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.
Problems for specific Ford E-150 years:
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Newest reported Ford E-150 problems
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.
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.
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.
A defective thick film ignition (TFI) module can cause the engine to stall while driving, or the engine may not start. A failed TFI module will require replacement.
In some cases with higher mileages, the Check Engine Light may come on due to insufficient Exhaust Gas Recirculation system (EGR) flow. For EGR flow concerns, the EGR valve is usually recommended for replacement and the intake manifold is removed to clean the EGR passages in the engine, which have clogged with carbon over time.
Rough idle, stalling at let off on road and at idle. Excess gas consumption and several error codes set. Excess raw gas smell and high gas consumption. Checked gas pressure at injector rail and found it to be three times greater than specs. Changed gas bypass relay & this corrected all codes and drivability problems.
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 Rear Anti-lock Brake System (RABS) light illuminates with no noticeable driving and stopping issues present, complete complex diagnosis must be performed, but most often the RABS control module has an internal fault and must be replaced. Replace the RABS module and recheck for proper operation.
A defective key-in warning chime switch can cause the ignition cylinder to bind from run to start and / or start to run movements. The key-in warning chime switch will need to be replaced.
If a buzzing noise is coming from the exhaust at different engine speeds and conditions, this is commonly caused by the heat shields on catalytic converters coming loose at points. The buzzing is the metal on metal contact. Installing a large worm clamp around the catalytic converter and heat shield assembly will prevent the noise and secure the shields.
This concern related to the 4R100 automatic transmission typically seen mated to the 5.4L V8. If the transmission does not shift correctly out of first gear, a “one-way” clutch inside the transmission may have failed. If the transmission fluid condition is good, and other failures are not found upon transmission tear down, the one-way clutch may be replaced along with the drum and friction plates. Our technicians note this is a major internal transmission repair.
This concern is relating to the AOD automatic transmission typically seen mated with the 4.9L 6 cylinder and 5.0L V8 engines. If the Throttle Valve Cable (TV cable) becomes detached from the throttle valve, transmission shifts can be hard or delayed. The grommet that secures the TV cable to the throttle should be replaced. Our technicians note that delaying repair of this concern can lead to internal transmission damage due to the abnormally high internal pressures present when the cable is detached.