Old Style Ford Van - Known Problems

I am going to be needing to buy a van fairly soon for my new business and also want to build it out for sleeping and gear. Essentially I'll build a sleeping platform that can be removed when I need to load pallets of product into the van. 

I would love to get one of the new Transit (Sprinter style) vans, but I have to watch outgoing cash and I'm probably going to have to just make do with an older style (2000-2013)Ford Van. Those of you that have them are there model years that are especially bad with known engine/transmission problems? Are there known issues that every Ford van owner knows about? Things that arise after 100k miles, etc. 

I just want to know what I'm getting into so I can plan for, replacing a transmission at 150,000 miles, oil leaks after 200,000 miles, or whatever the problems are. 

Another resource that might be useful - http://www.cartalk.com/car-complaints 

Kind of a database of complaints, indexed by the Make, Model, Year of the vehicle.

Modular V8 engines are pretty bullet proof. There was a weird issue with them blowing out spark plugs, but uncommon as I recall. If you have the AOD (4-speed) transmission, they can either have problems around 100k or go forever. It's luck of the draw. I had a Crown Vic who's first gear went out at around 100k, but I drove it starting in 2nd for another 10k probably (including across the country).

Tim Lutz wrote:

90s Ford vans are more solid than post 2000, and cheaper!

No doubt, but does OP want to invest his outfitting time/money in a 20-25 year old vehicle?

Gunkiemike wrote:

No doubt, but does OP want to invest his outfitting time/money in a 20-25 year old vehicle?

That's my main thought. Though as I'd eventually like to get one of the newer vans, maybe it make sense to find a low miles 90's van that would work for me for 3-4 years and then get the nicer Transit van to really build out. Just trying to keep my dream van ideas in check until my business can handle the cost. Gotta be smart about this. 

Tim Lutz wrote:

90s Ford vans are more solid than post 2000, and cheaper!

What is the parts availability for a vehicle that old? Are there new engine computers available since the capacitors in the old computers have dried out and changed electrical values, causing it to send incorrect control signals? What about the connectors on the wiring harness?

Unless the OP is into restoring vehicles, those vans of that era are at end of life.

Marc801 wrote:

What is the parts availability for a vehicle that old? Are there new engine computers available since the capacitors in the old computers have dried out and changed electrical values, causing it to send incorrect control signals? What about the connectors on the wiring harness?

Unless the OP is into restoring vehicles, those vans of that era are at end of life.

Hardly at the end of life. The chassis was the same from 1992 to 2007. And it's a popular fleet vehicle. Parts will not be an issue. 

ECU and harness plugs are the least of worries. Capacitors can be replaced and used ECUs are plentiful.

Marc801 wrote:

What is the parts availability for a vehicle that old? Are there new engine computers available since the capacitors in the old computers have dried out and changed electrical values, causing it to send incorrect control signals? What about the connectors on the wiring harness?

Unless the OP is into restoring vehicles, those vans of that era are at end of life.

Stuff I had not thought of. Mostly because I don't work on old vehicles. Good info, thanks!

Tim Lutz wrote:

https://www.ford-trucks.com/forums/1203429-eec-iv-pcm-capacitor-leakage-problem.html

Tim Lutz wrote:

pre-2000 trucks and vans don't really have computers.  parts are available at any Autozone, OReillys, etc

By the late 80s, even carbureted cars had ECUs to control some things and fuel injection was common. By the 90s pretty much everything was fuel injected.

Those 2015 Transits should be down to $20,000 or less by now. I bought a new one last year around August and it's great. But if your budget is significantly less than that, I understand why you're looking at the E Series.

Tim Lutz wrote:

by 'don't have computers' I mean computers that control all aspects.  My buddy has a 2016 BMW that wouldn't let him in the vehicle when the motor for the window went out.

True enough, but a PCM/ECU sending incorrect mixture signals can strand you just as easily. 

Tim Lutz wrote:

I am relating my experience.  I have dirtbagged and overhalued vehicles for 25 years.

That was my point to the OP, not so much to you. Does he want to get involved in overhauling a vehicle of that vintage?

I have a 2008 e-150. The I drove it around the U.S. for 3 months (coast to coast and times in the desert). I had two problems with mine. The heat stop working. Luckily, it kicked back on when driving through a Colorado snow storm. I've also had the good old spark plug blow out (at around 210 000 km (131000 miles). It cost 400 CA to get fixed. Other than that, she still runs like a dream. 

Tim Lutz wrote:

by 'don't have computers' I mean computers that control all aspects.  My buddy has a 2016 BMW that wouldn't let him in the vehicle when the motor for the window went out.  that little incident cost him $800.

I am relating my experience.  I have dirtbagged and overhalued vehicles for 25 years.  IME, pre-2000 is better on every level.  Gas mileage hasn't improved, and reliability and ROI has gotten lower.  IF a $1500 van that you drove for 40k blows a rod or something huge, what are you out? not much in the grand sceme.  If you keep the fluids changed, this won't happen.

If 'newer is better' and you have a trust fund or are willing to make monthly payments, then buy a new van and make monthly payments and have it serviced at the dealer for insane prices like the rest of Murica

Let's compare apples to apples. A new BMW is not a comparison to a new Transit or Sprinter. A $1500 car will always need maintenance and is always teetering on the edge of breakdown. 

Tim Lutz wrote:

of course.  My point is that any level and type of vehicle is constantly getting more and more complicated.  Compare the reliability of a Corolla now to the ones from that 90s that are widely considered the most reliable vehicles ever.

I'm not sure that comparison can be accurately made. Current economy cars have hardly gotten much more complicated as far as drivetrain is concerned. Most of the current technologies have been in cars since the 90s.

As an actual mechanic and not just going off internet searches, older Ford vans are pretty simple. Spark plugs have been known to occasionally blow out of the head. It's an easy enough repair that doesn't usually cost too much. I've been turning wrenches 12 years or so and only done 2. They have computers but I don't encounter too many Fords with computer problems. If it has a 4.6 the exhaust manifolds tend to leak. Couldn't tell you why it's mostly only the 4.6 as opposed to the 4.2 or 5.4, it just it. If you can find one that wasn't a work van and/or beaten on the trans should be ok. I've seen them go on usually delivery vehicles. A lot of stop and go by multiple people. Suspension wise, all Fords go through ball joints. As long as you keep they greased though they last. Rear leaf spring shackles do rust through and break sometimes. Worst I can think of is the intake manifolds have a tendency to leak. Some crack and suck air causeing the engine to run crappy. Others leak coolant. I have one customer with a delivery van that has a bad head gasket and a leaking intake. The head gasket blows coolant out the intake and he's gone well over 30k since i told him he needed a motor. The thing just keeps chugging along. They're not bad vehicles at all.

Mathias wrote:

Those 2015 Transits should be down to $20,000 or less by now. I bought a new one last year around August and it's great. But if your budget is significantly less than that, I understand why you're looking at the E Series.

I would like to be sub $10k. Maybe $5k if the vehicle makes sense. I need it to last 3-4 years. Doesn't have to be pretty, but can't leave me stranded on the side of the road either. 

Might be a bit heavy-duty, but I recommend a 7.3 Powerstroke Diesel E-350.  Better MPG than the gasser E-350 and if you do some research, you'll find that people are fanatic about the 7.3 PSD "million-mile engine".  Mine is from 2000 and just rolled over 180k.  Apparently she's just getting broken in, according to the enthusiasts.  These vans are what Sportsmobiles used to be built on.

My "van" is a bit unique--it's a used shuttle bus that I picked up on craigslist for $3200.  You can definitely find a real van for within your price range, and parts are available all over the place.

I expect I'll need new fuel injectors within the next 70k miles and that's gonna be a pain.  I just had my rear diff rebuilt, but I don't know if that's a common issue.  My transmission is still quite happy.  I had to replace all the shocks when I got the vehicle, and I had my passenger-side shock tower crack on me.  I had to have it replaced.  Ford issued a TSB about that one, so it's a known issue.  I think it's fixed on production models after 2003?

I think that's about all I've got.  I've had this bus for 2 years now, happy to answer any questions.

Good luck!

To Brian Matusiewicz, that was a great response. I just picked up a E150 with the 5.8 351 V8 that runs super good. When I was taking it home from the seller with my brand new battery the charging was at 18.5 or more voltage. But it made it on a 40 minute drive. Today the battery was totally dead, I blame a heavy draw from some circuit. When I jumped it the voltage was reading 14.5 and kept it that way for about 15 minutes I then drove it to a stereo shop to put a deck into it. They said it had to be jumped again when they finished the deck. Now I notice that I don’t have working headlights, the markers and park lights are on with the switch and rear too, but no headlights charging is still 14.5 V. Is there any known common issues in the electrical in these? And can a faulty alternator cause a draw with the vehicle switched off and parked with all accessories off? Where would you start?