Diesel Engine Problems of Ford F-250 - part 1

Ford F-250 owners have reported 206 problems related to diesel engine (under the engine and engine cooling category). The most recently reported issues are listed below.

car image   Diesel Engine problem of the 2011 Ford F-250 1
Failure Date: 07/07/2017

7/7/17 - 2011 Ford f250, 6. 7l diesel engine, mileage 79530. (purchased December 2010). I was pulling a small trailer up an incline (8%) on I-64 in wv. On this portion of the interstate there was no emergency pull off shoulder. The truck operated normally for the first 3 miles ascending the hill. During the 4th mile, the truck began to gradually, but progressively lose power, going from 70 mph down to 0. At approximately 30 mph, the truck began to shutter slightly, and continued to do so until it stopped in the lane of traffic and stalled. There were no warning lamps or chimes that went off before the engine stalled. This vehicle is equipped with a �stop safely now� warning, along with many other warning indicators � but it didn�t illuminate. The truck would not restart. I immediately call 911 to report that my vehicle was disabled in the roadway. After being stuck in the lane of traffic for about 10 minutes, I was able to drift the truck and the trailer backwards safely, off of the roadway, into the drainage ditch, after a break in traffic. Upon having it towed to a Ford dealership, I was informed that it was going to need a motor, and it sounded like it had spun the bearings on one of the engine rods. The engine would restart at the Ford dealership, but idled very rough. I confirmed that there were in fact metal shavings in the oil. The fuel was not checked for contamination. This vehicle has been maintained according to Ford�s recommended service guidelines. Because of the cost to me to repair ($16,000 or more), I�ve elected not to continue with diagnosis (at $120 per hour) to determine reason for failure. Again, there was no warning systems active at the time the engine stalled. This was an original owner, personal vehicle, and only towed a trailer on occasion. I have video from dash cam w/audio of this event.

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car image   Diesel Engine problem of the 2017 Ford F-250 2
Failure Date: 04/20/2017

Motorcraft FL-2051-s oil filters are leaking do to improper manufacture, can cause the engine to lose all oil. I have had 2 filters and both leak. They leak around the rolled top of the can. I have more than one picture. This is on the 6. 7 diesel engine.

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car image   Diesel Engine problem of the 2016 Ford F-250 3
Failure Date: 07/09/2016

The trucks diesel engine sporadically shudders/sputters/stalls creating a loss of power and doesn¿t respond to throttle input. The issue occurs sporadically while cleaning the exhaust filter. The vehicle is in motion when this occurs. This has occurred 4 times and it has occurred on city streets and highways. This has occurred 4 times. The dealer has reflashed the software once. It is currently at a Ford dealership for the past 30 days. They stated they are replacing the valves on the left side( head) and may send the head to a machine shop.

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car image   Diesel Engine problem of the 2014 Ford F-250 4
Failure Date: 02/01/2016

Letter from senator burr on behalf of constituent re 2014 Ford f250 fuel system. The consumer stated he dropped the vehicle off at the dealer on January 26, 2015, with a low engine light, water in the fuel separator and a leaking radiator. When the consumer picked the vehicle up on February 3, 2015, the dealer stated the replaced the radiator. While driving on February 7, 2015, the vehicle went into reduced power mode and the reduced power light illuminated. The vehicle was towed to the dealer. An inspection revealed the entire fuel system needed to be replaced. According to the dealer, water in the fuel sensor was unplugged. The consumer stated that would explain why the fuel separator light was on, when he picked up the vehicle.

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car image   Diesel Engine problem of the 2012 Ford F-250 5
Failure Date: 01/22/2016

I have experienced twice now with my 2012 F-250 super duty with the 6. 7 diesel engine. On Friday January 22nd and was similar to a previous event involving a sudden and unexpected acceleration of my truck while in drive. Both instances have occurred from the truck being in a parked position with the engine off. Upon starting the truck and shifting into drive, I begin to pull forward approximately 20 to 40 feet and prepare to stop prior to entering traffic or repositioning. The truck will suddenly accelerate and lunge forward. Fortunately in both instances my right foot is lightly on the break preparing to stop when this happens. I immediately depress the brake with a constant and hard pressure as the truck¿s rpm is in the 2500 to 3000 range and I can feel the truck wanting to surge forward. The first time this occurred I happened to be pulling up behind my son who was in his vehicle and very nearly missed crashing into him. I had to immediately shift into neutral and shut the truck off. On the second occasion I was repositioning around a vehicle when again the truck unexpectedly accelerated and I came with 6 to 8 feet of impacting a concrete light post base. Upon shifting into neutral the truck revved up to approximately 3500 to 4000 rpm and again I shut the truck off. After both instances the truck was restarted and appeared to drive normally. In both cases the service center was unable to identify the cause and related that they did not find any ¿error codes¿ or other electronic recorded events relating to what I have experienced and again the pcm was reprogrammed. The truck is still under warranty and currently has only 20064 miles on it.

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car image   Diesel Engine problem of the 2015 Ford F-250 6
Failure Date: 09/18/2015

2015 powerstroke 6. 7 diesel engine has <15,000 miles. Hammering of engine at all speeds. Lasting less than 8-10 seconds in duration. According to TSB 15-0124 this is a valve and valve guide clearance issue that Ford appears well aware of. Recommending major engine work to possibly fix design flaws. The loss of power during operation is dangerous. Vehicle has been in the shop for this issue. Powerstroke forums across country showing this to be a major issue with the 2015 6. 7 diesel engine with problems starting as early as 4,000 miles.

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car image   Diesel Engine problem of the 2015 Ford F-250 7
Failure Date: 08/31/2015

The vehicle runs rough, shakes violently and pings loudly when the diesel engine goes through the exhaust cleaning process. The vehicle loses power and requires 1-2 minutes to recover. The condition had occurred at various speeds but mainly when traveling 50-65 mph on multi lane highways.

car image   Diesel Engine problem of the 2012 Ford F-250 8
Failure Date: 07/10/2015

Traveling down the highway at 55mph with cruise set and hit brake to turn corner. Engine immediately died with subsequent loss of power brakes and steering--scary because it happened at a critical time while turning a corner on a highway. Absolutely no warning--engine seemed fine prior. Truck would not start. Towed the dead truck to nearest Ford dealer in wellington, KS. High pressure fuel pump failure was the diagnosis. Evidently when this happens, metal filings from the shredded pump take out all the injectors, fuel rail, pressure regulator, and also sends metal filings into the fuel tank via the return line. Ford corporate, not the dealer mind you, claims this failure is a result of fuel contamination in spite of the fact that there are 2 fuel filters and a water separator in the system and they were well maintained. Repairs are estimated at $8000 + and Ford has refused warranty saying it is not their fault. The "fuel contamination" claim by Ford may not even be accurate as their "diagnosis" was made from a picture of the failed part. No fuel tests by Ford were conducted although I did retain a sample of the fuel. No specifics were given by Ford as to what type of contamination either--they just state "contamination". I have no idea if they are talking fluid or solids. Just whose fault is it when the fuel filtering system designed by Ford fails to filter out contaminants? they are denying warranties to thousands of consumers like me, plus they put me in danger with a known issue they fail to take responsibility for--and my government is letting them get by with it. To my knowledge they are continuing to build these 6. 7l diesel engines (it is now August of 2015 as I write this) with the same high pressure fuel pump failures staring the next consumer in the face and pocketbook. Shame on Ford--and shame on the rest of us for letting them get by with it. . .

car image   Diesel Engine problem of the 2008 Ford F-250 9
Failure Date: 03/27/2015

We purchased this 2008 Ford F-250 super duty new at the Ford store in san leandro, CA on July 21, 2007 and continue to be the original owners. This vehicle is equipped with a 6. 4 turbo-diesel engine. This vehicle is subject to TSB 07-26-2 (wiring harness defect on hpfp) issued August 2007. On the morning of March 27, 2015, while accelerating onto a freeway and at an approximate speed of 50 mph, the engine shut down without any warning. I lost all acceleration and the engine died. Braking and steering were also diminished. I got lucky and was able to avoid a collision and coast to the side of the road where the vehicle would not restart. The vehicle was towed to a local repair shop (bud adams - castro valley, CA; bar#:228593 cal#:66801). Diagnosis revealed a short in the wiring of the high pressure fuel pump gasket wiring harness (the subject of TSB 07-26-2 wherein Ford recognized on or about August of 2007 a problem with unprotected wiring within the hpfp wiring harness). Repairs were extremely costly ($3,791. 89 reduced to $2,591. 89) but more importantly this instantaneous failure without warning is going to cause an accident, injury or death; it is only a matter of time. I got lucky. I see other complainants who had hours stuck in the desert, someone with a load of cattle stuck without warning, the list goes on. In each reported instance the operator described an immediate loss of power plant with no warning. I urge the ntsb to investigate these unplanned shut downs of this vehicle's power plant. Under certain circumstances this may lead to loss of control of the vehicle, collision, injury and possibly death. Ford has known about this issue since August of 2007 yet has not issued a recall. Some may say this is due to the large costs involved to remove and replace the hpfp gasket and wiring harness (in part involving the removal of the vehicle's cab).

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car image   Diesel Engine problem of the 2012 Ford F-250 10
Failure Date: 12/15/2014

This is a diesel engine f250. Egt sensor failed and engine immediately shut down in the middle of the road. Cel was on and message said " stop safely now". The failure of the egt sensor was known by dealer and he showed me 2 TSB s on the problem. Problem was fixed in 2 days but the safety aspect of this failure has not been addressed by Ford. A almost immediate shutdown of the engine without warning is very dangerous. In out case we were in town on a side steet but what if this had occurred on the interstate or going up or down on a mountain road or towing a trailer, etc. . We do all this and now that we know we have a over protective computer waiting to kill the engine at its whim we feel much less secure. The computer should give adequate warning before a shutdown and probably should include a limp home option.

car image   Diesel Engine problem of the 2012 Ford F-250 11
Failure Date: 11/16/2014

After driving for 5 monutes a warning light came on for the rear locking differential- no change in the drivability. About 5 minutes after that the computer started flashing different symbols indicating many problems- the alarms were going off non-stop- then the engine was shut down by the computer. This truck is heavy and I may have caused an accident when it happened because I had to use all my strength to keep it on the road and went into the other lane! if this happened while towing a load on one of the mountain passes I could have been seriously injured or killed- and hurt or killed others! Ford has had bad diesel engines since they dropped the 7. 3 years ago and are ripping off people in this country- please don't let someone die over a known problem. Seems cheaper for Ford to put us in danger by shutting down this engine and therefore not replacing the engine and computer system.

car image   Diesel Engine problem of the 2011 Ford F-250 12
Failure Date: 05/02/2014

Catastrophic engine failure at 3 years old and 124,000 miles. This $60,000 2011 Ford F-250 super duty with 6. 7 diesel engine is totaled. Driving down the road at normal cruise the engine started making a terrible banging noise and shuddering so violently that I was forced to immediately leave the road. I stopped and turned the engine off. Got out and the ground was covered in oil. Stranded. . Dealership quoted me $24,233. 67 to replace the engine. Although this engine is falsely advertised to be rigidly tested for 250,000 miles, Ford has sent email stating that they will not stand behind the product. This truck is still financed and quite frankly I cannot afford and should not have to afford this repair. I have had exhaust issues with overheating and burning sensors which were replaced by warranty a couple times and out of pocket a couple times. I have read many reviews that the heat that is built up during a regen exhaust cleaning cycle damages the valves within the engine. I also read that Ford fixed this problem in 2012 but that leaves people like myself, who paid Ford $60,000+ stranded without a vehicle in just 3 short years. I have service the truck as required and have never abused it nor put it in mud, etc. Please look into this and see if there is anything I can do. It appears I may be without a vehicle and have to default on my lender with the cost of this.

car image   Diesel Engine problem of the 2011 Ford F-250 13
Failure Date: 02/05/2014

The 6. 7 cid diesel engine driven vacuum pump suddenly begins leaking motor oil. Failure of this pump will affect 4 wheel drive systems including auto locking hubs and all interior climate controls. Loss of motor oil could cause engine failure. Failure of 4 wheel drive system during adverse weather could result in a vehicle crash or loss of control. Research indicates multiple failures of this part, indicating a systemic failure.

car image   Diesel Engine problem of the 2002 Ford F-250 14
Failure Date: 02/03/2014

Oil pan rusted out.

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car image   Diesel Engine problem of the 2012 Ford F-250 15
Failure Date: 04/27/2013

The contact owns a 2012 Ford F-250 sd. The contact stated that while driving 70 mph, the vehicle stalled and an alert advising to stop the vehicle immediately illuminated on the instrument panel. The vehicle was towed to a dealer for diagnosis and the contact was informed that the egt sensor would need to be replaced. The vehicle was repaired. The failure recurred within 8,000 miles. The vehicle was towed and repaired a second time. The manufacturer was notified of the failure. The failure mileage was 48,000 and the current mileage was 56,600.

car image   Diesel Engine problem of the 2008 Ford F-250 16
Failure Date: 01/16/2013

On numerous occasions my 08 Ford f250 6. 4 has had excessive bluish white smoke from the exhaust while driving and lasts around 20 seconds. Dealer was notified and situation met all criteria outlined in TSB 11-2-2. Cac was replaced. However, vehicle still intermittently has same problem. On one occurrence the smoke was so excessive that a motorcycle traveling behind me almost ran off the road due to visibility. Ford states that this is normal.

car image   Diesel Engine problem of the 2002 Ford F-250 17
Failure Date: 01/01/2013

2002 Ford f250 superduty. Consumer writes in regards to a strong diesel fuel odor and finding fuel on the passenger side of the engine compartment in the cab of the vehicle. The dealer informed the consumer, the diesel engine was designed with copper sleeves or cups around the fuel injectors. The purpose of the cups were to separate the engine cooling system from the pressurized fuel system. Over a period of time, the engine coolant reacted with the copper cups and created small pin holes or cracks in the injector cups. Since the fuel system was pressurized it injected diesel fuel into the coolant circulating in the engine. Eventually the diesel fuel came out of the radiator overflow and all over the passenger side of the engine compartment. Since there was no way to tell, which injector cup was bad, all of them would have to be replaced along with the coolant hoses and the radiator would need to be flushed. The engine would have to be taken apart, the heads would have to be removed and the injector cups replace.

car image   Diesel Engine problem of the 2008 Ford F-250 18
Failure Date: 12/03/2012

Cpsc# i1310184a. 2008 Ford F-250. Consumer stated that he has had numerous problems with the cooling system. Stated the radiator was leaking also. The consumer stated he was loosing a gallon of coolant a week. It was going through the air charge and out the exhaust. At 89,000 miles, he had to pay $ 1947. 00 to replace both the vertical and horizontal egr coolers. Again, dumping a gallon of coolant into the exhaust system a week which caused severe smoking.

car image   Diesel Engine problem of the 2008 Ford F-250 19
Failure Date: 10/15/2012

While driving engine power failed and loud knocking noise was heard. Upon being serviced, rocker arm was broken and caused the problems. There was no notice of this issue and it affected sudden loss of power/speed. It is noted that while searching the internet it was discovered that this appears to be a common problem with these 6. 4l diesel engines.

car image   Diesel Engine problem of the 2008 Ford F-250 20
Failure Date: 05/10/2012

Lifters and cam have failed. And has trashed the motor. Have asked for help from Ford and they have denied claim. The problem with this is that $55,000. 00 truck that is advertised to be super duty and should last 400000 to 500000 miles with only miner engine repairs, this should not be happening. Ford knows for a fact that they have a faulty motor and faulty internal parts on all the 2008 thru 2010 6. 4 l diesel motors. That's why they designed a new motor and are suing navistar the engine designer. Now you can go all over the internet and find thousands of customers with the same problems and more. Ford knows that the lifters will fail at some premature point, and the rocker arms will break. One of the problems is that there is so much back pressure on the motor due too the particulate filter. That has even been re-deigned in there new 6. 7 motor. Why is there not a recall on this motor or some kind of mandatory retrofit or financial aid to fix these problems. On another note I have all most had a least 8 head on collisions from lost power due to the egr coolers failing or the particulate filter clogging up. This is a common problem with this engine also you can be in great danger when trying to pass someone. I hope to hear from some one soon. . Thank you in this matter. How can Ford turn their backs on loyal americans. . . . . . .

car image   Diesel Engine problem of the 2011 Ford F-250 21
Failure Date: 05/08/2012

The contact owns a 2011 Ford F-250 super duty. The contact stated that the vehicle would hesitate when accelerating from a complete stop. In addition, the vehicle would exhibit an abnormal buzzing. The vehicle was taken to the dealer and the contact was advised that the problem was caused by unknown aftermarket additions made to the vehicle. The vehicle was not repaired. The failure and the current mileages were 22,000. Updated 7/9/12 the consumer stated when he needed a good acceleration, the engine had a very bad lag in acceleration. The rep at the dealer stated it was probably a turbo log. Updated 07/10/12.

car image   Diesel Engine problem of the 2006 Ford F-250 22
Failure Date: 04/02/2012

2006 Ford F-250. Consumer states problem with egr cooler/egr valve the consumer stated the purpose of the egr cooler was to cool the exhaust. After making some inquiries, it was brought to her attention that it was a very common problem. The consumer was informed since the egr valve was not manufactured properly, it was getting plugged up with wet carbon. The consumer was informed it would cost $3,000 to fix the problem.

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car image   Diesel Engine problem of the 2004 Ford F-250 23
Failure Date: 01/25/2012

The contact owns a 2004 Ford F-250 diesel. The contact stated that while driving 15 mph, excess smoke emitted from the exhaust pipe. The dealer was notified and stated that the egr cooler might be defective. The manufacturer was made aware of the failure and offered no assistance. The vehicle was not repaired. The failure and current mileages were 86,100. Updated 02/27/lj updated 02/27/12.

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car image   Diesel Engine problem of the 2010 Ford F-250 24
Failure Date: 12/26/2011

I recently purchased a 2010 F-250 sd, 6. 4l pickup. I was driving along a city surface street and looked in my rear view mirror, and noticed a thick white cloud bank billowing behind me, generating from my exhaust pipe. I about had a heart attack, thinking my truck just blew an engine. I immediately drove it back to have the service department to fix it. The service department stated that,? Ford is aware of the smoking issue and considers this normal with no fix?. They mentioned this could be caused by moisture condensation. That doesn't seem feasible since here in the pacific northwest there?s moisture in the air just about all year long. The truck continues to bleach this heavy, thick smoke, about every 20 to 40 miles, for approx. 45-120 seconds. I?m concerned about this being a public hazard/safety issue. When it billows, I can see cars peeling out from behind me, thinking my truck is on fire. I've even had people pull along side my truck and give me an earful, along with several obscene gestures. It's ironic that this 6. 4l diesel engine has been advertised as clean burning, less pollution, if a police officer observes this, I could get a traffic citation. We have expressed our safety concerns as well as concern for the environment and re-sale to the Ford dealership, (not to mention how embarrassing this is when the truck billows). Many phone conversations have taken place with the service dept. As well as bringing the truck back and we still cannot get this resolved. It's a head scratcher to me as to why the salesman didn't mention this issue when we first looked at the truck, surely he should know the product he is trying to get rid of.

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car image   Diesel Engine problem of the 2005 Ford F-250 25
Failure Date: 01/01/2011

The contact owns a 2005 Ford f250 superduty diesel. The contact stated that the engine would not start. The engine would only start when fuel was added. The vehicle was taken to the dealer several times for the failure where the dealer replaced the fuel injectors but the failure was not corrected. The vehicle was not further repaired and the manufacturer would not assist with the repair. The VIN was not available. The failure mileage was 115,000 and the current mileage was 121,000.

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Other Common Engine And Engine Cooling related problems of Ford F-250


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