2003 Ford Econoline Service and Repair Manual

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Factory-Grade Data

2003 Ford Econoline service and repair manual — a detailed, factory-style reference for maintenance, diagnostics, and repair. Use it to confirm correct procedures, specifications, and system coverage before you start work.

Built for technicians and DIY owners, this manual helps you troubleshoot accurately, follow step-by-step repair procedures, and use wiring diagrams and system sections to diagnose problems faster.

What’s included

  • Step-by-step repair procedures and service information
  • Specifications and reference data (where provided)
  • Electrical coverage with wiring diagrams
  • Coverage across key systems: engine, transmission, brakes, steering, suspension, HVAC, and more

Trims covered

  • Base Standard Cargo Van 3-Door

Engines covered

  • 4.2L 256Cu. In. V6 GAS OHV Naturally Aspirated
  • 5.4L 330Cu. In. V8 GAS SOHC Naturally Aspirated

Index / Table of contents

  • Body
  • Brakes
  • Chassis Electrical
  • Driveline
  • Engine Cooling
  • Engine Electrical
  • Engine Mechanical
  • Engine Performance & Emission Controls
  • Fuel System
  • General Information & Identification
  • Heating, Ventilation, & Air Conditioning
  • Hybrid & Electric Vehicle Systems
  • Steering
  • Suspension
  • Transmission, Clutch, & Transfer Case
  • Wiring Diagrams

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Vehicle Safety Data

2003 Ford Econoline Recalls & Complaints

NHTSA #09E02500011/05/2009Component: EXTERIOR LIGHTING:HEADLIGHTS

DOPE, INC. IS RECALLING 42,540 COMBINATION CORNER AND BUMPER LAMP ASSEMBLIES OF VARIOUS PART NUMBERS SOLD FOR USE AS AFTERMARKET EQUIPMENT FOR VARIOUS PASSENGER VEHICLES. THESE HE

Consequence

DECREASED LIGHTING VISIBILITY MAY RESULT IN A VEHICLE CRASH.

Remedy

DOPE, INC. WILL NOTIFY OWNERS AND OFFER A FULL REFUND FOR THE NONCOMPLIANT COMBINATION LAM

NHTSA #09E01200007/04/2009Component: EXTERIOR LIGHTING

SABERSPORT IS RECALLING 16,270 COMBINATION CORNER AND BUMPER LAMP ASSEMBLIES OF VARIOUS PART NUMBERS SOLD FOR USE AS AFTERMARKET EQUIPMENT FOR VARIOUS PASSENGER VEHICLES. THESE HE

Consequence

DECREASED LIGHTING VISIBILITY MAY RESULT IN A VEHICLE CRASH.

Remedy

SABERSPORT WILL NOTIFY OWNERS AND OFFER A FULL REFUND FOR THE NONCOMPLIANT COMBINATION LAM

NHTSA #03V28200005/08/2003Component: FUEL SYSTEM, GASOLINE:STORAGE

ON CERTAIN CUTAWAY CHASSIS CAB WITH THE SCHOOL BUS OPTION, TWO BRACKETS AND TWO OUTRIGGER MEMBERS ARE MISSING IN THE AREA OF THE FUEL TANK.

Consequence

THE BRACKETS AND OUTRIGGER MEMBERS ARE INTENDED TO ENHANCE CRASH PERFORMANCE.

Remedy

FORD WILL SEND TECHNICIANS TO THE OWNER'S LOCATION TO INSPECT AND ADD THE BRACKETS AND OUT

TSB #10148820

This SKU is a front upper ball joint. The Customer communication requested return of unsold inventory to inspect for ball studs with excessive rotational friction in the ball joint assembly. Excessive friction in the ball joint assembly may

TSB #10096433

MERLIN MULTIPLEX SYSTEM WHEN A PROER/GROUND LUG IS NOT CORRECTLY TIGHTENED OR BECOMES LOOSE FOR ANY REASON; ERRATIC SYSTEM OPERATION IS POSSIBLE.

TSB #10026321

FORD: VEHICLES MISTAKENLY CHARGED $100 POWERTRAIN WARRANTY DEDUCTIBLE FOR FUEL INJECTOR REPAIR OR REPAIRS. NO MODEL OR MODEL YEARS PROVIDED. *PE ECONOLINE, EXCURSION AND F-SERIES SUPER DUTY VEHICLES, MODEL YEARS 2002-2005. UPDATED 10/24/08.

TSB #10013116

MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED - SYSTEM LEAN DIAGNOSTIC TROUBLE CODES (DTC'S) - SERVICE TIPS. VARIOUS MODELS INCLUDING 2004 F-SERIES. *TT

TSB #10013077

VARIOUS 2003 VEHICLES EQUIPPED WITH PREMIUM CD-6 RADIOS - CD-6 SHUFFLE FEATURE BETWEEN DISCS NOT AVAILABLE. *TT

TSB #10008288

LOW POWER, POOR FUEL ECONOMY, FUEL GELLING COLD, EXCESSIVE WHITE SMOKE COLD, OR HARD START. *MJ THIS OASIS UPDATES PREVIOUS OASIS DATED 12/01/03. *TT

TSB #10008195

AIR BAG LAMP ILLUMINATED. *TT

TSB #10007812

EMISSION RECALL 04E10: COMPRESSED NATURAL GAS (CNG) VEHICLES - FITTING CONNECTOR REPLACEMENT. *MJ

Showing the 8 most recent of 18 technical service bulletins on file with NHTSA.

20060216Component: ENGINE AND ENGINE COOLING:ENGINEFire reported1 injured

2003 ECONOLINE MADE A LOUD POPPING SOUND IN THE ENGINE COMPARTMENT, LOST POWER SHORTLY AFTER. VEHICLE LATER CAUGHT ON FIRE. *TS ***NO ANSWER REQUIRED*** AFTER THE NOISE WAS HEARD

20050308Component: VEHICLE SPEED CONTROL:CRUISE CONTROLFire reported1 injured

VEHICLE WAS PARKED OUTSIDE THE OWNER'S HOME. OWNER WAS AWAKENED, AND TO DISCOVERED THAT THE VEHICLE WAS ENGULFED IN FLAMES. THE FIRE DEPARTMENT WAS NOTIFIED AND EXTINGUISHED THE FI

20050412Component: ELECTRICAL SYSTEMFire reported

2003 FORD ECONO-LINE VAN CAUGHT ON FIRE IN THE ENGINE COMPARTMENT.*MR THE CONSUMER HAD THE ABS RECALL REPAIRED IN DEC 2004. THE FIRE SEEMED TO ORIGINATE IN THE AREA OF THE ABS

20161010Component: FUEL/PROPULSION SYSTEM

FUEL TANK DELAMINATION. THIS WILL BE THE SECOND TIME I HAVE TO REPLACE THE FUEL TANK, SENDING UNIT AND FUEL PUMP ON MY E350 DIESEL VAN. FORD HAS HAD KNOWN ISSUES FOR SEVERAL YEARS

Showing the 4 most serious of 27 complaints filed with NHTSA.

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