Checking Your E350 & E450 For Power-Robbing Mistake

[ron_dittmer]

There is one thing you will want to check for on your E350 or E450, something that will rob power and reduce your fuel economy. It is a very easy mistake for a mechanic to reassemble incorrectly, and it is very easy for you to inspect for.

Make sure the large black flat engine air inlet piece is assembled over the radiator properly. It is the piece that the oval air inlet from the air filter snaps into. In cleaning out a dead bird from my a/c condenser, I had to remove that large black plastic piece, held in with 4 plastic push-pins. If the back-side hidden hinged plastic part is positioned incorrectly when installing it, air for the air filter to the engine's throttle body will be severely restricted.

There was a recall around 2010 concerning that piece. Apparently a Ford line worker misunderstood it too. I can easily see a good mechanic making the same mistake. I almost did it myself had I not previously known of the problem.

To check is extremely easy, takes all of about 5 seconds. Just grab the oval engine air inlet to the air filter, give a jerk upward to unsnap it and continue pivoting upward. Then look in the hole it was snapped into. If you see a black plastic obstruction, you need to take that large piece out and swing the hinged plastic piece on the back side of it in the opposite direction, then reassemble.

[gordhog]

Here is a link to the official TSB from Ford:

https://www.revbase.com/BBBMotor/TSb/DownloadPdf?id=169332

Hope this helps. I discovered this problem personally on my 2010 E450. Properly moving the flap solved it.

Mike

[pnichols]

I just ran across this article (from a Lazy Daze info page) on a Ford service bulletin that confirms the reason for Ron opening this discussion: http://lazydazearticles.blogspot.com/search/label/Engine

Many thanks Ron for alerting us to this!

I'm going to check my V10's air filter intake system as soon as possible.

[ron_dittmer]

j-d,

I don't know which model years the air intake assembly was designed for. Maybe earlier model years don't have such a thing. Maybe later don't either. Still it was worth checking. Glad your rig is fine.

Ron

[OFDPOS]

Talked with a 23 year ford tech , last 15 years in drivabilty ,he said their little trick was to remove the plastic cover that attaches to that very oval restrictive inlet piece and the other half connects over the cone filter.

If you turn it upside down it has a small drain hole for water to drain out.
He said they took a 3/4 inch hole saw and made about 4-5 more holes.
Sucks a little more air in , instead of just coming through that restrictive oval inlet section...

[j-d]

Looked at ours today, 2002 E450 V10. Nothing apparent when I popped the rectangular scoop off and looked into the piece attached with four pins, so I completely removed it. All this one has is a permanently attached deflector that seems to attach only one way. Anyhow, didn't seem to be a restriction.

[pianotuna]

Thanks Ron,

Any chance of a picture?