I realize that this is an old thread but my questions are along these lines. I recently purchased a 2003 E150 high top conversion van (70k miles), never had a van before so I'm new to this. It is scary driving it any faster than 40 miles an hour because it sways and wanders so much, then I try correcting, then over correcting the other way, then over correcting back the other way, etc. Steering wheel vibrates. Leans a lot around corners. Often a white knuckle experience, and having buyers remorse. I can see that the front sway bar bushings in the I beam are worn out, light shows through them. There is no rear sway bar, and I understand they don't have them unless they are added later. There is play in the front wheels at 12 and 6 which a mechanic told me is probably bad wheel bearings. The rear leaf springs are pretty much flat, essentially no curve left I assume from from carrying the extra conversion van weight all these years and maybe from towing too. Shocks are original and one is leaking. Upper ball joints have been recently replaced but the lowers look old though no boots are torn. Don't know how to check tie rods or the drag link or pitman arm. I plan to begin by replacing the wheel bearings and sway bar bushings and putting KYB Gas-a-just shocks on it. Do experienced folks think that doing these things could correct the problem or does it sound like there are other things going on? Thanks in advance.

 

I don't think those things will fix your problem. My van has the same problem although Ive gotten pretty used to it by now. Over time and for reasons other than this issue I've replaced the tires, shocks, coil springs, tie rods, wheel bearings, etc.. and it still has the same issue you described. I used to think a steering dampener/stabilizer was the trick but now I think the only thing that might solve the problem is increasing the positive caster next time you get an alignment.

 

Upgrade to a heavier sway bar and bushings, polyurethane bushings often can feel tighter than the factory rubber, I had installed air bags inside my coils to prevent my wheelchair lift from breaking down the passenger side prematurely, made it really stiff, they have since rotted, holding no air anymore, my van is still stiff, likely due to not wearing out because the bags, tho to replace them I will have to cut the bags out.

 

Replace all the worn parts, then install a larger front swaybar. That will take care of the problems. The worn parts are an accident waiting to happen. The larger swaybar will improve the handling by 200%. I did this with my 96 conversion van when I bought it about 8 years ago. It'll cruise at 90 mph now with no worries

 

I noticed in your post that you said that you have the handling package on your '02 van because it apparently was made into a conversion van after leaving the factory. I have a 2003 E150 Regency conversion van and I am wondering how I can determine if I have the handling package, and if so, what the handling package included. Would this be indicated on the door jamb VIN code sticker? Does the handling package have implications for what kind of shocks to put on the van? I just ordered a set of 4 KYB gas-a-just shocks (KG5495 and KG5496). Thanks in advance for any input you (or others) can provide.

 

Thanks, I'll look into increasing caster. Did you install a steering dampener/stabilizer, and if so, did it help?

 

Do you recommend any particular brand of sway bar? The only ones I know of are Hellwig and Addco (and Ford).

 

Thanks for your reply, that's two recommendations for a larger front sway bar. Do you recommend any particular brand? What do you think about adding a rear sway bar?

 

To my mind and actual experience with Hellwig sway bars they're the only one's I'd recommend. Addco tends to have the same issues of bushings in the I-Beams which just like the factory version tend to wear out requiring replacement perhaps several times over 5 or more years. The Hellwig method of attachment to the I-Beams is superior.

Adding a rear sway bar is a huge yes from me. They were not part of most E-Series builds as they were an option.

It might not apply to your vehicle but because I run a bit heavy as a daily driver I use Hellwig's short wheelbase motor home sway bars---they're upwards of 40% larger diameter so handle my 8,400# weight without issue. I do run Bilstein shocks too but any short wheelbase motor home rated shock would behave much the same. Do keep in mind my '05 E-350 extended body with raised roof has about 2,200# if tools, supplies and interior build out materials so the over all effect is a "comfortable" ride but still good handling characteristics. The same components on a van with a lower daily driver curb weight would experience a very harsh and uncomfortable ride.

 

ALL conversion vans were done outside the factory. Ford supplies an empty box, and then the converter puts in the full interior, running boards and junk, often does paint, and adds the raised roof if applicable. Using substandard junky parts and cheap labor. This is one reason why conversion vans died. No safety rating on anything behind the front seats, no side air bags, etc. Carpeting and fabrics were not automotive grade. They were done like campers. Consumer Reports stopped reporting on vans because buyers thought "Ford" built their van and the conversion stuff was notoriously junky. Cheap rear A/C and heat unit also. If you have children or passengers behind the front seat, none of the seating is NHTSA approved and the plastic top might fall off if you roll the van over That said, I drove conversion vans for 30 years and they served me well and nobody died.

Your van was converted by a company called Regency and they are still around doing camper conversions. I would bet money that they will be of no help to you and will have no parts or information for your van. But they will sell you a new Sprinter conversion. https://www.regencyrv.com/

I am now driving a Grand Caravan with real crash protection. It was built totally at the Dodge plant.

I don't have the mfr info, but recall there was an RV package from Ford that included chrome bumpers, leather steering wheel with cruise and intermittent wipers, a power seat base, aluminum wheels and white letter tires, and whatever they called a handling package--typically the larger OEM shocks, maybe a slightly larger front sway bar. If you have stuff like the leather steering wheel you have the RV package--look up a 2003 E150 brochure and the option is probably listed there. Shock fit would be the same as any E150 and KYB's are good shocks.

 

Thanks for the info. Based on what you said, my van must have from the factory with the Ford RV package because it has all of the things you listed. It was manufactured as an 'incomplete vehicle' and then went to Regency for all of the conversion van stuff. I plan to do whatever I can to make mine handle decently at highway speeds, hopefully I can get it there.

 

Here's an '03 brochure on line. My memory may be fogging out on me, but by 03 it looks like Ford had the E150 RV model which was set up for conversions. Aluminum wheels were optional but would have been requested on the majority of conversions. (The loss leader conversions had hubcaps.) They even show a glitzy high-top conversion on one of their brochure pages.

In the specs, EVERY E van was listed as having a "handling package" in 2003. From before this time, I think that comprised bigger shocks and maybe a bigger front sway bar but it was probably cheaper to put them on all vans compared to using 2 different models.

You have a high roof. I want you to tell me you have at least the 4.6 (I had this in my low roof 02) and preferably the 5.4 engine.

Here's the brochure link: https://www.auto-brochures.com/makes...eries_2003.pdf

 

I searched for a brochure like this online today but came up empty, so I really appreciate you sending this - great info! My '03 conversion van has the 4.6L V8 and it seems adequate. The same engine is in my stock '03 Mustang GT which came from the factory rated at 260 HP and 302 ft lb torque.

 

Looks like the 4.6 was the standard engine in 03 for the RV package. The dealer accidentally gave me a test drive in a 4.2 V6 van but that's a tiny engine with the weight of a fancy conversion. My 4.6 was "OK" with my low top van, and got the best mileage of the 5 vans I owned (16.0 mpg over the 130k miles I drove it) but putting a high top in it would hurt that as well as your handling in winds. Before my '02 E150 which I bought new, I had a '96 GMC Savana with a 350 and that had some guts, again with a low top. But it was a POS (and I bought it new also).

 

Thanks for all the information. Here is an update on my the swaying issue with the 2003 E150 high-top conversion van that I bought on Oct. 7. I worked on the van (see the work that was done below) and my wife and I drove it from northern Ohio to south Florida, arriving last night. We put a cargo carrier tray on the back hitch with about 50 lb. on it. The van swayed badly in the wind and got moved around by every semi or large truck that passed by in the adjacent lane. I drove at 65 mph or less most of the time to keep it under control, but that's slow going. During the last 2 hours of the drive on I-75 there was no wind and very few trucks and that was the only time it was a pleasure to drive. So, it tracked straight at highway speeds when there was no wind or buffeting from other vehicles.

Based on previous comments, to reduce swaying it needs a Hellwig sway bar in front and possibly one in back too for maximum stability. The Hellwig is backordered everywhere until December, too late for this trip. I also looked into the Addco rear sway bar but couldn't get any reply from my multiple voice mail messages over 2 weeks to Addco's tech service dept. about an issue with their installation instructions -- the written instructions say to install the mount on the side of the frame rail but the drawing shows it mounted on the bottom. Lacking this information, I did not order it.

Here are my questions at this point, any advice or assistance is more than welcome! The van has 15 inch aluminum alloy wheels (5 lug) and it came with new Cooper light truck tires that have a C load rating. I've read that E load rated tires help with swaying also, I welcome opinions. Would a larger wheel size would help too? There is also some kind of horizontal front suspension shock that can be installed to dampen steering response, that I read a little about. Is that also needed?

Here's what I have done to the van so far: new KYB Gas-A-Just shocks (it was a challenge to get to those top shock nuts), new sway bar bushings installed, had front wheel bearings tightened, tires balanced, greased all grease fittings in front end, tightened all front suspension bolts to torque specs (most needed it), and got an alignment. The repair shop I take it to (honest guy) said 'I checked it over and everything in the front suspension is tight' after he installed the sway bar bushings (he put rubber ones in before I had a chance to tell him to use polyurethane bushings, which I've heard are better). It drives straight now, mostly after the alignment which was a mile off when we drove it back from Virginia. I'm guessing that the previous owner had new upper ball joints installed but didn't want to pay for an alignment since she was going to sell it.