New member with old question (s). I am going to be looking at a 2004 E-250 with the 5.4l. Years ago I owned 3 new Ford pickups with the Triton engines and never heard about the spark plug problems.
Just recently I have read varying opinions about the issue. Anyway, I believe I have read in late 2003 the number of threads were increased in the heads and also the three valve engines were not put in the E series and so two piece plugs shouldn't be an issue either.
If that is the case as long as installing plugs with a few more lbs of torque there shouldn't be any unusual problems that have been attributed to F series?
Also about cam phaser problems....is that also a three valve head issue? I'm trying to get a reliable van to use for some traveling and don't own a bank to keep one on the road.
Appreciate any thoughts about that engine in that E-250.

 

I have a 97 with the 5.4 and 4R100. I believe the 04 engine is the same?
220,000 miles.
No plug problems.
No cam phasers to worry about.
I recently replaced 1 coil.
I had to replace a vacuum fitting a while back.
The 5.4 got a pan gasket replacement years ago.
The transmission was rebuilt at rough 120,000 but I'm not sure it really needed it.
Drivetrain is not usually an issue with these.
I consider this van very reliable.

I did spend a little money replacing all the moving parts in the front suspension and steering and these should be considered wear items. If your buying a 10+ year old van, plan to rebuild the front end and replace shocks.

Also check out the rear axle - depending on mileage - it's a Dana 60 which is usually very strong but seem to have occasional pinion bearing wear issues.

If anything happened to this van, I would replace with another - although I'd get a long body with a V10. Saw one on CL yesterday...

 

Thanks, jbwheels...... Not sure if I will come up with this one or not. Also looking at a low mileage 1996 model. 5.8l Looks just like the 1995 I have. May have to think about restoring. Needs a bunch of TLC....