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E450 Maintenance list and repair
Good Morning and Happy New Year!!! Thank you to all of the members here for an open, honest, non-judgmental place to go for such input. Love this forum and its been one my the positive finds for 2020!!

Thinking about getting my maintenance scheduled and caught up before taking a trip from WI to NC in April.

I am looking for a comprehensive list of scheduled maintenance on my engine / chassis. Would like to have a list and do some homework on what needs to be done before I call the shop  - instead of just calling to ask them to get it ready for a trip. I tried to search though the forum but didn't find specifics. If I missed something and there is a link - please send.

History - I bought this rig last April and drove it from Phoenix to Wisconsin. I had it inspected twice in Phoenix before purchasing and nothing was found to be out of order. But, I definitely feel there has been some deferred maintenance. 

When I got it back to Wi - I had the oil changed, new oil, air, and fuel filters. Replaced rear brake pads and calipers, replaced steering stabilizer. Rotated tires. I asked them to check the emergency brake reservoir mentioned in the forum and they said it was all good. I attached the invoice here too.

There is still a distinct "clunk" / "chunking" sound when pulling to a stop. Usually within the last few feet before halting. I can feel it in the brake pedal and steering wheel. It happens maybe 95% of the time. The shop didn't see anything wrong on inspection and dismissed it as this rig isn't going to drive like a car. Hmmm... thoughts?

and, since I have had it in garaged storage - have noticed a slow leak underneath engine - we think its transmission fluid - hopefully just a hose / clamp. see pic. Its almost mid engine but slightly toward passenger side (see pic with ice cream pail to catch drip).

Previous owner placed labels with previous mileage and service dates. We are now at 57,000 miles.
Transmission flush, Brake fluid flush / change, and Power Steering fluid change @ 34,000 in 2012

I am looking to properly update all maintenance but not be taken for a ride. I think these guys did an ok job but don't have any reference. Also, they didn't mention needing to change any of these fluids again... I am not dedicated to this shop and have a recommendation for another near by.

Other stuff - generator isn't working - stays on for 15 minutes then putters out. Truck repair place thought replacing the truck fuel filter might help. Improved but didn't fix it. Then RV shop guy thinks its overheating and suggested taking it to Cummins Sales and Service in DePere WI.  Yet to figure that out.

Thanks for any / all input. Hoping to get a plan together and maintenance repairs done well before April so they can be tested before trip :)

I am not able to upload attachments right now - attempted in Chrome and Firefox - anyone else having issues?  Will try again later.
Jodi, Kevin, and Lincoln (the crazy doodle dog)
2011 TK - also the "DogHaus"- adopted October 2023
2000 30IB - the "DogHaus" - adopted April 2020 - rehomed October 2023
Re: E450 Maintenance list and repair
Reply #1 –
This is the basic maintenance list for a 2000 E-450 with 57000 miles:

https://owner.ford.com/tools/account/maintenance/maintenance-schedule.html

If the service is not on the list linked above - or you've already had it done - you might also consider having the following checked and/or repair/ replacement services done, particularly since you suspect deferred maintenance or if the services were done some time ago, e.g., 8 years ago per your list. I suggest following the recommendations for fluids and parts listed in your Ford manual.

Change the engine coolant.
Flush and replace the transmission fluid (and check for leaks!)
Flush and replace the brake fluid.
Replace the serpentine belt and check the tensioner.
Re-pack the wheel bearings.
Inspect the U-joints and carrier bearing.
Replace the differential fluid.
Check and/or lube the front end components, particularly the ball joints.
Check the shocks and shock bushings.
Carefully inspect the tire sidewalls, including the inside duals.

You will likely receive additional suggestions, but the above should provide a "starter list".  :o

As always, YMMV.

2003 TK has a new home
Re: E450 Maintenance list and repair
Reply #2 –
The list above is great for almost any rig.  Here are a few suggestions based on what you describe along with some common issues that many 2000 era owners have faced.

(1) Clunk when stopping - a substantial clunk isn't normal.  Something is likely loose and/or worn out.  I'd have a reputable mechanic used to vehicles this size drive it and take a look.  I would do this sooner rather than later.

(2) Brakes.  Fluid - if it hasn't been flushed since 2012, it's past time.  If the front brakes haven't been worked on, I would at least look at them and lube the caliper slide pins.  It's good that the rears have been serviced.

(3) Generator - if you're not aware of the infamous small section of decaying fuel line, you should be (lots of good info in the archives).  There is a short section of fuel hose on top of the tank (hard to reach), that decays and lets air in.  It's one of many things that could be causing your 15min run problem, but even if it's not the only item, it's very worth investigation on a 2000.  Most rigs of that vintage have had to address the issue.  Most of us address that at the same time as replacing the fuel pump.

(4) Spark Plugs - that age of engine is known for occasionally blowing out spark plugs.  Even though you're not due via mileage, I would consider having the plugs replaced by a mechanic who is familiar with the V-10's from that era replace them if you plan to own the rig for a good long while. 

No ideas on the leak, but obviously that's something to look into.  I would probably change the transmission fluid as well.

Rich
2003 MB
Re: E450 Maintenance list and repair
Reply #3 –
Hi Jodi,  do you have the Ford chassis manual for your LD?  There should be a maintenance list there, as well as online.
Greg & Victoria
2017 Mid-Bath  “Nocona” towing a manual 2015 Forester
Previously a 1985 TK
SKP #61264
Re: E450 Maintenance list and repair
Reply #4 –
"Clunk when stopping - a substantial clunk isn't normal.  Something is likely loose and/or worn out."
---
On review of the list posted above, I forgot to include checking the tie rods as well as the ball joints; loose/worn tie rods can be "clunky".

2003 TK has a new home
Re: E450 Maintenance list and repair
Reply #5 –
Quote from: Joan  - 
"Clunk when stopping - a substantial clunk isn't normal.  Something is likely loose and/or worn out."
---
On review of the list posted above, I forgot to include checking the tie rods as well as the ball joints; loose/worn tie rods can be "clunky".

-A badly worn ball joint or a loose brake caliper, along with other things, can make this noise,

-The driver's side top shock bushing commonly loosens and can make a lot of noise, the rubber may be totally gone.

-I would suggest changing all the fluids and start fresh. The radiator and brake fluid can be tested with test strips.

-Rich's suggestion the generator fuel line has rotted is my guess too, I have seen many LDs of this vintage with the same problem.
Replacing the fuel line requires either partially dropping the fuel tank or total removal to access the line. If the tank is removed, change the rubber emission lines, they rot over time. It also a good time to change the fuel pump, there are known problems with them in this vintage.

 -The front wheel bearings should be check for fresh lube and proper adjustment.

 -Change the spark plugs, as Rich mentioned. We had a spark plug blow out of our 2003, which destroyed the engine.

 -Verify the transmission mounted parking brake's fluid is topped off. 99% of mechanics are unaware of it, it is not a common item and it can not be easily seen. Failure to maintain the fluid level can lead to the parking brake failing, repairs run from around $1500 to over $8000, if the unit seizes and tears the end of the transmission housing off. It has happened.more than once.
Print these photos and take them with you to show the mechanic where the oil fill hole is. Odds are the mechanic has never seen one and will have no idea where it is, transmission parking brakes were common 80 years ago.
Parking brake oil fill | Flickr

 -The radiator and heater hoses have timed out and should be replaced, along with the serpentine belt, if none have been previously replaced.

 -Are the tire less than six-years-old?

 -How old are the batteries?

Next, the seals on the coach need to checked and renewewis necessary. The roof should have been resealed by now. Beisides the roof, the end caps and window frames may need sealing

Yes, you may be looking at a good chunk of money but if you want a dependable rig, it must be spent, it is twenty years-old.

Good luck and happy camping
Larry

Larry



Larry
2003 23.5' Front Lounge, since new.  Previously 1983 22' Front Lounge.
Tow vehicles  2020 Jeep Wrangler Rubicon, 2001 Jeep Cherokee
Photo Collection: Lazy Daze
 
Re: E450 Maintenance list and repair
Reply #6 –
Larry, confirming the transmission mounted parking brake fluid issue only applies to the pre-2008 chassis?
Greg & Victoria
2017 Mid-Bath  “Nocona” towing a manual 2015 Forester
Previously a 1985 TK
SKP #61264
Re: E450 Maintenance list and repair
Reply #7 –
Quote from: HiLola  - 
Larry, confirming the transmission mounted parking brake fluid issue only applies to the pre-2008 chassis?

In 2008, Ford upgraded the E450 with a new rear axle that has an integral parking brake, eliminating the transmission parking brake. At the same time, the front and back brakes were increased in size and the GVW increased from 14,050-lbs to 14,500-lbs.

Larry
Larry
2003 23.5' Front Lounge, since new.  Previously 1983 22' Front Lounge.
Tow vehicles  2020 Jeep Wrangler Rubicon, 2001 Jeep Cherokee
Photo Collection: Lazy Daze
Re: E450 Maintenance list and repair
Reply #8 –
Quote from: HiLola  - 
Larry, confirming the transmission mounted parking brake fluid issue only applies to the pre-2008 chassis?

In 2008, Ford upgraded the E450 with a new rear axle that has an integral parking brake, eliminating the transmission-mounted parking brake. At the same time, the front and back brakes were increased in size and the GCVW increase from 14,050-lbs to 14,500-lbs.

Larry
Larry
2003 23.5' Front Lounge, since new.  Previously 1983 22' Front Lounge.
Tow vehicles  2020 Jeep Wrangler Rubicon, 2001 Jeep Cherokee
Photo Collection: Lazy Daze
Re: E450 Maintenance list and repair
Reply #9 –
Thanks for all the input!! I organized a list from the above suggestions and came up with a few more questions.. Questions listed first and then the list.
Will need to find a worthy mechanic. ugh.
Any ball park cost estimates??

If I have to get the fuel tank lowered / dropped to access the line for the generator - is it a regular mechanic or the onan repair people that do this? And, are the rubber emission lines mentioned part of the engine or generator?
Is there a way to tell if spark plugs have been replaced already?
Does transmission mounted parking brake's fluid need to be drained / replaced or just topped off?


Ok - here is the compiled list from your suggestions above. Please feel free to suggest additions or clarifications.

Fluids -
replace brake fluid, transmission fluid, rear differential fluid, engine coolant / radiator fluid, transmission mounted parking brake fluid

Engine-
Replace the serpentine belt and check the tensioner
Replace spark plugs
Replace fuel pump (when fuel tank lowered for generator hose replacement)
Replace radiator, heater hoses, serpentine belt

Brakes-
Brake fluid flush
Inspect all brake components - replace as needed
Lube caliper side pins

Suspension / steering-
Re-pack and lube the wheel bearings.
Inspect the U-joints and carrier bearing
Check and/or lube the front end components, particularly the ball joints
Check the shocks and shock bushings - The driver's side top shock bushing commonly loosens
Inspect / replace tie rods and ball joints

Tires -
Date 2016
Replace - within next 1-2 years

Generator -
Replace fuel line ( partially dropping the fuel tank or total removal to access the line )

Coach battery -
New 2016

At the end a pretty picture to top it off. A reminder that it is all worth it!!

Thanks guys!! J
Jodi, Kevin, and Lincoln (the crazy doodle dog)
2011 TK - also the "DogHaus"- adopted October 2023
2000 30IB - the "DogHaus" - adopted April 2020 - rehomed October 2023
Re: E450 Maintenance list and repair
Reply #10 –
It's not possible to "ballpark" a figure for all of the listed/suggested services; the cost will depend on the labor and parts charges at the shop(s) who do the work. You'll want to vet local shops carefully for experience and knowledge of Ford engines and systems and overall quality of service, of course; you might start with a Ford truck center - if there's one near you - and/or find out which shops service your local (Ford-platform) ambulances and city/county service vehicles. If you can find an independent shop with mechanics who know Ford "trucks" and perform high-quality work at reasonable prices, great; review websites, e.g., Yelp, can sometimes be helpful. I suggest visiting shops that might be possibilities and talking candidly with the service manager (in a smaller, independent shop, that's often the shop owner) about the services needed.

Finding competent, experienced, knowledgeable service can be a difficult process, but I wish you good luck in doing just that. 
2003 TK has a new home