Which parts fail
Components named in complaints (engine, cooling system, oil leaks, timing chain, exhaust).
Mileage when the problem started
Owner reports
Selected complaints filed with NHTSA by 1997 Ford E-150 owners, lightly cleaned up (personal details are redacted by NHTSA).
While traveling on vacation 600 miles from home I experienced a well known failure to Ford triton engine owners known as a spark plug ejection failure. I was traveling @ 65 MPH and up to the failure the engine was running normal there were no abnormal sounds. At the time of the failure it sounded as if the exhaust or the intake was coming apart. I pulled over on the side of the highway and removed the doghouse at the rear of the engine to discover the right bank and 2nd cylinder from the rear had ejected the spark plug and destroyed the ignition coil. I unplugged the ignition coil and the power cable from the fuel injector from that cylinder and nursed the van to a friends house 40 miles away which took over 3 hours. …
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. On 12nov07 the dealer replaced the dpfe sensor at a cost to me of $364.04. I contacted Ford corporation on 06dec07 requesting reimbursement for the repair. My request was denied. Failure of dpfe sensor has the same results and the same safety implications as the failure of the camshaft position sensor. …
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? Http://www.fordmanifoldsettlement.com/index.html http://forums.treemedia.com/fb/archive/index.php/t-224.html
Ford motor co. Had knowledge of failure of the front cover gasket and lower intake manifold gasket in 97 & 98 e-150 and f-150 vehicles. Failure of any one of the above items will end the life of a engine. Ford will not ackknowledge this problem even though numerous TSB's have been put out. This is such a problem that a web site is dedicated to it. (leakingfords.com) another site that has many complaints about this is http://forums.treemedia.com/fb/showthread.php?t=224&page=4&pp=15 people that have this failure end up needing a engine replaced.
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.
My 97 Ford e150 has the 5.4 motor in it. The problem I am having is spark plug blow outs. This is my second in a years time. This could cause a fire due to raw fuel coming out of the spark plug hole and the coil Land on the head could case a spark and boom bad fire.
I dropped a rod today in my 1997 Ford-f150 with 77,000 miles. Check engine light seems to come on every 1000 miles. Highly unlikely that I would never purchase another Ford product. Maybe 1997 model was a problem with Ford acknowledging problem.
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.
Notified by auffenberg Ford service department that timing cover seal allowed moisture into engine block resulting in blown engine. Advised by service department that this is a recall problem with the 4.2 liter engines on the f-150 which is also the same engine installed on the e-150 van series. Contacted Ford customer service and they denied any problems with the vans. It is difficult to believe that a vehicle maintained as well as this one was would develope this type of a major problem at this low mileage. A synthetic blend was used for the oil which was changed at the recommended intervals and monthly during the winters. After talking to several service dealers in the area, I was left with the impression that this is a common problem of defective parts installed by Ford motor co.. …
I was informed by a certified Ford mechanic, the problem that I had experienced with my vehichle is a common defect with the Ford 4.2l v-6 engines. The seal for the intake of the fuel injection system cracks and causes coolant to leak into the cylinders. A cylinder will evantually contain so much coolant that on start up of the engine the push rod or main bearing for the piston will break. The reason being, coolant can not combust , causing so much pressure in the cylinder it breaks either the push rod or main bearing. I had also talked to other independent mechanics and have been informed that many of the 4.2l v-6 engines in these vans have been repaired or replaced for the same reason.
NHTSA investigations
Spark plug ejection from cylinder head
On September 6, 2005, odi received a petition requesting that the agency investigate allegations of engine spark plug ejection in certain model year 1997 through 2004 Ford vehicles with triton v-8 and v-10 engines.odi received a total of 474 non-duplicative complaints on the subject vehicles where the complainant, or the dealer repairing the vehicle, reported that a spark plug detached from the cylinder and/or…
Engine complaints in other E-150 years
Frequently asked questions
How common are engine problems on the 1997 Ford E-150?
NHTSA has 21 complaints about the engine & cooling of the 1997 Ford E-150, 21% of the model year's 102 complaints. The component named most often is engine › gasoline (8 mentions).
Is there a recall for 1997 Ford E-150 engine problems?
No. NHTSA lists no engine & cooling recall for the 1997 Ford E-150, though it has 5 recalls for other components. If the problem is widespread, a repair may still be covered by an extended warranty or a manufacturer service bulletin — ask a dealer.
At what mileage do 1997 Ford E-150 engine problems start?
Half of the complaints with a recorded mileage happened before about 125,000 miles, and 10% before 25,000 miles.
Source: U.S. National Highway Traffic Safety Administration (NHTSA) — owner complaints through October 20, 2026, recalls and defect investigations; fuel economy from the EPA. Complaints are unverified reports and are not proof of a defect. How we rate model years.