Gas Recirculation Valve (egr Valve) Problems of Ford F-250 - part 1

Ford F-250 owners have reported 69 problems related to gas recirculation valve (egr valve) (under the engine and engine cooling category). The most recently reported issues are listed below. Also please check out the statistics and reliability analysis of Ford F-250 based on all problems reported for the F-250.

car image   Gas Recirculation Valve (egr Valve) problem of the 2013 Ford F-250 1
Failure Date: 07/02/2019

Egr and egr cooler failed at 21,000 miles. Dealer fixed under warranty 3/22/16. Same parts have failed again at 46,000 miles and is out of warranty. Searching the web shows this is a common repeat failure for the 6. 7 diesel and costs $2,000 for repair. Engine trouble code is p0401. The parts or design must be defective as they only last for about 20,000 miles.

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car image   Gas Recirculation Valve (egr Valve) problem of the 2011 Ford F-250 2
Failure Date: 02/17/2016

This issue is around the diesel exhaust fluid system - specifically the reductant heater assembly but has also now affected the fuel pump and associated emissions. The problem is intermittent but occurs when the temperature falls below 30 degrees. This care has been in dealership repeatedly over the past 14 months for this issue. Part of the design of this system failure is to depower the engine which nearly caused an accident while I was driving. I have exhausted my abilities and patience with Ford motor company and now submit it to you for redress. See attached pdf document for full details. .

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car image   Gas Recirculation Valve (egr Valve) problem of the 2015 Ford F-250 3
Failure Date: 11/16/2015

During the epa mandated exhaust regeneration cycle the vehicle begins to shudder uncontrollably along with power loss. This behavior began at around 5,500 miles and now does it at least every other exhaust regeneration. It happens on multiple lane country roads and city roads at around 50 to 60 miles per hour. It seems more specific to the regeneration cycle than any other driving condition or input. Temperature is between 40 and 70 degrees outside so far. Each time it happens is worse than the last. The experience is scary and could be very dangerous. I no longer let my wife drive this vehicle for fear that it may shudder her off the highway.

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car image   Gas Recirculation Valve (egr Valve) problem of the 2012 Ford F-250 4
Failure Date: 10/24/2015

The vehicle's engine will stall (cut off) without any indication or notice during motion or at a stop. This has happened at city speeds (less than 25 mph) and at highway speeds (greater than 55 mph) the vehicle will not immediately start but may start after standing for some time. This causes power steering, power brakes and other important safety features to be degraded or lost.

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car image   Gas Recirculation Valve (egr Valve) problem of the 2006 Ford F-250 5
Failure Date: 10/21/2015

Heads went bad now I have to replace the heads and new head studs because the old head studs stretched and the heads warped , also had to do an egr delete . I was told it was built proofing and it has to be done to all 6. 0 ltrs.

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car image   Gas Recirculation Valve (egr Valve) problem of the 2011 Ford F-250 6
Failure Date: 07/12/2015

While driving approx 60 mph a message popped up on the display saying "stop when safe". While trying to get off the road the engine died and left me with no power brakes or steering. Had to be pushed out of the intersection. Would not restart. Truck weighs 8300 pounds. 1 hour prior I was going over a steep mountain pass. Half an hour later I was in 100+ degree desert with no cell service. Either one could have been a nightmare ending. This must be addressed.

car image   Gas Recirculation Valve (egr Valve) problem of the 2005 Ford F-250 7
Failure Date: 05/21/2015

F250 6. 0l diesel with 85844 miles had the egr/oil cooler go bad the repair cost 4744. 00 at the dealer. I have an extended warranty but as usual not covered. This a known problem with these 6 liters along with the head bols being substandard and faulty ficm which I replaced at the cost of 525. 00 and doing the work myself. I have tried to resolve this with Ford and my warranty company warranty direct to no avail. I did get the warranty company to admit the egr cooler was covered but they would not cover the other repairs required with this repair so I got 981. 00 from them. These problems have been well documented and I feel it is about time the nesta got involved and got recalls established. My vehicle just started having a small amount of fluid under it th a t I had checked out within 2 days of noticing which led to the egr/oil cooler being repaired and the ficm got replaced a fer truck started running real ruff on cold start up and the ficm sent code of the problem but it can also just stop functioning even while driving which could be fatal.

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car image   Gas Recirculation Valve (egr Valve) problem of the 2014 Ford F-250 8
Failure Date: 04/14/2015

Near the end of the highway I was setting thru a light and decided to et fuel. Once I reached the turn in got to the pump all is well. I was not towing or hauling anything the day temperature is 66 degrees. I set at the pump for a minute on the phone and then turned the truck off. Proceeded to fill up and then depart. I started my truck removed the emergency brake at the same time my dash indicator lights all started in with hight exhaust temp hight oil temp all sorts of other lights along with engine system start failure. I pulled away from the pump for safety and then shut it off. That was it no start same warnings. After calling a wrecker twenty minutes went by and I tried it again and it started with a service engine light on. No dealer could get to it for two or three days so I drove it home to schedule an appointment. Had this happened six miles earlier I would have beed in a bad spot.

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car image   Gas Recirculation Valve (egr Valve) problem of the 2012 Ford F-250 9
Failure Date: 04/02/2015

I have a 2012 Ford f250 king ranch 6. 7 diesel. The radiator started leaking so I took it to the dealership only to find out I needed a new radiator. Since my bumper-to-bumper warranty ran out at 36k miles this repair was on my dime. In researching online forums and such, there have been known issues with the diesel radiator as far back as 2008. The entire premise behind a diesel engine is "compression-ignition" in which fuel is ignited due to compressed air at approximately 1000 degrees f. There is no scenario where the either the manufacturer of the radiator and/or Ford motor company themselves should not be required to fix this faulty part at their expense. The repair estimate was over $2,000 on a vehicle less than 3 years old. In no way should any new vehicle owner be required to pay for a new radiator much less for the labor to install it and that goes double for the owner of a diesel engine.

car image   Gas Recirculation Valve (egr Valve) problem of the 2004 Ford F-250 10
Failure Date: 03/10/2015

I have a 2004 f 250 super duty with the 6. 0 engine it is a known fact that the bolts that hold the heads down streach when hot letting water into the oil system its all over the interrnet about the 6. O engine that Ford provides the only fix is to have the cab removed and replace the bolts with studs that can take the high temp that the engine produces this is only one of the problems but this problem cost me over 5000$ to fix sure would be nice for you all to look into this product that Ford has been useing and knows theres a problem with that engine,,you go to trade it in at Ford and they see it has a 6. 0 engine in it and the price drops ,way ,way to much for a truck that sold new for 45000$ , I found my truck leaking water in the drive way setting still no reason for it to start leaking ,,I have the bills from Ford dealer where I had it fixed if needed please look into this engine its not right to put so much money into a truck that has this problem that not one other engine Ford has does what the 6. 0 does ,also bad egr it has to be by passed this stuff should not happen also showed water in gas emptyed the cantainer and then gas gauge stops working and gas light stays on all the time ,,,,never buy Ford.

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car image   Gas Recirculation Valve (egr Valve) problem of the 2011 Ford F-250 11
Failure Date: 01/18/2015

Started vehicle and drove about 1/4 mile and warning came on to find a safe place to pull over. Check engine light came on. Soon as I slowed down and stopped the engine shut off. Had to have it towed to dealer. Was told it was a bad sensor. Something to do with egr/ oil pressure. This is second time this happen. Previous time was while driving through town, stopped at a red light and truck shut off for overheating. Again had to tow it in, and again was a bad sensor sensing the truck had overheated. Nothing wrong with the truck either time except sensor.

car image   Gas Recirculation Valve (egr Valve) problem of the 2012 Ford F-250 12
Failure Date: 11/13/2014

Driving down expressway about 70mph during rush hour traffic. Truck had been running about 30 minutes prior. Message pops up on instrument panel that states "stop safely now", no other message given. Once slowed to approximately 10mph the engine died and I had no power steering or power brakes. This is in rush hour dallas traffic. I pull over to the side of the road as much as possible and try to restart it for 40-50 minutes with no avail. Have it towed to dealership which now informs me that I have 3 bad egr sensors and they need to be replaced for the same reason, none. They state that they are not covered under warranty and Ford has not recalled them. This is concerning because this is the second time this has happened and this one was in a very dangerous situation. I know of 2 other very close friends that have Ford F-250 trucks that this exact thing happened to.

car image   Gas Recirculation Valve (egr Valve) problem of the 2006 Ford F-250 13
Failure Date: 09/19/2014

Towed on sept/19/2014 kn mileage dealer said no proplem found;. 2nd tow 11/02/2014 mileage 187190 egr valve failed will need engine replaced. Dealer where bought did not disclose. The truck had the motor rebuild in 2008. And many class action suits have been filed. On 6. 0l engines.

car image   Gas Recirculation Valve (egr Valve) problem of the 2005 Ford F-250 14
Failure Date: 05/16/2014

The contact owns a 2005 Ford F-250. The contact stated that the vehicle failed to start and the check engine warning indicator illuminated. The vehicle was taken to the dealer where it was diagnosed that the fuel injector control module failed and needed to be replaced. The vehicle was repaired; however, the failure recurred. The vehicle was towed to an independent mechanic where the fuel injector was replaced again. In addition, the vehicle experienced excessive coolant consumption and operated abnormally. The vehicle was taken to an independent mechanic where it was diagnosed that the egr valve and oil cooler failed and needed to be replaced. The vehicle was repaired. The manufacturer was notified of the failure. The failure mileage was 90,000.

car image   Gas Recirculation Valve (egr Valve) problem of the 2012 Ford F-250 15
Failure Date: 02/23/2014

Driving 65 down road with light acceleration. Truck had been running approximately 20 minutes. Message comes on instrument panel that states "stop safely now". There is no other warning or message. Slow down to pull over and truck dies at 10mph. No power steering or brakes. Tow it to the dealership. Told that it is a faulty egr sensor and they have seen a ton of these. There are 4 sensors on the exhaust system and if one goes bad it will disable the whole truck. Replaced sensor and not covered as recall or warranty. This is extremely dangerous as depending on the surroundings it could cause injury or death being stranded on road from a sensor, when there are 3 other redundant sensors.

car image   Gas Recirculation Valve (egr Valve) problem of the 2004 Ford F-250 16
Failure Date: 01/26/2014

Our 2004 f250 diesel 4x4 super duty was parked in the driveway overnight, properly plugged in due to the cold. A neighbor woke us up to state it was on fire. The entire front and interior of the truck was engulfed in flames before the fire department arrived. After it was extinguished, the county fireman pointed the believed the point of ignition appeared to be at the firewall on the drivers side due to the fact that the master brake cylinder & battery were disintegrated. Plus the secondary battery & radiator were partially intact which are in the front. The fire dept stated that if it had been a frontal point of ignition due to the block heater the radiator & battery on front passenger side would've burned first due to aluminum materials.

car image   Gas Recirculation Valve (egr Valve) problem of the 2006 Ford F-250 17
Failure Date: 11/13/2013

My Ford f250 super duty 2006 model truck started up just fine on way to job site and then about 1:00 p. M. That day my truck over-heated even though no indication on the electrical panel. I saw white smoke coming out of tail pipe, started over-heating, and I was losing power in motor. I put water in coolant over-fill because all of my antifreeze drained out and I just had put in prior to this date above about two weeks. I regularly change the oil and maintain all the fluids and do required maintenance on truck per the mileage. I was able to make it to my house where I waited 30 minutes for truck to cool and then drove immediately to diesel mechanic named [xxx] who knew immediately what had happened because (6) other trucks came in the same week with the same issue which was to replace the egr's and also the oil cooler. My bill for this was over $3,000. 00. I was very lucky that I had work and was able to pay for this huge expense otherwise I would be out-of-pocket in a bad way because the truck is my livelihood in my making money as I am a general contractor and need a heavy duty truck. I think that there should be a re-call on this part because of the six other trucks that came into his diesel shop the same week. This was a very expensive experience and I feel like Ford should know about this and correct the error because this part should not go out on a super duty truck like this. Information redacted pursuant to the freedom of information act (foia), 5 u. S. C. 552(b)(6).

car image   Gas Recirculation Valve (egr Valve) problem of the 2006 Ford F-250 18
Failure Date: 09/10/2013

The contact owns a 2006 Ford F-250. The contact stated that while driving at 3 mph, the accelerator pedal was depressed but it failed to respond. In addition, the contact noticed smoke coming from the exhaust pipe. The vehicle was taken to a dealer. The technician stated that the oil cooler, the exhaust back pressure sensor, the turbo and the egr valve needed to be replaced. The vehicle was repaired however, the failure recurred. The manufacturer was made aware of the failure. The failure mileage was 160,000.

car image   Gas Recirculation Valve (egr Valve) problem of the 2004 Ford F-250 19
Failure Date: 08/30/2013

The contact owns a 2004 Ford F-250 tdi. The contact stated that while driving 55 mph, white smoke started to emit out of the exhaust pipe. The vehicle was taken to the dealer. The technician diagnosed that the vehicle had blown a head gasket. As a result, the cooler, egr, and head gasket needed to be replaced. The manufacturer was made aware of the failure. The vehicle was repaired. The failure mileage was 75,961 and the current mileage was 76,000.

car image   Gas Recirculation Valve (egr Valve) problem of the 2008 Ford F-250 20
Failure Date: 08/15/2013

The contact owns a 2008 Ford F-250. The contact stated that fire emitted from the exhaust pipe. The vehicle was taken to a private mechanic where it was found that the egr valve assembly needed to be replaced. The vehicle was not repaired. The manufacturer was contacted about the failure. The failure mileage was 190,000.

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car image   Gas Recirculation Valve (egr Valve) problem of the 2005 Ford F-250 21
Failure Date: 07/08/2013

Losing water and oil from exhaust, white smoke. Vehicle losing coolant from exhaust pipe. Hard start. Acts like high pressure oil, blows lots of white smoke out of exhaust. Installed ids/ computer and installed coolant pressure gauge in line on cooling system. Monitored ect/eot and coolant pressure. . Got vehicle to normal operating temp. Ect/eot were at 15 degrees difference which is maximum allowance for oil cooler temp. Ford recommends it be replaced when it reaches 15 degree difference. Also recommend replace egr cooler with oil cooler as a set. Perform TSB 09-08-3, test degass bottle-ok. Egr test on vehicle passed, installed pressure gauge. Road test for head gaskets - 21 psi in cooling system failed. Performed turbo over boost - test passed. Failed items: head gaskets, oil cooler. When tearing apart need check concern with high pressure oil system. Estimate to repair around $7000 which neither Ford nor dealer, legacy Ford, will cover under warranty. What is the warranty for if not to repair Ford's junk? so now an expensive truck sits unusable because of Ford and they have lost a long time believer in Ford vehicles, this is my last Ford.

car image   Gas Recirculation Valve (egr Valve) problem of the 2006 Ford F-250 22
Failure Date: 06/30/2013

The contact owns a 2006 Ford F-250 sd. The contact stated that while traveling approximately 5 mph, smoke emitted from the exhaust pipe. The vehicle was moved to the shoulder where it was shut off and towed to the dealer. The technicians determined that the egr valve, egr cooler and oil cooler had failed. The vehicle was repaired. The manufacturer was contacted about the failure. The failure mileage was 117,624.

car image   Gas Recirculation Valve (egr Valve) problem of the 2004 Ford F-250 23
Failure Date: 05/03/2013

Driving on interstate 65mph. Engine started binding down and speed dropped to 25mph and finally completely died. Had it towed home. Now won't start. Have replaced egr cooler and oil cooler previously . This time replaced fuel pump and all fuel filters. Will crank and run for a very short amount of time then will die again- and not crank back for awhile. Just repeats this process. Now told that it needs head gaskets or high pressure pump. These problems are very expensive. Why will Ford not fix these problems that seem to be on all 6. 0 diesel models?.

car image   Gas Recirculation Valve (egr Valve) problem of the 2006 Ford F-250 24
Failure Date: 03/31/2013

While pulling a travel trailer, engine began to overheat. Pulled over and notice coolant resevoir is emty. Took vehicle into a repair shop, motor coolant and both egr cooler failed. Service shop reported that Ford informed them that this is a common issue. They keep extra egr parts on hand from the massive amount of failures reported.

car image   Gas Recirculation Valve (egr Valve) problem of the 2006 Ford F-250 25
Failure Date: 02/20/2012

Egr and oil cooler failure. . . Caused engine failure and hydrolock situation. The engine stopped the truck right in the middle of an intersection almost causing an accident. Total cost of repairs to my vehicle $2542. 42. Sure would be nice for Ford to have a hand in the repairs due to their faulty engine design. I have read 100's of reports online about this and Ford still will not fix or help pay for their engine. Ford refused to help with repair cost. I only have 98000k miles. Please launch an investigation into these complaints. I believe you will find enough evidence to warrant an investigation. I am sure that the lobbyist at Ford are doing their job to keep this from becoming a recall situation. It is hurting no one but the owners of this 6. 0l diesel engine!!! we need your help!.


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


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