, P0404, P0478, P2262, P2263. The turbocharger can become internally contaminated with sludge and deposits causing the variable vanes within the turbo to seize. The turbocharger can be disassembled to be cleaned, and the internal parts can be replaced as needed. If deterioration is too bad, replacement of the turbocharger may be necessary.
A casting issue with the cylinder heads may allow fuel leakage into the cooling system. The cylinder heads should be inspected for fuel leakage where the injectors mount. Replacement of the cylinder head(s) that leak will be needed.