Engine Exhaust System Problems of Ford E-250

Vehicle warning system indicated to safely stop truck immediately. Truck would not restart. Truck was towed to dealership (~60 miles). Ford replaced one of the exhaust gas sensors under warrantee. Dealership personnel indicated that this was a recurring problem and it would probably happen again. March of 2015 similar circumstances, vehicle warning systems indicated to safely stop truck immediately. Truck continued running and drove the 80 miles back to dealership. Mileage at the date of the second occurrence was ~54,500. A different exhaust gas sensor was replace, no warrantee coverage. Dealership personnel continue to indicate recurring problem and it would probably happen again. Contacted Ford, no resolution on cost incurred or if there is a re-design and replacement of sensor (s).

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Information redacted pursuant to the freedom of information act (foia), 5 u. S. C. 552(b)(6) spark plug ejection or blowout, I have a 2005 Ford e250 van. This is a very serious and common problem on Ford motors, can you look into this issue for us Ford owners. The repair in my case is going to be very costly, due to the fact I will have to rent a replacement vehicle to continue servicing my customers. Thank you for investing this matter. [xxx].

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I own a 2001 Ford e250 van. This van has been a reliable vehicle and maintenance has been easy and predictable. However today the third spark plug on the passenger side blew out of the cylinder head. Though it was a exhaust leak at first because of the sound. I pulled of the freeway and opened the engine cover. At this point I restarted the engine to find the exhaust leak. A large flame immediately began bursting out of the open spark plug hole. Although I was able to turn the engine off quickly this scared me considerably as I know their are fuel lines that run right by the spark plug. I had it towed from their to a shop. I have researched this and found that it is a common problem with many of Fords engines. I even found cases were cars had been destroyed by fire as a result. It concerns me that there has been no recall. I do not expect warranty from Ford for a vehicle this old. However this seems to be a potentially life threatening problem and I would think that merits a recall. I have a three year old daughter that rides in her car seat next to me in the van at times. That car seat is less than two feet from the spark plug in question. Separated only by a thin engine cover. Again I am really quite amazed that this has not resulted in a recall.

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This is one of 2 1997 vans I own, the other van engine blew at 78000,this one did at 82000 ,and it is thought to be due to the rear seal leaking on exhaust and starting fire at tank.

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