2004 Ford E-350 Super Duty

Reliability tier: verified - see /disclosure/

Engine: 5.4L V8 2V (Triton, 5.4L), 2v

255 hp @ 4,500 / 350 lb-ft @ 2,500 (Edmunds/KBB/Ford brochure; fact-check 23.10 - the earlier '260 hp (Wikipedia/Ford spec)' citation was wrong, the Wikipedia E-Series table carries no ratings). E-Series 5.4 stays 2V through 2010 (3V never migrated to the van).

Applicable failure modes (6)

• Ignition coil (COP) failure / misfire
• EGR system faults / DPFE sensor failure (gas)
• Exhaust manifold stud breakage / manifold leak
• FPDM (fuel pump driver module) corrosion / failure
• Spark plug ejection / stripped plug threads (2V heads)
• Timing chain / tensioner / guide wear (2V)

Applicable parts (9)

• DPFE Sensor (EGR pressure feedback)
• EGR Valve, gas engines
• Exhaust Manifold Stud/Bolt Repair Kit (+ gaskets)
• FPDM (Fuel Pump Driver Module)
• Ignition Coil, COP - 2V engines (Motorcraft DG-508)
• Ignition Coil, 2V E-van 5.4/6.8 (3W7Z-12029-AA, Motorcraft DG-540 family)
• Spark Plugs, 2V heads (Motorcraft SP-479 / Ford AGSF-22W-MX)
• Spark Plug Thread Repair Kit, 2V heads (Time-Sert / Calvan 38900-class)
• Timing Chain Kit, 2V (chains, tensioners, guides)

Platform recipes (3)

• 2V plug maintenance: keep plugs from ejecting; know the repair path if a seat is damaged
• 3V spark plug service: remove original plugs without breakage, install the one-piece update
• Fix the 5.4L 3V cold-start phaser rattle: phasers + chain kit in one front-end job

Reference for this truck