2002 Ford E-250 problems

General information about Ford-E-250
Overview of popular issues
Recalls list

The Ford E-Series (also known as the Ford Econoline, Ford Econovan or Ford Club Wagon) is a range of full-size vans manufactured and marketed by the Ford Motor Company. Introduced for 1961 as the replacement of the Ford F-Series panel van, four generations of the model line have been produced. Marketed for both cargo and passenger transport configurations, the E-Series has been designed with multiple design variations for both retail and commercial sale, including vans, and commercial-grade cutaway van chassis and stripped chassis (a chassis without bodywork).

With over 8.2 million units sold since 1961, the Ford E-Series is the third-best selling van line in history (outranked only by the Ford Transit and Volkswagen Transporter). Ford retired the E-Series passenger and cargo vans after 2014, replacing them with the Ford Transit. As of current production, the E-Series remains offered exclusively in cutaway and stripped-chassis configurations. In 2021, the model line entered its 60th year of production (becoming the second current Ford line to do so).

The E-Series (cutaway/stripped chassis) is assembled by Ford at its Ohio Assembly facility (Avon Lake, Ohio), which has produced the model line since 1975. Prior to its closure, Lorain Assembly (Lorain, Ohio) assembled the model line from 1961 to 2005.

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Common 2002 Ford E-250 problems

The Ford E-250, a popular van model, has had its fair share of common problems over the years. This article will explore some of the most frequently reported issues based on owner complaints, focusing on the 2002 model.

Blower Motor: The blower motor in the Ford E-250 can fail or not work at certain speeds, often due to a bad resistor. This problem can be caused by loose wires that come into contact with the exhaust gas recirculation tube, leading to burnt wires and exposed metal that can rust or ground onto the tube. A blower motor that has completely failed may be due to a wiring issue.

Engine Misfire: An engine misfire in the Ford E-250 can be caused by a worn-out or cracked spark plug due to heat. Another possible cause is bad coil packs. An engine misfire can lead to a check engine light, skipping or bucking from the engine, and difficulty taking off or shaking at stops.

Rough Running Engine: A rough running engine in the Ford E-250 can be caused by ignition coils or ignition coil boots that have dried and cracked, leading to arcing. Replacing the ignition coil mechanism can cost between $140 and $200, depending on the model and year of the E-Series.

Engine Oil Leaks from Cylinder Head Area: Engine oil leaks from the cylinder head area in the Ford E-250 can be caused by a faulty cylinder head gasket. The best option is to replace the head gasket and mating surfaces on the cylinder head and block. In extreme cases, the cylinder head may need to be replaced. The average cost for replacing a head gasket is between $1100 and $1400.

Front End Makes Rattle Noise Over Bumps: Handling issues and excessive play in the upper and lower ball joints can cause a rattle noise over bumps in the Ford E-250. The ball joints will need to be replaced due to entry of moisture and lack of lubrication. Replacing one ball joint can cost around $250, while replacing both is about $550.

Loud Popping Noise and Misfire: A loud popping noise and misfire in the Ford E-250 can be caused by a spark plug that has been dislodged from the cylinder head, leading to stripped threads on the spark plugs. If the vehicle is still under warranty, it is recommended that the cylinder head be replaced. If it is not under warranty, using "Lock-N-Stitch" aluminum inserts to replace threads in the cylinder can start around $500, just to rent the Tool Kit.

Coolant Leakage from Heater Core: Coolant leakage from the heater core in the Ford E-250 can be caused by electrolysis that runs through the coolant, leading to corrosion and deterioration of heater core and radiator parts. Coolant liquid often finds its way onto the passenger side footwell. Replacing the heater core is a $200-$300 fix.

These common problems in the Ford E-250 can lead to significant repair costs, making it essential for owners to stay informed and proactive in maintaining their vehicles.

What engine is in a Ford e250?

The Ford E-250 cargo vans are built on a rugged platform and offer large interiors with vast cargo capacities. The Ford E-250 comes with a standard 225-hp 4.6-liter Triton V8 with an optional 255-hp 5.4-liter Triton V8. Both engines are mated to a four-speed automatic transmission.

How much can a Ford E-250 carry?

The E-250 has a payload capacity of 3,470 pounds.

How long is a 2002 Ford e250?

211.9 to 231.9″2002 Ford E-250 / Length

What is the mpg on a 2007 Ford Econoline E-250?

Based on data from 13 vehicles, 756 fuel-ups and 226,167 miles of driving, the 2007 Ford E-250 gets a combined Avg MPG of 12.02 with a 0.18 MPG margin of error.

What engine is in a Ford e250?

4.6-liter Triton V8

When did Ford stop making the e250?

Ford retired the E-Series passenger and cargo vans after 2014, replacing them with the Ford Transit. As of current production, the E-Series remains offered exclusively in cutaway and stripped-chassis configurations.

What is the difference between Econoline 150 and 250?

The Basic Difference:

The higher the number, the more weight the van can haul and the heavier duty it is. For example, in this case, the E-250 is more of a heavy-duty option than the E-150. This means that vans are all built with different parts, so they can accommodate different weights.

How much does a 2000 Ford E-250 weigh?

8,600 lbs. 35.0 gal. 250 lb-ft.

2002 Ford E-250 complaints

The NHTSA has received 0 complaints about various vehicle components related to the 2002 Ford E-250.

You can leave your car complaint via the special form below.

2002 Ford E-250 recalls

The National Highway Traffic Safety Administration (NHTSA) has issued 4 recalls for different components of the 2002 Ford E-250.

2009-10-13

Manufacturer: FORD MOTOR COMPANY
Components: VEHICLE SPEED CONTROL
Summary: FORD IS RECALLING MODEL YEARS 1995-2003 WINDSTAR, 2000-2003 EXCURSION DIESEL, 1993-1997 AND 1999-2003 F-250 SD THROUGH F-550 SD DIESEL, 1992-2003 E-150 THROUGH E-550, 1995-2002 EXPLORER, 1997 AND 2002 MERCURY MOUNTAINEER, 1995-1997 AND 2001-2003 RANGER, AND 1994 F53 VEHICLES EQUIPPED WITH THE TEXAS INSTRUMENTS SPEED CONTROL DEACTIVATION SWITCH (SCDS). THE SCDS MAY LEAK INTERNALLY AND THEN OVERHEAT, SMOKE, OR BURN.
Consequence: A VEHICLE FIRE COULD OCCUR WITH OR WITHOUT THE ENGINE RUNNING.
Remedy: FORD WILL NOTIFY OWNERS THAT DEALERS WILL INSTALL A FUSED WIRING HARNESS IN LINE WITH THE SCDS. ON 1999-2003 WINDSTAR VEHICLES WITH A LEAKING SCDS, DEALERS WILL ALSO INSPECT THE ABS CONTROL MODULE CONNECTOR AND REPAIR AS NECESSARY. REPAIRS WILL BE COMPLETED FREE OF CHARGE. THE SAFETY RECALL BEGAN ON OCTOBER 27, 2009. OWNERS MAY CONTACT FORD AT 1-888-222-2751.

2008-02-04

Manufacturer: FORD MOTOR COMPANY
Components: VEHICLE SPEED CONTROL:CRUISE CONTROL
Summary: FORD IS RECALLING 225,000 MY 1992-2003 ECONOLINE, MY 1993-1995 TAURUS SHO, MY 1992-1998 CROWN VICTORIA, MY 1993 BRONCO, F-SERIES, MY 1995-1997 F-SERIES SUPER DUTY STRIPPED CHASSIS, MY 1992-1998 MERCURY GRAND MARQUIS, AND MY 1992-1995 LINCOLN TOWN CAR VEHICLES. THE AFFECTED VEHICLES WERE PREVIOUSLY REPAIRED USING A WIRING HARNESS THAT IS NOT COMPATIBLE WITH THE VEHICLE CIRCUIT POLARITY.
Consequence: AS A RESULT, THE FUSE IS LOCATED IN THE OUTPUT CIRCUIT RATHER THAN IN THE INTENDED INPUT POWER FEED CIRCUIT, AND MAY NOT OFFER THE INTENDED PROTECTION IN THE EVENT OF AN ELECTRICAL SHORT TO GROUND.
Remedy: DEALERS WILL INSTALL A NEW WIRING HARNESS, OR REPLACE THE MATING ELECTRICAL COMPONENT. THE RECALL BEGAN ON FEBRUARY 18, 2008. OWNERS MAY CONTACT FORD AT 1-800-392-3673.

2007-08-03

Manufacturer: FORD MOTOR COMPANY
Components: VEHICLE SPEED CONTROL
Summary: ON CERTAIN PICKUP TRUCKS, PASSENGER VEHICLES, SPORT UTILITY VEHICLES, AND MOTOR HOMES CHASSIS, THE SPEED CONTROL DEACTIVATION SWITCH MAY, UNDER CERTAIN CONDITIONS, LEAK INTERNALLY AND THEN OVERHEAT, SMOKE, OR BURN.
Consequence: THIS COULD RESULT IN AN UNDERHOOD FIRE.
Remedy: DEALERS WILL INSTALL A FUSED WIRING HARNESS. OWNERS OF THE PASSENGER CARS INCLUDED IN THIS CAMPAIGN WILL BE INSTRUCTED TO RETURN THEIR VEHICLES TO THEIR DEALERS TO HAVE THE SPEED CONTROL DEACTIVATION SWITCH DISCONNECTED AS AN INTERIM REPAIR. AS SOON AS REPAIR PARTS ARE AVAILABLE (EXPECTED OCTOBER 2007), OWNERS WILL BE INSTRUCTED TO RETURN TO THE DEALERS FOR INSTALLATION OF A FUSED WIRING HARNESS. THE RECALL BEGAN ON AUGUST 13, 2007, AND MAILING COMPLETED BY SEPTEMBER 19, 2007. OWNERS MAY CONTACT FORD AT 1-888-222-2751.

2004-05-13

Manufacturer: FORD MOTOR COMPANY
Components: EQUIPMENT:OTHER:LABELS
Summary: CERTAIN VANS AND WAGONS FAIL TO CONFORM TO THE REQUIREMENTS OF PART 567, "CERTIFICATION." FOR CERTAIN 2003 E250 VANS BUILT WITH LT225/75R16E TIRES, THE REAR AXLE RATING IS INCORRECTLY LISTED ON THE LABEL. IN ADDITION, THE TIRE PRESSURE IS INCORRECTLY LISTED ON THE LABEL FOR THE REAR TIRES ON CERTAIN 2002 E350 WAGONS AND FOR THE FRONT TIRES ON CERTAIN 2002 E250 VANS BUILT WITH THESE TIRES.
Consequence: FAILURE TO FOLLOW PROPER VEHICLE LOADING SPECIFICATIONS OR TIRE INFLATION RECOMMENDATION CAN RESULT IN TIRE FAILURE, INCREASING THE RISK OF A CRASH.
Remedy: OWNERS WILL BE PROVIDED WITH SUPPLEMENTARY TIRE LABELS CONTAINING CORRECT INFORMATION AND INSTALLATION INSTRUCTIONS. IF AN OWNER SO DESIRES, THEIR DEALER CAN INSTALL THE LABEL FOR THEM. THE RECALL BEGAN ON JULY 8, 2004. OWNERS SHOULD CONTACT FORD AT 1-800-392-3673.

Additional sources

More sources of information about 2002 Ford E-250 problems:

Common 2005 Ford E250 Transmission Problems - Q&A

https://www.justanswer.com/transmissions/bw8ko-believe-i-ve-common-problem-05-e250-transmission.html

Dec 30, 2018 ... I believe I've got a common problem. '05 E250 transmission slips above 35mph. More noticeable during/after - Answered by a verified ...

2002 Ford E250, 128k Miles - Life expectancy? - Sportsmobile Forum

https://www.sportsmobileforum.com/forums/f9/2002-ford-e250-128k-miles-life-expectancy-14233.html

Jan 14, 2015 ... It could last you at least another million miles. ... Many of the common problems seem to be more age related than miles. Common items that may ...

Common Problems with 2004 Ford E250 Van - Q&A

https://www.justanswer.com/ford/bxbu2-common-problem-2004-ford-e250-van.html

Jan 8, 2019 ... I have a common problem on my 2004 Ford e250 van, where I can[t fill the tank without the pump clicking off constantly.

Looking at a 2003 E-250, thoughts? - Ford Truck Enthusiasts Forums

https://www.ford-trucks.com/forums/1222715-looking-at-a-2003-e-250-thoughts.html

Feb 10, 2013 ... The 4.6 and 5.4 vans did have the spark plug blowout problems prior to about 2005. Rare, and less common with the 4.6. I have a 4.6 in my 2002 ...