1997 Ford E-150 Problems

What owners report

Complaints on this model year are dominated by two themes: fuel leaks from the tank area, most often on conversion vans with the 35-gallon midship tank, and engine problems — coolant and oil leaks from intake and front-cover gaskets, plus spark plugs ejecting from the head. Cooling-system and brake complaints are also common, with brake reports ranging from pedal vibration and short rotor life to rusted lines. Many complaints describe leaks found while filling up and repeat repairs at dealers, often after owners were told their vehicle was outside a recall.

1. 1
   Fuel system

   Fuel tank leaks, cracks and filler-hose leaks

   • 18 complaints (18%)
   • median 89,000 mi at 9.4 yrs old (11 state mileage)
   • filed 2002–2013

   Owners describe gasoline spilling on the ground while filling up, a strong fuel smell around the van, or being unable to fill past half a tank. In several cases the leak was traced to the midship tank rubbing against a frame cross member, or to a split or corroded rubber filler hose where it meets the tank. Complaints often note that the tank had to be replaced, and several owners say they were told their vehicle was not covered by the fuel-tank recall. Reported from roughly 45,000 to 185,000 miles, frequently on conversion vans with the 35-gallon midship tank.

   Recall 01V114000

   What to check: Fill the tank fully on a test drive and look under the van for drips, and check the tank's top surface and the filler hose for cracks or rust. Ask whether the tank has ever been replaced and whether the vehicle was included in the fuel-tank recall.

   2 excerpts from owner complaints in NHTSA records

   “This is the exact same situation others have experienced on NHTSA recall campaign number 01v114000 relating to cracks/leaks to the 'mid ship' style fuel tank. My van is a 1997 E-150 conversion van. Unfortunately, I am in the same situation as many others in the fact that Ford motor company does not acknowledge my particular VIN number is affected in this recall. There have been a number of other incidents reported with vehicles mysteriously catching on fire for unknown reasons. …”

   NHTSA complaint #10502516, filed 2013-03, 90,000 miles

   “Ford's recall number is 01s14. My e150 fills the requirements of near the gross vehicle weight with ... Rough road... The 35 gallon mid-ship fuel tank ... Crack ... Ford tells me that my VIN is outside the range of covered vans. The recall covers 1997 through 2001 models. I see no way that Ford would know which vans are used in the above mentioned manner. This problem appeared from the beginning of my ownership. Any filling of more than 3/4 tank, resulted in strong gasoline smell and leakage. This was a very serious problem. …”

   NHTSA complaint #10152210, filed 2006-03, 45,000 miles
2. 2
   Brakes

   Brake pedal vibration, rapid rotor wear and brake line

   • 13 complaints (13%)
   • median 81,431 mi at 11.1 yrs old (4 state mileage, few)
   • 2 mention a crash, fire or injury
   • filed 1998–2012

   Owners describe front rotors warping and pads wearing out in short intervals, with a shimmy or vibration through the pedal and steering wheel when braking. Others report rusted rear brake lines that failed and lost brake fluid, or ABS warning lights and lock-up at low speed on wet or slippery roads. Several say dealers found nothing wrong or replaced calipers without resolving the vibration. Spread broadly from low mileage up to about 170,000 miles; vibration reports often follow rotor replacement.

   1 related service bulletin

   What to check: Test braking from highway speed for pedal or steering-wheel vibration, inspect the brake lines underneath for rust, and ask when the rotors, pads and rear lines were last replaced.

   2 excerpts from owner complaints in NHTSA records

   “Approximately every 15,000 to 20,000 miles I need to replace the front rotors and pads. The rotors are badly warpped. The dealer replaced the calipers, but that did not help. The rear drums are original equipment and has little wear. I have paid to have the rear drums adjusted regularly, in an attempt to improve the longevity of the front breaks. I have about 140,000 miles on the car and replace the front brakes 7 or 8 times. I did have one accident due to poor breaking, and the next day needed to replace the front pads and rotors.”

   NHTSA complaint #10105866, filed 2005-01, 15,000 miles

   “This is to report a continual problem I have had with this van. It is not uncommon. I have talked to over 30 Ford van owners with similar complaints. Front brakes develop an incurable shimmy and premature wear causing minor drivability problems and also excessive rear brake wear. In my case, rear brakes were prematurely worn to the point that ABS engaged and created further pulsing . This has been explained as Ford problem with calipers to Ford problem with ABS on late model vans. Ford refuses to acknowledge possibility of a problem. …”

   NHTSA complaint #746565, filed 2001-06
3. 3
   Engine cooling

   Rough running, stalling and hesitation

   • 10 complaints (10%)
   • median 105,569 mi at 9.5 yrs old (6 state mileage, few)
   • 1 mention a crash, fire or injury
   • filed 1998–2019

   Owners describe the engine hesitating, running sluggish or stalling at stops and intersections, sometimes with the check engine light on. Complaints mention clogged EGR ports, a faulty sensor, or a reset of codes by the dealer followed by the symptoms returning. A few owners report intermittent stalling they link to ignition or sensor faults. Reported from under 80,000 miles up to about 135,000 miles, with no clear seasonal pattern.

   What to check: Have a mechanic scan for stored codes and check for EGR port clogging and sensor faults. Ask whether the intake has ever been cleaned or the camshaft position sensor replaced.

   2 excerpts from owner complaints in NHTSA records

   “I experienced the same symptoms described in the camshaft position sensor recall which affects e-series vans. On 05nov07 my engine light came on and my engine began to hesitate, as if it would stall. I took the van to the Ford dealer on 06nov07. They said they could not find anything wrong. They reset the codes and the engine light went off. On 09nov07 the engine light came on again and the engine began to run sluggishly. I did not drive the van over the weekend because I was afraid it would stall while I was driving. …”

   NHTSA complaint #10211135, filed 2007-12, 135,039 miles

   “1) engine begins to runs rough. ) EGR ports become clogged 3) intake has to be removed and ports cleaned and injectors flushed. Was told by the mechanic that this is a known design flaw with the Ford 6 cyl. Engine, and that there is nothing that can be done to prevent it. It will have to be done again periodically.”

   NHTSA complaint #10086783, filed 2004-08, 76,099 miles
4. 4
   Engine cooling

   Coolant and oil leaks from intake and front-cover gaskets

   • 7 complaints (7%)
   • median 47,904 mi at 9.5 yrs old (4 state mileage, few)
   • filed 1999–2007

   Owners report coolant or oil leaks traced to intake manifold and front cover gaskets, sometimes progressing to coolant entering a cylinder and major engine damage. Complaints often say the repair was costly and that repeated leaks returned, and a few mention a hydro-lock condition where the engine would not turn over after sitting. Some owners say the dealer did not identify a cause on early visits. Seen from about 13,000 to 150,000 miles, with several reports under 80,000 miles.

   What to check: Look for coolant residue or oil weeping at the front of the engine and around the intake, and check the coolant level and condition. Ask whether the intake manifold and front cover gaskets have been replaced.

   2 excerpts from owner complaints in NHTSA records

   “Engine coolant leaked into cylinder due to gasket failure causing piston rod to bend. I have learned that this is all to common problem with 1997 4.2 v6. I am unable to have my truck repaired at this time .the engine needs to be replaced $4,000.00.”

   NHTSA complaint #10168587, filed 2006-09, 144,000 miles

   “Engine hydro-lock. I own a 1997 E-150 conversion van. It has the 4.2l v-6 engine. I have had to have the intake manifold gasket replaced along with the water pump and gasket and also timing gear gasket. All due to a faulty intake manifold gasket. Ford replaced this in the v-8 model cars due to reading a lawsuit about it on their site. I have read in many forums that I'm not alone in this costly repair. I contacted Ford to be told that the lawsuit did not pertain to my van. Since I'm not alone, I would like to know what if anything can I do? …”

   NHTSA complaint #10185463, filed 2007-03, 48,008 miles

Summary written with AI from a sample of 60 NHTSA complaints for this model year (picked at random, with complaints that state a mileage and recent ones taken first), then checked automatically against the source records. Where a problem shows a complaint count, every complaint for this model year was matched with fixed keyword rules (written with AI and tested against the sample), and the mileage, age and repair figures are calculated from those complaints; owners' figures are as stated, not verified. Other counts refer to the sample. The excerpts come from NHTSA's public complaint records and are unverified; capitalisation is normalised, NHTSA staff notes are removed, and shortened text ends with “…”. Something wrong? Request a correction.