Engine Failure Problems of Ford E-350

Engine failure on a 2021 Ford E-350 cutaway, 7. 3l v8, used for parcel delivery. The vehicle was taken out of service and has not run since. Two diagnoses, both in writing. Acme mobile service, July 27, 2026, at 152,760 miles: "found the #5 cylinder is completely disabled and dropped out. Truck will need a new motor. " Ford of spartanburg (Ford dealership), repair order 595835, August 25, 2026: "found engine is knocking, will need to replace motor. " Ford quoted $16,000. 82 for a long-block replacement. The engine is available for inspection. This is the second engine failure on this VIN. In March 2023 at 83,575 miles the engine was rebuilt with new Ford parts (camshaft, sixteen lifters, rocker arms, cylinder heads) after a camshaft and lifter failure. On the day the rebuild was completed the shop recorded "03/31/2023- new engine failed. Engine started knocking and had noise coming from top end. " and Ford replaced the complete engine under warranty in April 2023 (Ford claim cas-42271539-g0f3zf). That Ford replacement engine is the one that has now failed, after 69,185 miles. Ford's own repair order of August 25, 2026 lists safety recalls 20s73 and 24s07 for this VIN at $0. 00, I. E. Not performed, while the vehicle sat at the Ford dealership. Ford customer experience declined assistance on August 25, August 28 and September 9, 2026 and closed the case. The same 7. 3l engine has failed on nine vehicles in this fleet; NHTSA already holds voq 11582566, 11582592, 11582598, 11582601, 11582604 and odi 11714692, 11714694 on those, and NHTSA odi (mr. J. Williams) has the complete vehicle-by-vehicle record as of September 6, 2026. North carolina doj consumer protection file no. 2026-180591 is open on the same matter.

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Powerstroke 7. 3 diesel. The camshaft positioning sensor (cps) failure is a serious problem that Ford will have to deal with. I have had three instances of the unit failing on me since this first one on Dec 13th, 2007. In the first case, I was taking my son to school. The van was sputtering the whole way and I eventually had to have it towed to a repair shop after a complete engine failure. Ford had just issued the recall on Dec 6th, 2007, and they honored the repair. The second cps incident happened on Feb 23rd, 2010. The vehicle would not start; I had it towed to a repair shop after getting a parking ticket. I cannot find proof that Ford honored the repair. The 3rd cps incident happened on Sunday Feb 27th, 2011, one year after the 2nd incident. I was in flagstaff, az during a snowstorm, and the vehicle was failing on me on route 66. It stalled twice on the main highway as the snowplows whipped around me. I got back to where I was staying, and waited until Monday morning when I had it towed to a repair shop and had the cps unit replaced. This engine is unsafe and unreliable. The cps unit can fail at anytime, anywhere, and maybe at any speed, though my issues were at low speed or at startup. Ford will not honor this latest incident because they say after my first replacement in Dec 2007 that my "case was closed in 2007".

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