2001 Ford E-350 Problems

What owners report

Owners of this model year most often report spark plugs blowing or being pushed out of the cylinder head, sometimes with a loud bang, a popping noise, or a gasoline smell. Transmission failures and brake component problems, including ABS sensor and module faults and early rotor wear, are also described, though less often. Where mileage is listed, most spark plug reports come from vehicles with more than 100,000 miles.

1. 1
   Engine cooling

   Spark plugs blowing out of the cylinder head

   • 15 complaints (29%)
   • median 119,000 mi at 9.2 yrs old (15 state mileage)
   • filed 2004–2020

   Owners describe a spark plug blowing or being pushed out of the cylinder head while driving, sometimes with a loud bang, a popping noise, or a gasoline smell. Some say the plug came out with no advance warning, and some plugs came out again after repair. An owner says the dealer attributed the failure to heads that were not milled properly, and the repairs described include re-threading the head, an insert repair, or a temporary fix. Most reports list more than 100,000 miles, from about 14,000 to 193,000 miles, and where speed is given it is between 25 and 40 mph.

   What to check: Ask for service records showing the spark plugs and cylinder head threads were checked or repaired. During a test drive, listen for a loud pop and check for a gasoline smell under load.

   2 excerpts from owner complaints in NHTSA records

   “Our family was riding in our 2001 Ford E-350 super duty 15-passenger van powered by fords 5.4l v8 255 hp on I-80 eastbound near milesburg, pa this past saturday afternoon (july 7,2007) and one of the spark plugs blew out of the cylinder head. I am awaiting repairs even now. I have noticed our government's reluctance to issue a recall on what appears to be a recurring problem for '97-04 Ford engines with the aluminum heads. The repairs are very expensive! Please help! Thanks, david lipsy”

   NHTSA complaint #10196033, filed 2007-07, 113,000 miles

   “Twice within the past two years I have been driving down the road, at reasonably low speeds, and a spark plug has blown completely out of my engine ,with no advance warning . Twice I have had to bring it back to the dealer . He now tells me ,and the extended warranty company confirmed it ,that the heads for the 5.4 litre engine were not milled properly (only 4 threads for each spark plug, causing the plug to strip and come out of the engine) and that this is an enormous problem with this engine . …”

   NHTSA complaint #10219853, filed 2008-03, 89,000 miles
2. 2
   Transmission and drivetrain

   Transmission failures, lost second gear, and vibration

   Mentioned in 4 of 42 sampled complaints

   Owners describe transmissions failing while driving, including a complaint about a transmission that burned up on a hill. The dealer reportedly said the transmission was not large enough for the vehicle, and the replacement used a larger fluid pan to help cooling. Another describes delayed or missing second gear traced to a failed one-way clutch, and says the manufacturer declined to pay once the vehicle was out of warranty. A further report describes strong vibration traced to loose transmission bolts, and a complaint says a transmission part was redesigned and known to fail early. Where mileage is listed, reports range from 38,000 to 92,800 miles, and a failure happened while driving on a hill at 25 to 30 mph.

   What to check: Ask for the transmission service history and whether the fluid pan and cooling setup were updated, and check the transmission mounts and bolts for looseness. During a test drive, check for delayed or missing second gear and for vibration under acceleration.

   2 excerpts from owner complaints in NHTSA records

   “While driving could feel an strong vibration coming from transmission. Took vehicle to dealer, and at time of inspection found out that transmission bolts were loose and had to be readjusted. Please provide more information.”

   NHTSA complaint #8004216, filed 2002-02

   “Dt: the contact stated the transmission burned up while driving on a hill at 25-30 MPH. The dealership stated this happened frequently t because the transmission was not big enough for the vehicle. The transmission was completely replaced at a cost of $4,000. The old transmission carried 13.9 quarts of transmission fluid, the dealership told the contact he needed the over size pan that carried 24 quarts. The new transmission was put in with a larger pan to keep the new transmission cool.”

   NHTSA complaint #10145936, filed 2005-12
3. 3
   Brakes

   Brake rotor separation, early wear, and ABS faults

   • 5 complaints (10%)
   • median 58,000 mi at 6.0 yrs old (3 state mileage, few)
   • filed 2002–2009

   Owners describe a front rotor separating from the spindle during a swerve, which the complaint links to a crash, and front rotors needing replacement again at about 66,000 miles after an earlier replacement at 48,000 miles. In an ABS-related report, the dealer reportedly found a shorted left wheel sensor after the warning lamp came on, and the owner says no warning came before the failure. Another ABS report describes a module that shorted after brake fluid got into it, producing smoke, and the owner could not find a related recall. Where mileage is listed, reports range from 48,000 to 83,000 miles, and the module failure was described while the van was parked near a home.

   What to check: Ask for records of rotor replacements and any ABS wheel sensor or module repairs, and check for stored ABS fault codes. During a test drive, check the ABS warning lamp and watch for pulsing or noise from the brakes.

   2 excerpts from owner complaints in NHTSA records

   “I have a 2000 Ford econoline van with about 60,000 miles driven. The ABS warning lamp is on. I took it to my Ford dealer for checking. The service manager reported that the left wheel sensor was shorted out and needed to be replaced. I told him to fix it. It seems that this may be a subject for recall, since there is no before-failure warning.”

   NHTSA complaint #10168129, filed 2006-09, 58,000 miles

   “Abs module shorting out because of brake fluid in the module. I heard a loud popping noise just outside my home where my van is parked, less than 2 ft. From the house, and went out to investigate. Smoke was billowing from the drivers side engine compartment, so I raised the hood and disconnected the battery. The smoke was coming from the area of the ABS module, so I removed it and the cover had blown off, and the circuit board inside was fried. This is a potential fire hazard, and yet I was unable to locate a recall about this issue. …”

   NHTSA complaint #10279112, filed 2009-08, 83,000 miles

Buying note. For someone considering this model year, ask for service records showing spark plug and cylinder head repairs, transmission work, and ABS or brake component replacements. A pre-purchase inspection that includes a scan for stored ABS codes is a practical step.

Summary written with AI from a sample of 42 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.