2002 E350 4x4 van. Mikes 5 Star tune, FlowMaster 70 and AFE cold air. Nothing but breaks, regular fluid changes, fuel filter and serpentine belt have ever been changed so it needs some love. It suffers from vapor lock type stalling condition when it’s very hot outside or at high elevation. The AC only blows out of the defrost vents when under load. It throws a lean and spark knock code when it vapor locks.

I think it may need a fuel pump to solve vapor lock? I may for the first time pay a local shop. They can trouble shoot the AC (maybe a vacuum leak?) as well.

It may need it’s first spark plug change as well so the shop can have that fun. What else should I tell them to change? I plan on keeping the Van for a while and may finally regear to 4:10 from the 3.73 to pull a bigger trailer. Give me a list to make it ready for the next 135000 miles. I do not mind for the first time ever paying a shop. I usually do the work but I would like to just have it all fixed at once because it may need some troubleshooting and heavy lifting. Any suggestions appreciated.




Bartlett res.
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The A/C defaulting to the defrost vents is related to the vacuum control system, in this case typically the very well hidden reservoir and check valve have failed, need replaced. I created a "how to" in the van's section---here's a link to those threads: E-Series HVAC Controls Since you might not be doing your own repairs there might be too much there to pass along to a shop---but the failing reservoir and check valve is certainly at issue here.

Spark plug wise I don't let mine go past 50K miles before being renewed---its a preventative maintenance issue and even if in my mind it seems to be good idea. I use nothing but Motorcraft as I've read here over a few years those seem to be the most reliable and problem free.

Best of luck on your project!

 

Describe this "vapor lock" thing more. What does it do?

EFI pressurized fuel usually doesn't vapor lock. Does it just stall like when you turn the steering wheel or put it in Drive? Does it restart right away? Might be the IAC.

 

Agreed - had mine go crazy in my 01 E350 and the culprit was mice/rats chewing through a couple of the vacuum lines during the winter. Same thing happened to my 02 Class C this past fall. Finally was able to eliminate the rat and then get it in for repairs.

 

Thanks all you gents! First time it “vapor locked” I was driving very slow for an hour on little more than a trail in New Mexico Mountains. On a hill it just stalled and would not start. After 5 minuets it started and ran normal. Same trip it started to miss, bog and loose power on the I-40 across Arizona after a few hours on the interstate. I limped to a nearby gas station and filled the tank. It sputtered and bogged to go the mile or two to a station. With a full tank and cooled a
engine it was fine after that. It was very hot outside. Engine temp runs normal. Pulling an empty 20’ box trailer from Cali on a hot day it did the same thing. I pulled over, waited 10 minutes and it started and ran fine. I usually run 89 or 91 because I pull a trailer. It pinged for a while but I dropped timing with the Mike’s 5 star programer. I also always put a shot of that oily Lucas fuel injector cleaner in every tank. Mobile One oil, dry climate and well loved machine.

This may be a clue...If the van sits a week or more it often starts and sounds liike its running on 5 cylinders for 10 seconds.
Yesterday for the first time I started it cold just fine. I backed up and it chuged or loped a few seconds before it cleaned up.

 

I'm not familiar with vans so maybe there's something I'm missing but changing the plugs isn't all that big of a deal. Time consuming (going slowly) maybe but nothing all that technical. If you do pay the shop to do it, I'd be ABSOLUTELY CERTAIN they torque those new plugs properly to prevent blowouts later on.

Also, re-gearing from 3.73 to 4.10 seems hardly worth the money. You'd only be gaining 10 percent. You may not even notice, especially if towing a large trailer is in the future. Definitely I'd be looking at 4.30 (at least) instead. Had I not moved houses last year, I would've gone 4.56 by now. The funds for that got diverted, again....

 

I hear you on the gears. Problem is that I do not see genuine Dana Spicer gears in 4:30. They make 4.56 but then I’d be screaming on these Western 75 mph speed limits that we have. My opinion is after market China gears are junk. Every ring and pinion problem you read about is with aftermarket gears. The other benefit of Dana Spicer gears are that they generally drop right in without a whole lot of setup and shims. The ones I did when I was younger droped right in without any setup change. Does anybody today make a decent gear set that fits as well?

 

Hmm. I'd get a quote on those plugs before they do the work personally. I just bought a 2002 F250 CCLB 4x4 V10 and the guy before me had the plugs done a few months before he sold it. I was surprised when I looked over the receipts. I get where you are coming from on just getting it all done at once though.

I wonder if your fuel pump isn't starting to fail. Fuel filter has been changed recently I take it? I'd put a pressure gauge on it and make sure it is in spec. Even if it works OK most of the time I bet that if it is failing it will read a bit low.

If you have ever considered putting anything over a 33" tire on I'd get the 4.56 gears. I have a F150 with 4.10's in it and running 33's and a 4.56 wouldn't be bad at all with the OD. I'm a slow poke though.

 

I guess fuel pressure was OK. They found a mouse chewed Fuel injector pigtail. They will install the the vacuum canister and vac line upgrade/repair kit. They have done a bunch of Ford spark plugs so they can do those and boots as well. $800 for everything.
I’m not so sure it will fix the vapor lock and I did just install a Wix fuel filter. Maybe I should install a genuine motocraft filter? It was defiantly acting like a starving, bogging and stalling fuel problem. Problem now is I may not see the problem again until its hot outside.

 

I have run wix fuel filters on my F150 for years and never had any issues with them. Hopefully, the work you had done solved your issue and you won't need to worry about it going forward. That sounds like a decent price for the work you had done. The guy that had my truck before me paid substantially more than that but he also had some AC work done at the same time.

 

That's a nice looking van. What's the orange light for? Former ambulance?

 

A new fuel pump solved exactly the same symptoms on my 02' Excursion. The problem was worse when ever the tank was near the 1/4 mark.

 

It was built for the city of Colorado Springs. Some kind of computer and camera van with a generator and fresh water tank.
It was built with a Factory Authorized F350 4x4 conversion with Dana 60’s. I turned it into a Camper and tow rig. It’s been flawless! I added a sink, bed and ARB fridge. The whole van strobes but I only use it so people can find my camp spot or for changing a flat on the side of the road. Traffic goes from 70 to 45 when I light it up so I only use it if I have to. The generator was a 5500 watt Onan. I sold that and cary a little IU2000 honda. A big solar panel on the roof and an extra battery is really all I use except for the AC I installed. I’m worried about the fuel pump still....