Ford E-250 Problems
RepairPal has identified the most common problems with the Ford E-250 as reported by actual vehicle owners. We'll tell you what the problem is and what it'll take to fix it.Refine by vehicle
The engine may have a misfire, hesitation, and/or run roughly – notably after a service and/or ignition wire replacement. If after recent ignition wire replacement, the cause can be misrouted ignition wires. The wires from the distributor to the valve cover must be routed correctly to avoid interference and induction crossfire. Verify all clips are used to secure and separate ignition wires.
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.
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.
This concern relates specifically to the E4OD and 4R100 automatic transmissions. Transmission fluid leaking from the front of the transmission bell housing may also be accompanied with shifting and transmission engagement issues. This is often caused by transmission overheating and is the sign of a significant internal transmission problem. The superficial cause is the failure of the front pump seal of the transmission. The immediate repair is to remove the transmission, replace the front pump and seal, replace all fluid with the transmission filter, and verify proper flow through the transmission fluid lines and cooler. It is also recommended to make sure the vehicle is not pulling a load that is heavier than the gross vehicle weight limits because this can cause the transmission to overheat. Depending on the transmission's mileage, this can also be a good time to consider a complete overhaul or replacement with a remanufactured unit, as often just the pump and seal replacement is a short lived remedy.
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.
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 engine idle rolls up and down, and diagnosis rules out Idle Air Control (IAC) valve issues and vacuum leaks, the Programmable Speedometer/Odometer Module (PSOM) can be at fault electronically. The instrument cluster will need to be replaced, the PSOM is inside the cluster.
This concern relates to vehicles equipped with the E4OD and 4R100 automatic transmissions. Fluid leaks from the rear of the transmission and excessive vibration felt in the vehicle while driving can be caused by a lack of lubrication to the rear of the transmission and rear seal failure. The extension housing (rear portion of transmission) can lose lubrication if the fluid supply hole becomes clogged. This leads to rear seal failure from lack of lubrication, and can cause bearing failure in the extension housing. The extension housing and gasket should be replaced and verify the fluid supply hole is clear of debris.
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.
On vehicles equipped with the E4OD (4-speed automatic) transmission, harsh engagement of the automatic transmission when shifting into reverse or drive, and irregular shifting while driving can be caused by failure of the Manual Lever Position (MLP) sensor. Water intrusion can lead to failure of the sensor, which should be replaced with a revised sensor and wiring kit to prevent future failure.
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.
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.
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.