2007 Ford E-Series Problems: 9 Known Issues

On the 2004-2009 Ford E-Series 6.0L Power Stroke V8 diesel, ford's 6.0L coolant-loss bulletin tests the engine oil cooler for coolant-flow restriction: engine oil temperature 15°F (8.4°C) or more above coolant temperature on a loaded road test means the cooler is restricted. The bulletin says coolant degraded by combustion gases, low system pressure or overheating drops silicate and loses corrosion protection, and that rust flakes and silicate can collect in the oil cooler. It affects 2004-2009 E-Series vans with the 6.0L Power Stroke diesel V8 (Ford TSB 09-8-3), not the gasoline E-Series engines.

On the 2004-2009 Ford E-Series 6.0L Power Stroke V8 diesel, ford's bulletin says some 6.0L diesel E-Series vans may vent coolant from the degas bottle cap, lose coolant, blow white smoke from the tailpipe, lose power from overheating or lose cabin heat, typically under load such as towing or climbing hills. A leaking EGR cooler can cause white smoke and internal coolant loss that may hydro-lock the engine, and can push exhaust gas into the cooling system so it looks like a leaking head gasket. It affects 2004-2009 E-Series vans with the 6.0L Power Stroke diesel V8 (Ford TSB 09-8-3, which supersedes 08-11-3), not the gasoline E-Series engines.

On the 2004-2009 Ford E-Series 6.0L Power Stroke V8 diesel, ford's 6.0L coolant-loss bulletin includes a road test for leaking head gaskets: cooling-system pressure rising above the cap's holding pressure, or the degas cap venting continuously under load. It says a turbocharger over-boost condition, from irregular variable-geometry turbo response or a biased exhaust back-pressure sensor signal, causes excessive cylinder pressure that may lead to head gasket failure. It affects 2004-2009 E-Series vans with the 6.0L Power Stroke diesel V8 (Ford TSB 09-8-3), not the gasoline E-Series engines.

On the 1992-2014 Ford E-Series, owners report rust on the floor and on the body reinforcing members welded under it, which turned out deeper than it looked once it was wire-brushed and ground. They blame moisture held against the floor by the factory carpet or mat backing, and water and road spray getting in from underneath. It affects 1992-2014 E-Series vans (fourth-generation body); the owner reports linked here are from a 2003 E-350 and a 2007 E-350 extended van.

On the 1992-2014 Ford E-Series, owners report play in the front door hinge pins and bushings that lets the driver's door contact the body or rub the fender. One owner reports replacement brass bushings breaking again after a pin-and-bushing kit. It affects 1992-2014 E-Series vans (fourth-generation body); the owner reports linked here are from a 1997 E-350 and a 1999 E-350.

On the 1992-2014 Ford E-Series, owners report transmission fluid leaks at the front of the van from the cooler lines: at the short rubber hose sections and clamps where the lines meet the coolers, and where the steel cooler lines have rusted through near the external filter housing. It can affect 1992-2014 E-Series vans with automatic transmissions; the owner reports come from a 2000 E-250 (5.4L, 4R70W) and a 2005 E-350 Super Duty (5.4L). One owner reports the leak at 160,000 miles on the 2000 E-250.

On the 1992-2014 Ford E-Series, owners of vans with factory rear A/C report refrigerant leaks at the rear evaporator and along the long lines that run to it, so the A/C stops blowing cold. They report the lines leaking around the brackets that hold them and above the rear tire, from corrosion or rock damage. It affects 1992-2014 E-Series vans with factory rear (auxiliary) A/C; the owner reports linked here are from a 2007 E-350 and a 2012 E-350 wagon.

On the 1999-2010 Ford E-Series, on 1999-2010 E-Series vans with the 5.4L 2-valve V8 or the 6.8L 2-valve V10 (non-supercharged), the studs that hold the exhaust manifolds to the cylinder heads can break. Ford covers this in technical service bulletin 09-22-8 (Oct 28, 2009), which replaces the earlier bulletin 5-5-4. The 4.6L is not listed. When a stud breaks, the manifold starts to leak exhaust at that spot. One repair guide for the V10 says owners usually hear a ticking or clicking sound when the engine is cold that fades as it warms up. The same guide blames heat cycling: the cast-iron manifold, aluminum head and steel studs expand at different rates, which stresses the studs every time the engine heats up and cools down. Road salt makes the corrosion worse. The guide also says exhaust from the leak can get into the cab through the heating and ventilation system, which is a carbon monoxide risk. Studs tend to break one at a time, so the leak can get worse over time.

On the 2004-2010 Ford E-Series 6.0L Power Stroke V8 diesel, ford's bulletin says some 6.0L diesel E-350 and E-450 vans may run rough, lack power, start hard or not start, with or without code P0611 or injector circuit codes. The cause may be the DC-DC converter in one half of the fuel injection control module (FICM), which boosts battery voltage to 48 volts for the injectors, or the main circuit board in the other half; low FICM supply voltage increases its load and can damage it or shorten its life. It affects 2004-2010 E-350 and E-450 vans with the 6.0L Power Stroke diesel V8 (Ford TSB 10-12-6, June 11, 2010), not the gasoline E-Series engines.