The Check Engine Light may come on with no driving issues noticed. If P0401, P0402, P1400 and / or P1401 are in memory, the Delta Pressure Feedback Exhaust Gas Recirculation (DPFE) sensor is at fault. The DPFE sensor should be replaced.
Problems for specific Ford E-350 years:
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Newest reported Ford E-350 problems
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.
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.
There was a program in 2004 to replace the automatic transmission reverse planetary assembly for a factory defect. The defect caused the transmission to shift hard and possibly slip. If this repair is not done already, further damage may occur to the transmission, and overhaul / replacement may be necessary.
This concern related to the 4R100 automatic transmission typically seen mated to the 5.4L V8, 6.8L V10, and 7.3L Turbo Diesel. 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 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.
Common sources of rear axle leaks are the rear differential cover seal, and / or the pinion seal. Reseal the rear differential cover with the appropriate sealant and / or replace pinion seal for leakage.
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.
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.
If the vehicle hesitates on acceleration, idle is low, and the Check Engine Light may be on, this condition can be caused by contaminated throttle body. Diagnosis is needed but the throttle body should be inspected and replaced if needed, and the engine's computer programming should be updated.
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.
Internal issues with the Fuel Injector Control Module (FICM) can cause the engine to run rough, lack power, not start, or it may be hard to start. The FICM should be inspected for proper software revision and internal function. To repair, update the software, replace internal parts, and / or replace the entire FICM as needed.
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.
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.
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.