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

The contact owns a 2017 Ford F-250. The contact stated that while operating the vehicle, the check engine warning light remained illuminated. The vehicle was taken to the local dealer, who diagnosed that the egr valve was faulty and needed to be replaced. The contact indicated that while the egr valve was being replaced, the bolts connecting the egr valve to the exhaust intake fractured and also needed to be replaced. The vehicle was not yet repaired. The manufacturer was notified of the failure, but no assistance was offered. The failure mileage was 95,000.

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The contact owns a 2014 Ford F-250. The contact stated while driving at an undisclosed speed, there was a message displayed informing the contact that the vehicle was limited to 50 mph, after which the vehicle entered limp mode. The driver was able to pull over to the shoulder of the roadway, where the failure persisted. No warning lights were illuminated. The vehicle was taken to the dealer, who diagnosed a failure with the exhaust gas recycling (egr) system. The vehicle was not repaired. After investigating the failure, the contact related the failure to customer satisfaction program: 21m04. The manufacturer was notified of the failure, a case was opened, and the contact was referred to the NHTSA hotline for assistance. The failure mileage was 147,000.

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The contact owns a 2013 Ford f250. The contact stated while driving at an unknown speed, the check engine warning light illuminated and the warning message saying that the vehicle was going to be in lamp mood. The contact was able to stop on the side of the road and have the vehicle towed. The vehicle was towed to the dealer, and they stated that egr cooler needed to be replaced. The vehicle was not repaired because the dealer stated that the code did not match with the customer satisfaction programs campaign#21m04. The manufacturer was contact, and they also stated that code did not match with the customer satisfaction programs campaign#21m04. The failure mileage was 99,000.

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Egr sistem fails to soon and I have dead wobble front suspension.

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I have paid over $6. 000 dollars to my local Ford dealer to fix my truck just to have them tell me there is no way to fix the problem, its a design flaw from Ford that can not be fixed. I have been back and forth with Ford motor company, I have been lied to, strong along, calls not returned and so on. The design flaw has to do with the egr. And today its seems the 3rd new turbo stopped working and the motor has started to have a bad vibration. This has been a nightmare and even though Ford kept telling me they will take care of me, nothing has happened. When the turbo failed as I was trying to get onto the freeway I had no power and nearly was rear ended by an 18 wheeler who was extremely angry. I had to stay off the freeway on other roads till I could get home. The truck developed a bad vibration and I was not sure I would get it home. If I would had been told by Ford the first time I took it in of the design flaw and there is no way to fix it, I would have never poured so much money into it. It is a lemon and should have been recalled. I have talked to many people and researched this truck. I found out Ford new of this design flaw and that their customers would have these problems but released the truck to us anyway. I now can't afford to put any more money into this truck, I can't fix it, I can't sell it, and Ford will not do anything to help me. When I found out I was lied to and caught them and said, I now you have been lying to me and I do not trust you, I was labeled a hostel customer. I ask you, who likes to be lied to? this has been going on into 2 years now. Now I have no truck. I am interning where it asks "when this happened" today's date. Please help. Thank you.

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Tl-the contact owns a 2004 Ford F-250. The contact stated in the fuel system, there was a cone that breaks apart in the fuel pickup sender unit. The failure recurred numeros. The contact stated that while driving the vehicle stalled without warning. The contact bearly was able to coast over to the side of ramp and was not able to restart the vehicle. The contact stated that the vehicle was towed more than once to grieco Ford of delray beach dealer, (3000 s federal hwy, delray beach, FL 33483, (561) 278-0303) and was diagnosed the the cone pickup disintegrated in the fuel tank and needed to be replaced. The vehicle was repaired. The technician replaced the cone unit, fuel filter, fuel lines and injector. The manufacturer was notified of the failure and provided a case number: cas-24538661. The failure mileage was approximately 59,000. Aw.

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#1: 2019 Ford f250 truck randonly loses control of stealing and goes out of control at speeds above 45. This occurs when slightly turning truck or if hitting a bump in the road surface. #2 lack of power: dealer told me after 3 attempts to solve lack of power problem that egr value needs replaced. This was after they reprogrammed the trucks computer. Part has been on back order since 9/14/19 (over 47days with no eta on repair part). Truck is out of service at this time.

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2014 Ford f250 high pressure fuel pump exploded and sent metal throughout my field system. Was driving to houston going 80 mph on ih 10 and my truck came to a stop and power steering turned off so I could barely get it off the highway. 18 wheelers were going by me going over 80 mph. We were almost killed. Was left in 106 degree heat for over 2 hrs waiting for a tow truck. Ford dealer in houston where it was towed (100 miles) wants $14,000. 00 to fix the truck.

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.

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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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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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.

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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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.

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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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.

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.

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.

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.

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.

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.

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.

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.

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.

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).

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.

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.

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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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.

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.

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?.

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.

Have had numerous problems with the cooling system on this vehicle. Had the air charge cooler replaced under warranty at around 70,000 miles. The radiator was leaking as well but dealer refused to replace it and wanted 1400. 00 to replace. Was losing coolant at a rate of about 1 gallon a week going thru the air charge cooler and out the exhaust. At 89,000 miles I had to pay $1947. 00 to replace both the vertical and horizonal egr coolers. Again, dumping a gallon of coolant into the exhaust system a week causing sever smoking and pollutants. This is a serious problem that thousands or probably millions of F-250 and others with the 6. 4l diesel engine. Ford refused to do the right thing and do a total recall on these ill designed trucks. I cannot believe they have been allowed to get away with turning their head on this design flaw and not made to correct the air charged coolers, plastic radiators and the egr coolers.

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!.

Bought vehicle used in Nov,2011. About 4 months later started having problems with engine power. Was told by Ford dealership that I bought it from would need to rebuild engine, should be covered under extended warranty (involved egr, gaskets and bent head bolts). Call Ford extended warranty people. Refused to pay anything. Now truck has about 96000 miles on it and the truck is stalling out while driving down the road, took back to dealership again, was told that the injectors are the problem now. Decided to check out recalls on this veh. And found out several things (1) that Ford had a recall for the injectors and (2) that the problems before were probably caused by this. Called the recall center at Ford and was told that VIN # did not match up to any recalls, even though it was on 180000 05 Ford f250 sd. Was also told to check with extended warranty that is also through Ford. Once this is fixed will have more money invested in this and rebuilding engine 6 months ago than the truck is worth. No more Fords for us.