Q: What year did ford stop using the 5.4L 2V in their E Vans. I am looking for a low milage used one with all the updates, I presume Ford incorporated over the years: thickened spark plug boss with more threads, PI: heads, cam, pistons intake manifold, improved plastic manifold that doesn't warp like in 99'-2000, etc.
My 98' is getting tired and will cost too much to fix all the little noises, may as well drop a newer one in and I want that extra 25 HP to.
They never stopped. Vans never got any 3 valve engine, so any 4.6, 5.4, or 6.8 van is 2V.
I heard they stopped at in the last few years? And, do these engines have all the engineering updates, fixed problems of the past?
I gave you the correct answer to your question. No 3V engines in any factory E van, ever. Period. Check specs year by year if you want to confirm.
I believe they put more plug threads in around 2005 to lessen the chances of plugs blowing out but you still want to be careful not overtorquing plugs in the 2V engines. As for other global issues the 2 valve mod motors ever had; intake manifolds were always all aluminum on the trucks. Very early 5.4's (1990's) had head gasket issues; the very early PI Romeo 4.6's had a flaw in the cylinder heads (and I got new heads under warranty for free) but this was corrected by 2005 as well.