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Van purchased in 2015, suffers from poor steering tracking, following ruts, requiring constant two handed steering corrections. The steering wheel would not return to center on it's own coming out of a turn. Extreme wind effects and from passing vehicles, van will move out of lane. Requires constant steering corrections even on flat smooth roadbed with no wind.

New rebuilt steering box installed 2015 by Ford shop during a long trip. Reduced the steering slop compared to the original box. Still drove bad.

Helwig large heavy duty sway bars and Bilstein shocks personally installed on both front and rear in 2016. Incredible improvement in handling in corners and low speed turns. Also installed a new OEM steering stabilizer and bracket on front end. Van still had tracking and wind problems on the freeway. Next step was to increase the positive caster on the front axle.

Adjustable eccentric aftermarket two piece bushings were installed on front axles for top ball joints, and caster increased 4 degree positive, from 3.2 to 7.3 degrees, to vastly improve steering tracking, and return to center after turns. Wind and rut tracking effects were greatly reduced. The van would go down the road like it should and not wander on it's own or with the wind.

The result was huge improvements in tracking and reduction of wind effects, reduction of steering input required to drive comfortably on the freeway by increasing the caster to maximum. The test drive was the first time I could totally relax and drive one handed with this van at speed. The van stayed going straight, and now returns to straight on it's own (returns to center). Slight remaining wind effect from passing vehicles currently, but easily managed.

Brand new 2016 complete E350 takeout front axle installed in early 2017 by John at Quadvan in Portland. Larger new front rotors, calipers and radius arms with new frame mounting bracket, all OEM design of 2008. New Twin I Beam axles and knuckles, all as taken out of the 2016 van by Quadvan.

The new larger 2016 calipers required new 2016 takeoff OEM steel wheels all around and for the spare, mounted up with new Michelin Defender LT245R16 tires to replace worn, aged, under rated stock LT225R16's. (Original tires were not causing problems). Again from Quadvan, brand new takeoff wheels and covers.

The improved braking capacity with the larger rotors was worth having this brand new front end installed alone..... Brake caliper clicking, clunking from original calipers, due to wear at the knuckles was eliminated, making wife happy.

A new Spicer Trac-Lok limited slip rear differential was installed in December 2020 for possible snow on a trip.

Michelin Agilis LT245R16 tires were installed new in December 2020 for possible snow on a trip. Mounted on black Plastidipped OEM E-Series 5 slot aluminum wheels. What a great tire the LT Agilis is. Noticeable improvements in smoothness, ride quality and quieter ride at speed. Add the snow rating as a year round tire plus. These improvements were noted compared to the relatively new Michelin Defender II's prior, another good tire, but not as good.

Next project is replacing rear axle with a 2008 donor Dana 60 full float, complete with the brand new in 2008 upgraded larger 13.58 inch rotors and calipers that have become standard up through the current E350's. This axle will have a new Eaton Truetrac helical gear (no discs) limited slip differential, maintaining the original 3.73 gears. Housing will be bored for the original anti lock braking single sensor.

Axles will change to Dutchman 36 spline heavy duty to mate with the Truetrac. Work is started on the housing, most new parts are in hand now, including the TrueTrac. When installed, the braking capability should see another marked improvement over the original rear drum E250 brakes. Rear leaf springs and shackles will be replaced during the install. A rear track bar is being fabricated as well.

The 1992 was the first year of the 4th generation of the E-Series vans. The frame rails were widened, and the front end was changed from a kingpin based Twin I Beam axle assembly to the new Twin I Beam with upper and lower ball joints, including adjustable / replaceable eccentric bushings for the top ball joints. This improvement allows for adjustment of caster and camber alignments, compared to the old fixed kingpin design. A huge step forward at the time, and continued currently, with brake upgrade and radius arm design improvements.

As explained above, taking the caster up to 7.5 degrees positive is within the Ford specs. With the 4 degree fully adjustable aftermarket bushings, that can be achieved or approached, easily. Replacing them can be done if one has some skill and tools. Self alignments can be done. Finding a good shop to do what you want is often a challenge, I did the work myself, then had a good "old time" shop verify the final alignment numbers I had measured.

With the suspension and alignment improvements to the van it is a joy to drive one handed when desired now. A huge improvement...