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.
Ford E-350 Problem Reports
RepairPal Verified Ford E-350 Problem Reports
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 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 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.
Multiple drivability concerns such as rough running, poor power, stalling, poor fuel economy, and/or excessive oil consumption may be caused by worn or deteriorated fuel injector o-rings. The o-rings seal the injectors in the cylinder head. The fuel injector o-rings should be inspected, and all should be replaced if any are found to be deteriorated. Our technicians note that fuel injector wear and tear from fuel quality and oil quality over time may also cause driving concerns.
If the engine runs rough, has low power, and is overfilled with oil on dipstick, this is often caused by a leaking fuel injector(s). Each injector should be inspected for looseness and / or leakage. Loose or leaking injectors will need to be replaced.
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.
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.
Delamination of the diesel fuel tank can occur resulting in a loss of power due to debris clogging the fuel filters. In some cases the fuel injection pump and/or fuel injectors have also been damaged. Ford has issued a service bulletin (#
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.
Leaking exhaust manifold gaskets can cause exhaust fumes to enter the vehicle. The exhaust manifold gaskets should be replaced as needed.