This is an old revision of the document!
[note from Secessus – this page is updated as I find verifiable information. Problems listed (or not listed) below do not mean one is better than the other. I may have researched some more than others so far. Truly, I don't care what van you buy and live in. It's your home, not mine.]
All vans have issues
Everybody thinks their pet van is the best, and that all others will drain your wallet and/or leave you to die a gruesome death on the side of the road. As has been observed in a different context:
That is the way of us chili men. Each of us knows that his chili is light years beyond other chili in quality and singularity; each of us knows that all other chili is such vile slop that a coyote would turn his back on it.
1)
In actuality, all vans have issues. The challenge is to find a van that meets your needs, not to find some mythically perfect unicorn that was designed directly by god, never breaks, never needs maintenance and runs forever on one tank of gas and one crankcase of oil. It's like dating: find a van whose weirdnesses don't bother you, and that you can personally live with.
On the likelihood of problems
Only a small percentage of failures occur on any particular vehicles; it's not like “this is guaranteed to happen to you!” It's more a list of things to look for, to be aware of. Forums and complaint sites list tons of problems because people with problems are more likely to post. It is rare to see a post saying “drove my van for a year and nothing happened!”. Beware of people who claim “the [fill in the blank] forum is full of unhappy owners!!!” without mentioning unhappy owners of their vans on their forums. Forum links are included below for further research.
With that being said, use extreme caution with modern Diesel engines. Tightening emissions requirements have lead to extremely predictable (and expensive) repairs.
Timely maintenance is likely to prevent or lessen the impact of the issues listed below. If your van has recalls or TSBs, try to have it fixed under warranty while it's still free.
You may also want to think about Total Cost of Ownership or average annual repair costs.
Chevy Astro
The Astro/Safari have a cult following due to their mid-size and available AWD.
Learn about this van on the Astro/Safari forum
steering knuckles that cut ball joint boots
2)
door handles break off
1998-1999 particularly hard hit by transmission valve body failures
3) “Less common problems are the failures of the transmission's fluid pressure (TFP) switch, failure of the transmission's “reaction sun shell” and failure of the transfer case shift motor.”
power locks fail: “grease them once a year with lithium spray in grease. The rear door lock may be fixed by drilling a hole through the piece of zinc to repair the piece that broke off.”
4)
power windows fail - switch failure?
ABS controller failure
rough idle or misfires: “problems with the spark plugs, ignition systems and poor vacuum seals have been implicated in some cases”
5) “Get a good [distributor] cap with brass contacts.”
idler/pitman arm failure
transmission output seal failures
intake manifold gasket leaking oil or coolant
1984-early 1985 models may have oil pressure idiot light incorrectly wired to CHOKE indicator
fuel pump failure – earlier than normal fuel filter changes may help alleviate
P1870 This can be caused by wear of the bore for the TCC isolator and regulator valves in the valve body.
alternator failures
Chevy Express / Savanna
Transmissions are regarded as generally good, with lifespans like 120,000-180,000 miles on the 4-spd auto 4L80E and 130,000-200,000 miles for the 6-spd 6L90.6)
Learn more about these vehicles on the Express/Savanna subforum.
Chrysler Pacifica
the Pacifica has historically been slightly oversized in order to “package protect” (preserve space for) for AWD which finally came out in 2020.
10)
2004-2008 rust, especially in the engine cradle area
11)
TIPM issues, as with the other FCA minivans since 2008.
approx 15k 2007 (?) models had faulty torque converters, causing shuddering while driving. Sometimes described as “like driving over rumble strips”.
hard shifting
some 2017 have engine vibration due to incorrectly-drilled balance shaft
12)
2017 hybrids may have defective inverter (recalled)
Dodge B-series
Made from 1971 - 2003, and hardly changed in the interim. This can be a good thing, as known issues are stable over time. It can be a bad thing in that deficiencies are not addressed over time.
Dodge Caravan / Town & Country
Ford E-Series
Ford E-Series specific article
Generally very reliable, and 250,000+ miles can reasonably be expected without any major repairs. Relatively easy to work on and fix for the few things that do break. The exception being the diesel engines, however this problem is not limited to Ford.
The 6.0L and 6.4L diesel engines can have problems
This is the exception to the line at the beginning of the article that said “Only a small percentage of failures occur on any particular vehicles”. The failures rate on these engines is 100% once the vehicles reach 150,000 miles. These engines should be avoided at all costs, no matter how inexpensive the van is. Especially on vans that have spent a lot of time idling (ambulances), $5,000+ repair bills are a guarantee.
The International VT365 (rebadged as Ford 6.0L Powerstroke)
14) was put into the 2004-2010 model year Ford E-Series vans/chassis. It has the reputation of being
one of the worst engines ever used in a commercial vehicle.
The 6.4L Powerstroke was slightly better than the 6.0,
but not by much. Vehicles using it are considered “throwaways” once they hit 150,000 miles.
Easy to steal
A flat-head screwdriver and
maybe a hammer is all that's needed to punch out a door lock, and there's no computer chip in the keys so if someone can turn the ignition cylinder by force (again not hard, screwdriver and maybe pliers), the engine will start. It is
highly recommended to install a hidden kill switch (the start relay and/or fuel pump relays are popular), and to reinforce your door locks with kits such as the
Jimmy Jammer.
Ignition coils/packs failure
E-150 ball joint failure
The E-150 was generally very under-built for its weight
spec, and other brake/suspension repairs are common
leaking cylinder head gasket
HVAC Blower motor problems
The blower motor resistor can fail every 3-4 years. Symptom is that the HVAC fan only works on one speed (usually high). Replacing it is cheap and
takes ~45 minutes.
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This applies to all of the gas engines that were installed in the entire range of Econoline vans from 1997-2008.
Replacing spark plugs on these engines is a delicate process due to the limited threads. It should be done using a very accurate torque wrench, they should be torqued to the Ford specification.
2V engine sparkplug issues may be addressed with Calvan kit or Timesert kits. tstechmind recommends the Calvan design.
16)
5.4L V-8 can experience oil pan gasket leaks. The part costs ~$20 but replacement runs about $1000, due to requirement to lift the engine.
4R70E 4-spd transmission (found behind the 4.6L V-8 gas engine from 2002-2005)
While it's reliable in light usage, the transmission is generally “weak” and under-sized for the load application. It's advised to not do any towing with this transmission, and to keep build-outs as lightweight as possible.
2005 – 2006 E-150 w/4R75E
17) Transmission can experience slipping. Replace forward clutch drum and update ECU with program 06B06.
Sticking solenoid regulator on 4R100
18) Transmission (P0715, P0716 & P0717)
1996-2001 2v Tritons may have a nylon intake manifold that can crack and leak.
19)
2011 - 2013 5.4L 2V and 6.8L 2V Engine – Excessive Engine Oil Consumption (valve seals)
20)
Common problems on Ford engines not installed in vans, but might be in RVs and Trucks. (All van engines are 2-valve, not 3-valve).
2004-2007 3-valve 4.6L, 5.4L and 6.8L can experience spark plug breakage or head damage during removal.
21) Changing at 50k miles instead of the stated 100k and using anti-seize may help prevent seizure.
2004-2011 3-val 5.4 Tritons with Variable Valve Timing can have timing chain, tensioner, or cam phaser issues – listen for noises at startup.
22),
23),
24)
Ford Transit
Ford Transit article
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Warped exhaust manifolds
The cast iron exhaust manifolds only use 8 studs to attach to the engine, and are prone to warping/cracking. While Ford did not issue an official recall, they did update the part to a new Stainless Steel part that uses all 9 stud holes on the block. Transits built after December 2020 use the new part.
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Attempting to re-use the rear axle bolts after replacing or servicing the rear brake rotors will result in them breaking and
the axle taking a
horizontal exit from
the van.
Not so much a design problem, but the result of a common mistake made by inexperienced mechanics (even Ford Dealership techs). Removing the rear brake rotors for replacement or resurfacing requires pulling out the axle, but the five bolts holding the axle in are single-use. Like head bolts, they stretch upon install and have to be replaced every time. Trying to re-use the bolts will result in the failures described above.
Transmission filter cannot be accessed for normal service; requires removal of front subframe which may be difficult due to seized bolts. Normal service is done by a fluid exchange machine at the Ford dealer.
Ecoboost carbon fouling on intake valves
Direct-injected engines like the EcoBoost can experience
carbon build-up on the intake valves. Although uncommon in normal use, it could be more common for vandwellers due to
idling for long periods to
charge from the alternator. This requires removal of the head to address:
“The only Ford-approved course of action at this time is to replace the cylinder head, although “Manual cleaning with a brush and various carbon dissolving products has been used with great success on vehicles out of warranty.”
25)
Ecoboost shuddering from plug fouling (see above)
Windshield gutter runoff can flood airbox –
workaround.
Speed sensor failure causes limp mode
Water can drain on ECU plug; diverter installed at some point per Customer Satisfaction Program 15B39.
Workaround using iced tea jug.
Cabin leak near passenger footwell
Transmission solenoid failure (SSM 45065) requires removal of transmission.
Heater core failure - TSB 18-2172. Flushing with
Prestone Cor-Guard and refilling (as in the TSB) may be good preventative maintenance.
Leaking roof rack mount plugs
26)
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TSBs
2015 Transit – Interior High Intensity LED Cargo Lamps May Emit A Low Glow When They Should Be Off – Built On Or Before 4/22/2015
27)
Body panels detach from interior bracing
Ford Transit Connect
Ford Windstar
Honda Odysssey
Mercedes Sprinter
Mercedes Sprinter page
Autel MD802 code readers are often recommended for those that do their own maintenance.
In general, the (before 2010) T1N models are simpler and often preferred for field maintainability.
Body rust issues until 2017 (?) - Metallic colors may have received better clearcoat.
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T1N: glow plug seizure in cylinder head
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Service may be difficult to locate. When found the parts and hourly rate are expensive, particularly at M-B dealerships.
Nissan NVx500
V8 + auto shifting issues (usually late shifting/slipping)
V8 #3 plug fouling from oil leak in valve guides or elsewhere - no clear info yet.
P0441, P0455 codes caused by gas evap sensor pulling out of the charcoal canister
34)
P0448 code caused by dirt clogging evap valve/solenoid/canister, possibly due to vent location in wheelwell.
Possible workaround: blow out with air, reset code.35)
Nissan NV200
The NV200 is rated as the most reliable cargo van (any size).39)
Learn more about this vehicle on the NV Forum.
RAM Promaster
Learn more about this vehicle on the Promaster forum or the Promaster article.
use of non-
spec transmission fluid can cause failure, with Dexron II being the worst offender.
44)
spark plug changes must be done with care to avoid damaging the spark plug carriers “tubes”
45)
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2014 model known for squeaking brakes, sticking parking brake
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marker lights leaking
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the small bolts on the intake plenum can rust and seize.
46) Solutions include waterproofing the bolts or cutting and installing an engine cover
47).
a plywood or other load-spreading subfloor should be installed to prevent fatigue to metal floor. At least two cases of floor damage have been reported when the floor was repeatedly flexed in the same area.
the odometer cannot record more than 1 million kilometers (~620,000 miles)
48)
diesel version transmission disliked by many
steering wheel is bus-like and not tilt-adjustable
seating is high
6th gear is very high for MPG purposes; the PM will downshift to 5th on minor grades
some fuel pumps shut off frequently while fueling the vehicle
if the transmission-to-frame ground is loose it can affect the ignition interlock
49)
RAM Promaster City
recalls
ram promaster city vans manufactured september 26, 2014, to march 5, 2016. a low-voltage electrical harness connector by the front driver seat may be susceptible to water intrusion and corrosion.
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Toyota Sienna
oil sludge buildup requiring engine rebuild or replace
V6 3.5L engine may have a faulty oil line causing sudden oil loss.
50) LSC-90K
3.5L 2007-2010 gen2 vans with the tow package may have a faulty oil cooler line.
51) TSB-0201-11, Warranty Enhancement Program ZE2.
broken weld in door
52). Symptoms: failure to close or lock, noises.
2004 - broken side door cable
53)
VSC, Trac, and other dashboard lights may indicate misfire, leaking gas cap, emisssions, or steering rack
54) issues.
On 1st Gen Siennas, the Integration Relay (“yellow box”) can fail, causing difficult to diagnose electrical issues.
misc
most reliable
The most reliable van with lowest upfront cost, longest warranty, and lowest annual repair costs outside warranty appears to be the full-size Nissan NV or its minicargo sibling NV200.
Since only a tiny minority of 'dwellers own those vans we can deduce that absolute reliability is not the driving factor in our van-buying decision, no matter what we say.
lowest total cost
The cheapest vandwelling solution in terms of purchase price and yearly maintenance appears to be a used Dodge Caravan.55) They are cheap on the used market and even though they are not paradigms of reliability they do have low repair costs. The Town & Country variant is fancier so costs more and has more options to break.
Since only a tiny minority of 'dwellers own those vans we can deduce that absolute cost is not the driving factor in our van-buying decision, no matter what we say.