Manifold/header/muffler/tail Pipe Problems of Ford F-250 - part 1

Ford F-250 owners have reported 54 problems related to manifold/header/muffler/tail pipe (under the engine and engine cooling category). The most recently reported issues are listed below.

car image   Manifold/header/muffler/tail Pipe problem of the 2006 Ford F-250 1
Failure Date: 07/16/2018

Exhaust manifold is separating from the heads (both sides); cab corners and rear outside fenders rusted through necessitating replacement; back of muffler blew out requiring replacement.

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car image   Manifold/header/muffler/tail Pipe problem of the 2008 Ford F-250 2
Failure Date: 03/16/2018

Exhaust manifolds leak. Ford uses alumina heads with steel manifold bolts and cast iron exhaust manifolds. The three metals have different heat ranges which cause the exhaust manifolds to wrap or crack and break the bolts causing leaks.

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car image   Manifold/header/muffler/tail Pipe problem of the 2009 Ford F-250 3
Failure Date: 02/17/2017

My F-250 has had every brake caliper lock up and cause total brake system failure and repair. Starting at 40k miles it is out of warranty but there is an obvious defect in the design if every caliper has had this problem. My shop did a repair history search and found that the 2009s had a higher failure rate than other years. I also had the manifold warp and needed replacement at just 40k miles. Thanks - dan.

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car image   Manifold/header/muffler/tail Pipe problem of the 2004 Ford F-250 4
Failure Date: 06/01/2015

Faulty exhaust manifold bolts break off and cause excessive noise, exhaust enters the drivers cabin, vehicle will not pass emissions inspection and is expensive to repair. I have 4 Ford vehicles with this problem. First incident was at around 50,000 miles and 48 months after purchase. Ford refused to make repairs under any portion of the factory warranty. They claim lifetime emissions warranty doesn't cover it, nor the 100,000 powertrain warranty. I have spent over $8000. 00 making repairs to these exhaust manifolds.

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car image   Manifold/header/muffler/tail Pipe problem of the 2001 Ford F-250 5
Failure Date: 04/01/2015

The contact owns a 2001 Ford F-250. While the vehicle was idling at a stop sign, the contact heard a loud abnormal popping noise coming from the engine compartment. The contact drove the vehicle to an independent mechanic where they replaced the spark plug taps and diagnosed that the intake manifold needed to be replaced. The manifold was not replaced. The contact stated that the failure recurred several times. The dealer was not contacted. The manufacturer was contacted and did not assist. The failure mileage was 128,000.

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car image   Manifold/header/muffler/tail Pipe problem of the 2008 Ford F-250 6
Failure Date: 09/12/2014

The contact owns a 2008 Ford F-250. The contact stated that the exhaust manifold bolts were rusted and fractured. The vehicle was taken to the dealer where it was diagnosed that the exhaust manifold was fractured and leaking. The technician replaced both exhaust manifolds, 20 studs, four nuts, and two gaskets. The manufacturer was made aware of the failure. The failure mileage was 110,851.

car image   Manifold/header/muffler/tail Pipe problem of the 2001 Ford F-250 7
Failure Date: 04/01/2013

Tl - the contact owns a 2001 Ford F-250 sd. The contact stated that while inspecting the vehicle, the vehicle started to exhibit an abnormal stuttering noise and the contact noticed that the exhaust manifold was leaking. The vehicle was not taken to the dealer. The manufacturer was made aware of the failure but did not offer any assistance since the vehicle was not included in any recalls. The vehicle was not repaired. The failure and current mileage was 72,000. Kmj.

car image   Manifold/header/muffler/tail Pipe problem of the 2000 Ford F-250 8
Failure Date: 09/04/2012

I have a 2000 Ford F-250 with a v-10 engine. I have had 5 of my 10 spark plugs blow out in the last year. 4 of them required a helo-coil replacement at a cost of about $1,600. 00 total. The spark plugs blow out without warning ripping the threads out of the heads, rendering the truck useless. In that last incident I was towing a camper when it blew leaving me in an extremely hazardous and dangerous position. I can not emphasize how dangerous this problem is. Ford tells me I now need new heads at a cost of about $5,000. 00. Fords states they are not responsible and will not do anything about this, even though their have been thousands of complaints for this issue. They tell me that it is up to the NHTSA to make a recall. And until they do nothing will happen. This is unbelievable. . . . . This is not a blown muffler or a blown windshield wiper. This is a seroius problem that has been going on for years yet nothing is being done. Will the NHTSA stand tall here and order a recall or push it off?.

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car image   Manifold/header/muffler/tail Pipe problem of the 2004 Ford F-250 9
Failure Date: 01/01/2012

Ford f series and super duty pickups with 5. 4 engines. My 2004 Ford F-250 has an issue with leaking exhaust manifolds. When looking into this further while getting pricing, I found out that this was not an isolated issue and that it was a common occurrence due to a mistake in material used for the exhaust manifold bolts. So common that aftermarket suppliers are making replacement kits for the problem. The exhaust manifold attaching studs were made out of a metal that quickly rusts out causing the failure. After the failure, I began to notice exhaust gasses entering the cab of the vehicle through the climate control, which its fresh air intake is in the general direction of the exhaust manifold. I also question the emissions standards because of the exhaust leak not to mention the potential fire risk from heated gasses and flames entering the engine compartment.

car image   Manifold/header/muffler/tail Pipe problem of the 2005 Ford F-250 10
Failure Date: 07/20/2011

The contact owns a 2005 Ford F-250. The contact stated the fumes enter the cabin and make the vehicle occupants dizzy. The vehicle was taken to an authorized dealer and the contact was informed that the bolts for the engine manifold corroded and fractured. The dealer stated that this was a known failure because the bolts were metal and the frame was aluminum. The failure mileage was unknown and the current mileage was 55,000.

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car image   Manifold/header/muffler/tail Pipe problem of the 2010 Ford F-250 11
Failure Date: 07/01/2010

Since I have owned this truck from 2010 to current I have had problems with the exhaust manifolds and a transmission overflow relief valve. The exhaust manifolds keep popping the studs which allows fumes inside the truck upon a $2000. 00 bill every time. . . This issue could cause the whole exhaust system to fall right out from under the truck while driving. The other issue is the trans overflow. . . . Everytime it happens it spits the fluid out all over the exhaust which causes a fire everytime. I have been reporting these problems since I have purchased the truck. These problems need to be adressed before someone gets hurt or worse.

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car image   Manifold/header/muffler/tail Pipe problem of the 2002 Ford F-250 12
Failure Date: 05/15/2010

Leaking head gaskets on 2002 Ford f250 truck with 5. 4l engine allows oil to leak onto starter and exhaust manifold creating safety hazard. This is a known problem with this type engine.

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car image   Manifold/header/muffler/tail Pipe problem of the 2002 Ford F-250 13
Failure Date: 01/15/2010

I own a 2002 f250 v10 with approx 84,000 miles. I was just driving along and the spark plug from the # 8 cylinder blew out. I had to retap it and put a helicoil in it. The spark plugs were the original spark plugs and have never been replaced. I have seen numerous complaints of the same problem on kline. It is definitely a manufacturing defect. Also I need to replace the exhaust manifold bolts on the same cylinder heads. This is another problem I have found numerous complaints about online.

car image   Manifold/header/muffler/tail Pipe problem of the 2001 Ford F-250 14
Failure Date: 11/01/2009

I was on a delivery with my 2001 Ford f 250 v10 with 8 thousand miles, when I heard what I thought was tappet noise then I heard a pop and then realy loud exhaust noise like I lost a exhaust manifold seal, I pulled over to find I had a suddden spark plug blow out, I was on a delivery and work in the hollywood andthe production needed me at location on time, so I drove it there after I isolated t he spark plug wire from grounding by floating it in air by purring it threw the oil dip stick, I drove on with the 9 remaining cylinders and made my delivery, I was out 250 miles and had to return to la for a child custody hearing so I drove it back the whole way sounding like a tug boat, it was like I was lindberg crossing the atlantic I did not know if I would make it, but I did, I called Ford and they want 700 to re tap the hole and put a insert in, I looked at the consumer complaints and see hundreds of people have had the same issue, I think Ford should recall the engines and fix the thread issue.

car image   Manifold/header/muffler/tail Pipe problem of the 2002 Ford F-250 15
Failure Date: 10/20/2008

I purchased an f250 2002 triton v8 super duty mid year 2007. Less than a year after the purchase a spark plug blew out of the manifold. This all happened under normal highway driving conditions. The dealer put in an insert, rethreaded it and replaced spark plug. Almost a year to the day it happened again. So now #2 & #4 have blown out. On 5/30/09 a third one blew out. All on the left side (passenger side) of the manifold. So now #2, #3 and #4 have blown out. I researched the incident online and have found 500 other cases. I'm curious how many are really out there that weren't reported. I've been fortunate because in some cases the spark plug blew through the hood or damaged the manifold. I do however wonder what damage is occurring each time it happens. How many reports or how many vehicles does it take before there's a recall? even though I have extended warranty I've been charged a deductible each time and now face a third if my warranty is still good. I have one more plug on that side that hasn't blown yet and since this one was only 7 months since the last one I suspect I'll be paying again. I saw online where it was suggested as a piston problem.

car image   Manifold/header/muffler/tail Pipe problem of the 2001 Ford F-250 16
Failure Date: 08/14/2008

Sounded like manifold leak spark plug ejection.

car image   Manifold/header/muffler/tail Pipe problem of the 2002 Ford F-250 17
Failure Date: 07/21/2008

2002 Ford f250 crew cab 4x4 short box, 5. 4l v-8 gasoline engine just under 92000 miles. On 7/21/2008 merging on the expressway under heavy acceleration, a loud bang with spring popping sound was heard from the engine followed by the distinct odor of exhaust and unburned gasoline. Verified throttle control and continued to drive with loud noise coming from engine. Drove 4 miles to work to safely inspect the problem. Noted that the exhaust y-pipe was separated from the drivers side exhaust manifold. Assuming that it was just a failed manifold bolt, drove ~20 miles to the dealership to have it looked at. Received the call that the number 6 spark plug was ejected from the head. Upon the dealerships inspection, found that the threads were stripped out of the head. The spark plug then arrested in the ignition coil which was separated from the head due to failure of its mounting flange. The ignition wire held the coil and plug on the engine. There was zero gap noted on the spark plug electrode with anti-seize compound on only about . 5" of the spark plug thread. Thus suggested that only . 5" of thread engagement was present from the factory original plugs (I. E. The spark plugs were not replaced since the recommended replacement interval is 10 years 100000 miles). Advised that at a minimum a head needed to be replaced, but that an engine may be a better economical choice so that both heads are replaced and this design issue could be overcome (the newly remanufactured engine is supposed to have larger thread engagement at approximately . 75"). Engine replaced to insure that this failure would not occur on one of the other cylinders in the head that would not be replaced.

car image   Manifold/header/muffler/tail Pipe problem of the 2002 Ford F-250 18
Failure Date: 04/10/2008

Two manifold bolts snapped off each side of my 02 6. 8 liter engine. The rest are horribly rusted. The truck has only 37000 mi on it. There has been a TSB concerning this, but it is a huge and common problem. There needs to be a recall for the people out of warranty,as it does concern emissions and the leaking of exhaust gases from before the cat.

car image   Manifold/header/muffler/tail Pipe problem of the 2000 Ford F-250 19
Failure Date: 04/05/2008

Blown out spark plug.

car image   Manifold/header/muffler/tail Pipe problem of the 2004 Ford F-250 20
Failure Date: 03/30/2008

Exhaust manifold bolts broken, leading to carbon monoxide (as well as other exhaust gases) being released into passenger compartment.

car image   Manifold/header/muffler/tail Pipe problem of the 2002 Ford F-250 21
Failure Date: 02/08/2008

I heard a sound coming from my exhaust and after looking over the exhaust I notice that I had some exhaust manifold studs and nuts that hold the exhaust manifolds to the engine heads had either broken or snapped off causing the exhaust leak I heard. After seeing that I had an issue with the exhaust studs I took my 2002 Ford F-250 super duty with 6. 8 liter engine to the dealership were I have my service work done and had 1 of the service technicians look at the issue. I was told at the dealership that Ford motor company knew of the problem with the studs and nuts that was used when my truck was manufactured and knew of that problem since 1997 through 2005. Yet Ford motor company will not do anything to resolve this issue. From 1997-2005 Ford motor company used steel studs and nuts for attaching the exhaust manifolds to the enines on there 5. 4 liter and 6. 8 liter engines. That's a period of 9 years of using parts that were faulty for use in manufacture. The failure of these exhaust studs and bolts can and will cause the exhaust manifolds to warp thus the consumer having to replace the exhaust manifolds as well. Also with the failure of the faulty exhaust studs and nuts could cause engine problems like warped valves, or head damage, which could cause engine to blow or lock-up. I have notified Ford motor company on 3 occasions and have met with the same response that they will do nothing to amend the issue at hand. They have a technical service bulletin that they have available which requires that the use of stainless steel studs and nuts in service for the 5. 4 liter and 6. 8 liter engine. As well as replacing the exhaust manifold on the affected bank(s), exhaust manifold gaskets. Ford motor company failed to notify the consumer while the vehicle was under warranty so repairs could be made.

car image   Manifold/header/muffler/tail Pipe problem of the 2004 Ford F-250 22
Failure Date: 02/01/2008

Exhaust manifold bolts rusted/corroded & broken off + rust/corrosion related crack in exhaust manifold itself. This is obviously an ongoing problem with no specific date as to when it happened only when it was discovered. I believe this to be an emissions issue.

car image   Manifold/header/muffler/tail Pipe problem of the 1999 Ford F-250 23
Failure Date: 08/29/2007

Exhaust leak from the manifold of a 1999 v10 f250 Ford pick up truck. This truck has 43,000+ miles on it and went in for a annual safety penna. Safety inspection. It failed because of the exhaust leak. This problem is caused by the fact that Ford use uncoated steel bolts to attach the manifold to the engine. Without notifying the owners, new coated bolts were available from Ford to prevent this problem. This failure of notifying the vehicle owners endangered the occupants by allowing exhaust fumes to be drawn into the interior of the cab. The dealer stated the aim on headlights are low, checked front bearing and suspension parts, and replaced shocks. Updated 09/25/07.

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car image   Manifold/header/muffler/tail Pipe problem of the 2001 Ford F-250 24
Failure Date: 08/19/2007

Exhaust manifold studs/bolts deteriorating and or breaking off from the engine cylinder heads. The exhaust manifolds are still attached to the engine by some of the bolts that have not broken yet,but they are very deteriorated. I feel this is a very serious issue that could result in a serious accident if the remaining bolts break off while my vehicle is being driven. I feel strongly that the vehicle manufacture should be responsible for this repair at their expense.

car image   Manifold/header/muffler/tail Pipe problem of the 1999 Ford F-250 25
Failure Date: 06/28/2007

The contact owns a 1999 Ford F-250 sd. While driving 45 mph, the contact heard loud noises coming from the engine. The vehicle then lost power without warning. The vehicle was towed to the dealer who stated that a spark plug became unseated and blew through the manifold. The vehicle needed a new cylinder and manifold. The dealer stated that the engine had a design flaw. The VIN was unknown. The current and failure mileages were 43,000.


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


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