Engine complaints by model year
Which parts fail
Components named in complaints (engine, cooling system, oil leaks, timing chain, exhaust).
Mileage when the problem started
What owners report
2003 Econoline made a loud popping sound in the engine compartment, lost power shortly after. Vehicle later caught on fire. ** answer required*** after the noise was heard the driver pulled to vehicle onto the side of the road and that's when the driver noticed that the vehicle was on fire. The driver and firemen were injured while attempting to extinguish the fire. A recall was received in October 2004. The recall referenced safety recall 04s22 and 04s23.
We have a 2003 Ford Econoline van that ejected it's first spark plug this spring costing us towing and $500.00+ in repairs. Wednesday, it happened again, this time on the new york state thruway. We were forced to stand in a 10 foot piece of grass between 3 lanes of traffic and a rock cliff with 4 small children. After we managed to get 7 people packed into a tow truck and get to the nearest Ford dealership, we had to rent a car for 3 days and pay for yet another repair. I investigated and found out that this is a recurring defect in this type of Ford engines. I called the Ford motor company to see what can be done to repair the actual engine problem. I was told that my van is now fixed, so technically it is fine. I was also told that there is only a 50% chance that the problem May occur again and if it does I should call back. …
Left house for vacation, got 75 miles away at 60 MPH on the freeway, and engine started making a popping sound. Pulled off road and called a nearby mobile repair company. They sent out a mechanic, he diagnosed a blown out spark plug, and said this was common for the Ford v-10. Made it to his shop, and that's where it sits. Estimates are over $4000 to repair.
Took the van to the store. Upon returning from store started the van, there was a loud explosion as if a bomb went off. Everyone looked because it was so loud. Turned the van off and restarted it. It sounded like a drag car at the track, no exhaust system at all. Took cow off and looked inside, found the spark plug with the boot laying on top of the valve cover or intake, not sure there is no room and just enough to get two fingers in to retrieve it. I had noticed a little ticking earlier in the day like an exhaust leak, but did not find one. Had vehicle towed to repair shop, where it is now. Not sure what will happen next.
Tl* the contact owns a 2001 Ford Econoline. The contact was driving 40 MPH when the vehicle exhibited an abnormally loud backfire noise from underneath the hood area. The contact moved the vehicle from the roadway and found a small fire in the engine compartment. The contact was able to extinguish the fire and the vehicle was towed to an independent mechanic. The mechanic advised that the failure was caused by a blown spark plug that ejected from its housing. The vehicle was not repaired. The manufacturer was not contacted. The failure and current mileage was 220,000.
Tl* the contact owns a 2001 Ford Econoline. The contact stated that while driving approximately 70 MPH, there was a loud bang heard from the front end of the vehicle. The vehicle was taken to an independent mechanic for diagnostic testing. The mechanic stated that the number one spark plug and the coil would have to be replaced. The failure recurred six times after the failure. The manufacturer was made aware of the failure and stated that an after market part could be inserted on the spark plugs to prevent the failure from recurring. The vehicle was not repaired. The approximate failure mileage was 86,000.
My Ford e350 1999 made a loud flapping noise as I was leaving my home. I pulled right back into the driveway and shut off the engine. I found out that the #2 spark plug had completely blown out of the cylinder head. This has never happened on any vehicle I have ever owned. I take good care of my vehicles. I am a mechanic, and former jet engine mechanic also. My obdii confirmed a misfire on cylinder #2 that is how I located which plug it was. Ford said it would cost $260 to look at it, and up to $1700 if they could repair it. Plus towing. I asked how much a new engine would cost since the van is in excellent condition. Ford said it would cost $7,200 for a new engine. This van has cost more for repairs than any vehicle I have owned in my life. I am 62. …
Engine check light is illuminating, indicating a malfunction within cylinder head and temperature sensor. Mechanic at Ford dealer stated that manufacturer has not produced sensor for Econoline truck, resulting in false warning to check engine on vehicle.
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…
Frequently asked questions
Which Ford Econoline years have engine problems?
By NHTSA complaints, the 1999 (14), 1996 (12), 1997 (11), 2002 (8) and 1995 (7) model years. Engine complaints make up 17% of all complaints for the 1999.
Is there a recall for Ford Econoline engine problems?
No. NHTSA lists no engine & cooling recall for any Ford Econoline model year. A widespread problem may still be covered by an extended warranty or a manufacturer service bulletin, so ask a dealer.
At what mileage do Ford Econoline engine problems start?
Across all years, half of the complaints with a recorded mileage happened before about 108,000 miles; 17% happened before 50,000 miles.
What part fails most often?
Owners most often name the engine (27 mentions), followed by the engine › gasoline (18).
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.