Engine Exhaust System Problems of Ford F-250 - part 1

The contact owns a 2014 Ford F-250. The contact stated that while driving at an undisclosed speed hauling a trailer, the exhaust manifold dropped raw fuel into the exhaust and it caught fire. The contact was able to extinguish the fire. The exhaust filter over maximum limit message was displayed. There were no reported injuries, crash , police report or air bag deployment. The fire department was on the scene. The vehicle was towed to the local dealer, where it was diagnosed and determined that cylinder one was down and the engine and transmission needed to be replaced. The mechanic informed the contact that the epf may be damaged and not work. The vehicle was not repaired. The manufacturer was contacted, who referred to the NHTSA hotline. The failure mileage was approximately 195,000.

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The contact owns a 2008 Ford F-250. The contact stated while driving approximately 60 mph, the cabin began to fill up with diesel exhaust fumes and white smoke. The contact stated that "drive vehicle to clean exhaust filter" warning light illuminated. The contact rolled down the window to relieve the cabin of exhaust fumes and smoke. The contact noticed that a rubber boot around the 4wd shift lever inside the vehicle was completely melted, and only a thick plastic ring around the shift lever opening where the rubber boot was attached remained. The contact replaced the rubber boot; however, the failure reoccurred within a week after replacement. The contact had taken the vehicle to a local dealer, where it was diagnosed and determined that the exhaust pipes needed to be replaced and that the repair required the vehicle cabin to be removed. The vehicle had not been repaired. The manufacturer had not been informed of the failure. The failure mileage was approximately 130,000.

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While operating in below freezing temperatures on the highway, the diesel exhaust fluid (def) tank heater failed, allowing the def to freeze inside the tank. With the def frozen, it was not able to be injected into the exhaust resulting in higher levels of nitrogen oxides (nox) to be released into the atmosphere through the vehicles exhaust.

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Reductant (diesel exhaust fluid) heater has failed on my 2014 F-250 with a 6. 7l diesel. Diagnostic code p20ba. Ford fsa 18m01 covers this failure on 2011-2012 F-250/350 and 2011-2015 f-450/550. From parts. Ford. Com " part # 5j225 (reductant heater and sender assembly),usages: 10/04/2011 - 07/05/2016, f250/350/450/550 super duty, 6. 7l 4v v8 t/c diesel, wide frame (pickup), with low sulfur diesel fuel content" stating that the same "reductant heater and sender" was used from 2011-2016. However the fsa does not include 2013-2015 F-250/350 models. I believe this is due to the large numbers of these specific models on the road and the fact that Ford does not want to be responsible for this emissions equipment related failures. This failure will keep my vehicle from passing inspection. My vehicle, which I am the original owner, has less than 65,000 miles as of 10/22/2020.

Thermal insulation panel under the truck bed body above the exhaust pipe became loose and fell onto the exhaust pipe and caught fire and melted to the pipe. Noticed the hanging insulation panel when truck was parked.

See all problems of the 2019 Ford F-250 🔎.

The truck has 87,000 miles and I was driving 45 mph, engine light came on the truck jurked like back fire, no brakes no acceleration . Went to the nearest dealer they said the exhaust valve stuck and through the rod through the piston and cylinder wall. Ford says sorry need new engine 10,000. 00.

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Tl the contact owns a 2016 Ford F-250. While driving at an unknown speed, the vehicle decelerated to 50 mph and would not exceed 50 mph. The vehicle was taken to an independent mechanic who diagnosed that the heater for the diesel exhaust fluid was faulty and needed to be replaced. The vehicle was not repaired. Baytown Ford (4110 I-10, baytown, TX) was notified of the failure. The manufacturer was not notified. The failure mileage was 82,000.

Tl the contact owns a 2008 Ford F-250. While driving 35 mph, white smoke came out of the exhaust without warning. The contact stated that the vehicle exhibited the same symptoms as listed in NHTSA campaign number: 07v139000 (power train). The vehicle was taken to colley Ford (1945 auto centre dr, glendora, CA 91740, 909-592-4131) where it was diagnosed, but the failure could not be duplicated. The vehicle was not repaired. The manufacturer was not notified of the failure. The failure mileage was approximately 70,000.

Driving truck it told me to pull over and shut engine off. I was stranded on the side of the road and it would not restart, had to get a tow home. I did some research and found this is exactly what my truck did as follows. When the egt sensor goes on the blink, the powertrain control module thinks there is an exhaust system overheating situation. The vehicle then goes into a �controlled power reduction mode� while five warning chimes are ringing away. This ends with the engine shutting down completely as soon as the truck slows to four mph, with no engine restart immediately available.

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Exhaust gas temperature sensors continue to cause issues, beginning within a year of purchase of vehicle new in 11/2013 (July 28, 2014). My truck has been in the Ford shop at least seven times now (currently in the shop now--July 2017--for a sensor that showed problems and was replaced last month--June 2017). The vehicle was moving in each circumstance; the first time my dashboard lit up and said "stop safely now"--I barely made it off the highway before the truck shut down. Had to have it towed to dealership.

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I have had the truck on the dealership 3 times now for the exhaust gas temperature sensors. Have had all the sensors replaced twice and am now on my way back in for a fourth trip to replace them. The truck currently has 41k mi.

Exhaust cleaning cycle causes extremely rough running conditions. Severe engine knocking seems as though a piston will fly through the hood soon. Significant loss of power at any speed during this time. Brand new truck purchased from dealership and this has happened from purchase point all the way through 27500 miles so far. In reading I have found thousands of others that experienced the exact same issue.

Engine runs rough during exhaust regen. Typically when driving between 55-65, the diesel exhaust fluid warning appears. Almost a minute later the truck begins to make loud jack hammer noise and loses power. Feels very unsafe as you lose power for about 10 seconds.

I have a 2015 Ford F-250 super duty with a 6. 7l diesel. I started having this problem intermittently and only noticed it on hot days while at slow speeds, but it has continued to get worse to the point that it happened with every re-gen, at any outside temperature and almost any speed. It all starts with the notification on the screen of clearing the exhaust filter and has an ok in the corner of the screen. Not sure why the ok, since you have no choice on whether to start the process or not. During the re-gen process the engine suddenly and without any notification, looses power, starts to shake and shutter so violently that it shakes the whole truck. The only way to stop it is to put the throttle to the floor. If I let off the throttle it starts over again. The two safety concerns that it causes are the sudden loss of power and my truck suddenly slowing down without any brake lights to warn drivers behind me (I was almost rear-ended last time it happened in town) and secondly, having to keep the throttle on the floor to stop the problem and the speed the truck obtains when doing so. There are times when I cannot step on the throttle because of the speed limit, traffic or road conditions, and am forced to pull over if there is an area to so, if not I keep chugging along holding up traffic until I can. I have not pulled a trailer as of yet, but quite frankly an afraid to do so with this problem for fear of being rear-ended. It occurs at speeds from 30 to 70 mph. It has happened in town on rural roads and on the highway. It has been into Ford several times and they have not been able to fix the problem. The last time it was at Ford, the service manager told me Ford is aware of the problem and will be coming out with a software revision, but not until April of 2016. The truck is unsafe to drive until then.

Exhaust region caused extreme rough running engine and loss of power when towing up hill and passing a semi. This caused the semi to almost hit the back of my trailer. This continues to occur with every exhaust regeneration on the 6. 7 powerstroke diesel.

Exhaust regeneration causes engine shake and loss of power. The last incident occurred when towing uphill and a semi almost took out the back of my trailer. Ford indicates this is normal, however, it did not do this when new. It occurred after approximately 6,000 miles and continues to happen. The dealer indicated they have not seen this before, so I don't believe "normal" applies here. If this is "normal," then Ford engineers need to go back to school.

When stationary exhaust fumes are drawn into cab of truck by the air handling system. This is an ongoing problem.

See all problems of the 2011 Ford F-250 🔎.

#6 spark plug blew out of the head. I had it repaired two days later. Two days after that, the #3 spark plug blew out of the head while I was driving at 25mph. During both incidents gasoline fumes and exhaust filled both the engine compartment and the passenger compartment.

See all problems of the 1999 Ford F-250 🔎.

Truck shut down by itself. Towed truck to dealership and was told the exhaust gas temperature sensor went out. Discovered that Ford was under investigation on a partial recall of same part for same engine for ambulance package trucks. Called Ford to ask if my truck was covered and was told no even through it is the same part and the same engine as the October 2013 recall of 2011-2012 Ford f 250 ambulance package vehicles equipped with a 6. 7lt diesel power stroke engine.

While driving down the high the dash display indicated it was start a exhaust clean cycle (regen mode). Within a minute the vehicle began stuttering, loss of power and the engine began knocking. The vehicle lost 15 mph in a blink of an eye. A very dangerous situation while towing an RV. This lasted for about a minute. Then the engine began to operate normally. This has happened multiple times since the first event. The last occurance was on August 16th. The vehicle has been taken to Ford service for an evulation.

Driver was piloting vehicle through turn at intersection fully loaded with salt and a snow plow. Vehicle dash display read shut down vehicle safely and then immediately shut the vehicle down. Truck was stranded impeding traffic for 40 minutes until a good samaritan was able to pull it back out of the intersection. Vehicle was towed to dealer and exhaust temp sensor was found to be bad. The charge was $100 for the work plus the tow bill which was $113. 50. This is a safety issue. I use this and another truck with the same engine (also submitted complaint for that VIN) to tow and heavy haul all the time. This is not safe if it happens when traveling down hill, fully loaded and the truck shuts down. That is not safe, but in fact rather scary.

While going up the highway the message of " stop safely now" was displayed. Once pulling over to stop the truck died and would not start back. Had to have it towed to a dealership. Turns out the exhaust gas temperature sensor was faulty. This seems to be a very common issue.

For the third time since our 2011 Ford f250 (diesel) was new a faulty temperature sensor in the exhaust system caused the engine to shut down with essentially no warning. On the first occasion, the incident occurred in a parking lot so there was no danger of injury or property damage. The second incident occurred while underway at 70 mph on an interstate highway and we were able to pull over to the right shoulder without endangering others. The shutdown today, however, occurred as we prepared to make a left turn on a busy two lane road. Fortunately the shutdown, which occurred without warning, stopped the engine before we crossed in front of oncoming traffic in the adjacent lane. In this last case there was a real possibility of serious injury and/or property damage. Ford is certainly aware of the problem (we're told by dealer service personnel that the problem is common) and we've asked repeatedly if there is a fix to eliminate these unexpected incidents. Nothing has been forthcoming. We believe the problem should be addressed from an engineering standpoint so that owners of similar vehicles can have confidence that these unexpected problems will reoccur and before someone is injured or killed. .

While driving message came up "stop safely now" I pulled over just enough to get off the interstate, when the engine died, and wouldn't crank again. I called my dealer tarver Ford, they called a wrecker to pick it up and brought it to their shop. 2 exhaust temp sensors bad, $260 to fix. Today 3-13-15 my engine light came on, I bought a code reader and p242a code came up another sensor bad.

The contact owns a 2012 Ford F-250 sd. The contact stated that while driving at approximately 70 mph, the stop safely now warning light illuminated as the vehicle independently decelerated. The failure recurred and the vehicle stalled, and failed to restart. The vehicle was towed to a dealer for diagnosis and the mechanic stated that the exhaust sensor needed to be replaced. The vehicle was repaired. The manufacturer was noticed of the failure. The approximate failure mileage was 58,000.

The contact owns a 2012 Ford F-250. While driving approximately 5 mph, the vehicle stalled without warning. After several attempts, the vehicle failed to restart. The vehicle was towed to a dealer who stated that the exhaust sensor needed to be replaced. The vehicle was repaired. The manufacturer was notified of the failure. The approximate failure mileage was 30,000.

I was driving on I 26 and a warning came on saying to slow down and pull over safely. I dad no chance to do this as the computer put the vehicle in "limp mode". An 18 wheeler narrowly missed hitting my truck as we moved to the shoulder and the engine died. The truck would not start for about 45 minutes. We then drove to the dealer who said he could find nothing other than a warning to change the oil. In the past 2 weeks, the truck has shut down twice again. A tow truck had to be called both times. The first time I was on I 77 and the truck went into limp mode and the shut down as I pulled to the shoulder. The next time I was on us 521 going uphill with no shoulder. The truck again went into limp mode and then stopped on the highway. Cars and trucks were swerving to avoid us. My wife was crying because she was certain that an 18 wheeler would not be able to miss us. I called the sheriff and Ford and later had the truck towed. These two times, the cause was an exhaust gas temperature sensor failure. I believe #2 failed and then #3 (there are 4 of these sensors). Dependability is of course an issue here. But the real issue is safety. Ford has designed a computer system that stops the vehicle no matter where you are to save the engine and/or the emissions system. In doing so, the lives of the driver and passengers are put at risk and could be killed as a result.

While driving my truck on a busy side road, the message center flashed a warning, "stop safe soon". A audible chime was heard and the truck shut off. Complete lose of power brakes, power steering. I was not able to get the truck off the road completely since it happened so fast. Traffic was stopped in both directions while we did our best to push the 7,500 pound truck to the narrow shoulder. Since the shoulder would not fit the entire truck, it was basically half in the road. Traffic has backed up and we had to wait close to an hour for a tow truck. After speaking with the dealer, he told me the truck has a bulletin out about a faulty exhaust gas temperature sensor. This small sensor fault shuts the truck down and will not allow the engine to run.

The contact owns a 2012 Ford F-250 sd. The contact stated that while driving at an unknown speed, the "stop safely now" message illuminated and minutes later the engine would seize. The failure recurred numerous times. The vehicle was taken to the dealer, where it was diagnosed that the heat sensor on the exhaust needed to be replaced. The vehicle was repaired. The manufacturer was not made aware of the failure. The failure mileage was 38,000.

Heard a loud pop from under the hood while driving at highway speed. Sounded like it was right in front of the globe box area. The engine ejected a spark plug which is a very common failure for triton engines with aluminum heads - threads failed that hold the spark plug in place. I did not hear any warning sounds that a failure was imminent. The passenger side of the engine, spark plug closest to the firewall was blown out which is also very common. I smelled gasoline and exhaust and fortunately this failure did not result in a fire.

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.

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I have had to replace exhaust heat sensors 4 times in my 2012 F-250. The same sensor twice,first at 26k around June 2013 and and again at 46k, oct 2014. I've been stranded 3 times and had to be towed to a dealer. I occasionally pull a 42ft 5th wheel camper and am very worried it will happen while pulling it with no place to pull over. Ford needs to step up to the plate and get a fix for this problem.

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.

Tl- the contact owns a 2008 Ford F-250 sd. The contact stated that while driving at various speeds he noticed that white smoke would emit from the exhaust system. The contact stated that the exhaust system was equipped with a self-cleaning function however, the white smoke still emitted after the function was completed. The vehicle was not taken to the dealer or an independent mechanic. The manufacturer was contacted and they offered no assistance. The failure mileage was approximately 179,000. The current mileage was approximately 180,000. The VIN was unavailable. Kmj.

Exhaust leak from behind the turbo. Exhaust enters the inside of the cab. Seems to be a common problem. Expensive to fix. Must remove cab from frame to repair. Hazardous fumes enter vehicle causing headaches. Dealer is acting like this is rare but in searching the web I have seen numerous complaints of the same problem I am having. ## VIN failed ##.