2003 Ford E-550 problems

General information about Ford-E-550
Overview of popular issues
Analysis of common problems
Сomplaints list
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 2003 Ford E-550 problems

The Ford E-550 2003 is equipped with the 7.3L Powerstroke engine, which is known for its robustness and reliability. However, like any other vehicle, it has common issues that owners have reported over the years. Here are some of the most common problems with the Ford E-550 2003 based on complaints from owners:

Injectors: The average 7.3L fuel injectors need rebuilding at around 125,000 miles. A wide range of options are available to replace or rebuild the fuel injectors in your truck.

Injector Sleeves: As the engine ages, injector sleeve failure can occur, leading to fuel entering the cooling system. When this happens, it's usually due to a split or cracked injector sleeve.

Up-Pipe Kit: A common issue that can rob power from the engine is leaking factory-installed donut gaskets designed to seal the factory up-pipes. An Up-Pipe Kit can fix this issue, improving engine performance.

Engine Oil Cooler: A failing engine oil cooler can cause leaks and elevated temperatures, which can lead to catastrophic engine damage. It's essential to address this issue promptly to avoid severe engine damage.

Camshaft Position Sensor (CMP): Camshaft Position Sensors (CMP) are one of the most common problems on the 7.3L Powerstroke. A failed CMP can cause issues such as the engine cutting out and even dying on you.

Injection Pressure Regulator (IPR) Sensor: A failed Injection Pressure Regulator (IPR) will result in the engine either getting too much or too little fuel. This can lead to a multitude of problems such as rough idling or stalling at idle.

Under Cover Valve Harness (UCVH): The Under Cover Valve Harness (UCVH) or internal injector harness is constantly subjected to heat within the valve cover and the constant vibration of the engine. Over time, this can cause wires to eventually melt or rub against the valves and break.

It's essential to address these issues promptly to ensure the longevity and reliability of your Ford E-550 2003. Regular maintenance and inspections can help identify these issues early on, preventing more severe problems down the line.

How many miles per gallon does a 2003 Ford F-550 get?

Based on data from 2 vehicles, 92 fuel-ups and 29,421 miles of driving, the 2003 Ford F-550 Super Duty gets a combined Avg MPG of 11.46 with a 0.66 MPG margin of error.

What engine does a 2003 Ford F-550 have?

2003 Ford F550 PICKUP (6.0L 8 -cyl Engine Code [P] P Diesel Turbo) Motor Oil, Filters and Lubricants - AMSOIL.

Which Ford diesel engine is the best?

The Navistar/Ford 7.3L Power Stroke® diesel engine isn't available on the latest Ford trucks, but its legendary reliability has earned it a high-ranking spot on our list all the same. Look for the 7.3L Power Stroke® in models produced between 1994 and 2003: Power — 275 hp @ 2,800 rpm. Torque — 525 lb-ft @ 1,600 rpm.

What class is a Ford 550?

The Ford F-550 has a significantly higher Gross Vehicle Weight Rating than the F-450; it ranges from 17,500 to 19,500 pounds depending on the configuration that you choose. This means it's always listed as a Class V Medium Duty Vehicle.

What engine does a 2003 Ford F-550 have?

2003 Ford F550 PICKUP (6.0L 8 -cyl Engine Code [P] P Diesel Turbo) Motor Oil, Filters and Lubricants - AMSOIL.

How many miles per gallon does a 2003 Ford F-550 get?

Based on data from 2 vehicles, 92 fuel-ups and 29,421 miles of driving, the 2003 Ford F-550 Super Duty gets a combined Avg MPG of 11.46 with a 0.66 MPG margin of error.

What class is a Ford 550?

What is the best Powerstroke engine?

The 6.7L Power Stroke V8 and the 7.3L Power Stroke V8 stand out as top choices for their exceptional power, reliability, and aftermarket support. The 6.9L V8 International Harvester IDI holds historical significance and remains a reliable option for those seeking a workhorse engine.

2003 Ford E-550 car problems categorized by type of issue

After analyzing all complaints sent to the NHTSA and researching popular Ford E-550 problems, we found that the most common problems with these 2023 model year vehicles are:

Electrical system problems

The graph below shows statistics for all 2003 Ford E-550 vehicle components and the number of complaints received.

2003 Ford E-550 complaints

The NHTSA has received 1 complaints about various vehicle components related to the 2003 Ford E-550.

2015-01-26

ELECTRICAL SYSTEM PROBLEM

Date Of Incident: 2015-01-19
VIN: 1FDAF56P43E
Components: ELECTRICAL SYSTEM
Summary: TL*THE CONTACT OWNS A 2003 FORD E-550. THE CONTACT STATED THAT WHILE DRIVING AT APPROXIMATELY 35 MPH, THE VEHICLE STALLED WITHOUT WARNING. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE AND STATED THAT THE VIN WAS NOT INCLUDED IN NHTSA CAMPAIGN NUMBER: 05V270000 (ELECTRICAL SYSTEM). THE FAILURE MILEAGE WAS 43,000.

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2003 Ford E-550 recalls

The National Highway Traffic Safety Administration (NHTSA) has issued 5 recalls for different components of the 2003 Ford E-550.

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.

2007-03-06

Manufacturer: FORD MOTOR COMPANY
Components: VEHICLE SPEED CONTROL
Summary: ON CERTAIN TRUCKS EQUIPPED WITH SPEED CONTROL, GASOLINE OR NATURAL GAS ENGINES, THE SPEED CONTROL DEACTIVATION SWITCH MAY OVERHEAT.
Consequence: OVERHEATING COULD RESULT IN SMOKE, BURN, OR AN UNDERHOOD FIRE.
Remedy: DEALERS WILL INSTALL A FUSED WIRING HARNESS INTO THE SPEED CONTROL SYSTEM FREE OF CHARGE. THE RECALL BEGAN ON MARCH 12, 2007. OWNERS MAY CONTACT FORD AT 1-800-392-3673. (NOTE: ALSO SEE RECALLS 05V017, 05V388, AND 06V286)

2006-06-13

Manufacturer: UFI FILTERS USA
Components: FUEL SYSTEM, GASOLINE
Summary: CERTAIN AFTERMARKET FUEL FILTERS SOLD UNDER THE PUROLATOR BRAND NAME, P/N F65277, SHIPPED FROM JANUARY 16 THROUGH JUNE 2, 2006, FOR USE ON THE ABOVE LISTED PASSENGER VEHICLES. DUE TO INCORRECT DESIGN, THE QUICK CONNECTORS MAY NOT FULLY SEAT WITH THE TUBE INTERFACE, EVEN THOUGH THE PERSON MAKING THE CONNECTION MAY BELIEVE THAT THE QUICK CONNECTOR IS FULLY ATTACHED.
Consequence: FAILURE OF THIS CONNECTION COULD LEAD TO FUEL SPILLAGE AND, IN THE PRESENCE OF AN IGNITION SOURCE, A FIRE COULD OCCUR.
Remedy: UFI WILL NOTIFY OWNERS AND REPLACE THE FILTERS FREE OF CHARGE. THE RECALL BEGAN ON AUGUST 4, 2006. OWNERS MAY CONTACT UFI FILTERS USA AT 800-230-5876.

2004-09-13

Manufacturer: FORD MOTOR COMPANY
Components: ENGINE AND ENGINE COOLING
Summary: ON CERTAIN VANS, THE AIR FILTER ELEMENT MATERIAL PROCESS RESULTED IN AN AIR FILTER PAPER ELEMENT THAT CAN SMOLDER OR BURN. THIS CHANGE IN FILTER PAPER COMPOSITION COMBINED WITH THE CONFIGURATION OF THE AIR INDUCTION SYSTEM, MAY ALLOW HOT CARBON PARTICLES TO CONTACT THE AIR FILTER ELEMENT DURING CERTAIN DRIVING CONDITIONS THAT CREATE HOT PARTICLES.
Consequence: THESE HOT PARTICLES MAY IGNITE THE AIR FILTER ELEMENT WITH THE POTENTIAL FOR AIR INDUCTION SYSTEM DAMAGE OR UNDERHOOD FIRE.
Remedy: DEALERS WILL INSPECT AND REPLACE THE AIR FILTER ELEMENT. THE RECALL BEGAN SEPTEMBER 27, 2004. OWNERS SHOULD CONTACT FORD AT 1-800-392-3673. ALSO FORD IS EXTENDING THE LIMITED WARRANTY (FOR A ONE TIME REPLACEMENT) OF THE ABS MODULE FOR A TOTAL OF 10 YEARS OR 150,000 MILES FROM THE WARRANTY START DATE, WHICHEVER OCCURS FIRST. IF YOUR VEHICLE HAS ALREADY ACCUMULATED MORE THAN 150,000 MILES, THIS COVERAGE WILL LAST UNTIL SEPTEMBER 30, 2005.

2004-09-13

Manufacturer: FORD MOTOR COMPANY
Components: ELECTRICAL SYSTEM:WIRING
Summary: ON CERTAIN VANS, A DIODE IN THE ANTI-LOCK BRAKING SYSTEM (ABS) MODULE MAY EXPERIENCE AN ELECTRICAL SHORT.
Consequence: THE ELECTRICAL SHORT MAY CAUSE AN ABS MALFUNCTION THAT WOULD ILLUMINATE THE ABS WARNING LIGHT, OR THE MODULE MAY OVERHEAT RESULTING IN A BURNING ODOR, SMOKE, AND/OR FIRE. THIS CONDITION MAY OCCUR WHILE THE VEHICLE IS BEING DRIVEN OR UNATTENDED.
Remedy: DEALERS WILL INSTALL A NEW FUSE IN THE ABS CIRCUIT AND INSTALL A HEAT SHIELD OVER THE ABS MODULE. THE RECALL BEGAN ON OCTOBER 15, 2004. OWNERS SHOULD CONTACT FORD AT 1-800-392-3673. ALSO FORD IS EXTENDING THE LIMITED WARRANTY (FOR A ONE TIME REPLACEMENT) OF THE ABS MODULE FOR A TOTAL OF 10 YEARS OR 150,000 MILES FROM THE WARRANTY START DATE, WHICHEVER OCCURS FIRST. IF YOUR VEHICLE HAS ALREADY ACCUMULATED MORE THAN 150,000 MILES, THIS COVERAGE WILL LAST UNTIL SEPTEMBER 30, 2005.

Additional sources

More sources of information about 2003 Ford E-550 problems:

Could anyone tell me the reliability on the E550's? - MBWorld.org ...

https://mbworld.org/forums/e-class-w212/796723-could-anyone-tell-me-reliability-e550-s.html

Oct 14, 2020 ... Every E550 sedan from 2012 forward is only available in 4Matic. All cars designated 550 are the 4.7L V8 bi-turbo. If you want rear wheel drive, ...

07-09 W211 E550 as a daily? | VW Vortex - Volkswagen Forum

https://www.vwvortex.com/threads/07-09-w211-e550-as-a-daily.5886794/

Nov 17, 2012 ... I never drove the 550 ... However, if you end up with a 2003-2006 car ... Front suspension parts (i.e. lower ball joints) are a common problem.

Common AC Problems in Ford F550 Diesels - Q&A

https://www.justanswer.com/heavy-equipment/3h1yb-common-problems-ac-f550-diesels.html

May 6, 2010 ... Any common problems w ac f550 diesels ... Hi there! My name is XXXXX XXXXX I think I can help you resolve your problem! I found a TSB(technical ...

Mercedes-Benz E-Class Questions - I just bought a 2008 E550 ...

https://www.cargurus.com/Cars/Discussion-t39845_ds680760

Sep 7, 2015 ... Ford, Genesis, GMC, Honda, Hyundai, INFINITI ... I'm taking in to my mechanic in the morning to have him diagnose the problem. ... The car sat until ...