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I bought this truck new and started having issues in the first year. The dealer claimed they could not replicate the problem. The service engine light would come on when I was speeding up to get on a highway or going up a steep hill. The light would come on as it slipped into the last gear and the truck would shutter and loose power and act like it was going to stall. No backfiring just loss of power. I brought it to a non dealership mechanic after it was out of warranty and he pulled multiple trouble codes for mis fires on random cylinders. These were the only codes recorded so I guess the dealership forgot to tell me this. My Mechanic did a complete tune up and then replaced the fuel injection system(spider) with a new one(new style). It seamed to solve the problem for a while but now it is even worse than before. What could the problem be?

well i have good news and bad news. I also have a 2002 savana with the 5.7l engine and have had the same problems for the past year. I have replaced plugs, wires, cap and rotor with no appreciable improvement in the performance of the engine. The scan tool indicated an injector problem, so i replaced three injectors and had the rest of the fuel system serviced...no  change. Scan tool now indicate Emmision control module, it was replaced. No improvement. I spent 4 hours at a  local dealership having the system rechecked. After an additonal $450. on top of the $1200 I have spent over the last two months, the problems have finally been diagnost as sticking valves. There is a little known service bulletin that describes the condition and the related fix

the bulletin #1539013 outlines the following:

The vehilcle  may exhibit a SES Light due to a P0300 and misfire. If the misfire is related to the information below, it will typically happen while cruising uphill, pulling a trailer or on hard accelleration and then stop misfiring shortly after returning toan idle. Typically cylinders 3,4,5 or 6will be the ones to experience this.

Recommendations/instructions:

Remove the valve cover, valve springs and valve seals on th eeffecrted cylinder  or cylinders. A small wire tie or elastic band in the can be placed in the valve stem keeper groove to prevent the valve from falling in the cylinder. Rotate the while moving it up an down in th eguide to see if it binds. If a binding valve is found, remove both cylinder heads and have the valve stem clearence increased to 0.002 inch per guide.

 I am releave to finally have the situation under control, even though it will cost an additional $1000/head to have the repair completed.

Hope this helps your situation.

hrmm, the only other thing i can think of is that you bought bad fuel with too much ethenol in it. If this is the case your fuel injectors will be stuffed and need replacing, apart from that I'm running out out ideas myself. Good luck

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A much cheaper solution is the put injector cleaner in the gass and oil. The engine rep at the factory says TEXRON ois the only one to use. This frees up sticky valves and worked for me.Paul5.7