Manifold/header/muffler/tail Pipe Problems of Ford F-250 - part 2

The contact has a rusted exhaust manifold on his 1999 Ford f250 super duty and this was causing an open flame in the engine compartment when starting the vehicle. Because he had 108,000 miles on his vehicle, Ford will not do anything. He noticed this around 20,000 miles. The dealer told the consumer it was a design issue and they recommended replacing the bolts with brass or stainless steel bolts.

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

: the contact stated the vehicle's exhaust manifold inner fender well cracked due to salt and weather and the bolts fractured off. The service dealer was unable to fix the issue.

See all problems of the 2001 Ford F-250 🔎.

Diesel fumes came out of passenger air vents making myself nautious and sick from co2 poisoning. Bought it in to the Ford dealer and service manager smelled the problem, said that there might be a problem with the y flange on exhaust manifold. Called back and pulled manifold and didnt see a problem was going to order a new one. Says not an uncommon problem.

See all problems of the 2005 Ford F-250 🔎.

2003 F-250 super duty 4x4 gas. 46,000 miles. Found 2 broken exhaust manifold studs on passenger side of engine. While investigating exhaust leak also found 2 front ball joints bad. Ford states that it is out of warranty and that it is normal wear and tear. I find this unacceptable. This vehicle was purchased less than 3 years ago. Most of the miles are traveling between texas and PA. This is a 3/4 ton super duty truck. Ford needs to stand behind their product.

See all problems of the 2003 Ford F-250 🔎.

Exhaust leak entering drivers compartment had this truck in shop four times have been tld to many ahead so it will be days maybe longer think they are wanting the warranty to run out but this leak can cause health problems are maybe an accedent. There has been a lot of the diesel pickups with this problem so I think it needs to be repaired under warranty no matter what the mileage is.

See all problems of the 2004 Ford F-250 🔎.

2002 Ford F-250 super cab spark plug blew out of cylinder head. Just driving down the street and all at once there was a loud bang like a big hole blew out of the muffler. Shut the engine off, pulled over and tried to determine cause. Drove truck another couple of miles to repair shop. The repair bill was over $2,000. The repair shop states they have had at least 6 of these situations in the last 2 months. We believe this is a defect in this truck - the truck has 61,700 miles on it and it is too early to experience this kind of difficulty.

See all problems of the 2002 Ford F-250 🔎.

I have a 2002 Ford F-250 super duty pickup truck with a v-10 engine. It has approx. 63,000 miles and is subsequently 'out of warranty' (3/36,000). On July 9, 2004 I heard a brief tapping noise and a pop then a loud noise like an exhaust manifold leak. Immediately upon hearing this noise I shut off the engine and called a tow truck, as I am not a mechanic and did not want to create further damage. When the mechanic arrived to tow my truck he observed that a spark plug had been blown out of the cylinder. I informed him to tow it to his lot until I could decide what to do. The next dy I had the tow truck company bring my truck to the Ford dealership I purchased it from. Today after the dealership's mechanic inspected my truck they informed me that the cylinder head was broken and I would be liable for the $3,700. 00 repair. What I find distubing is my scheduled spark plug replacement service interval: Ford recommends 100,000 miles before replacement. How would I ever know that the speark plug was not installed properly at the factory prior to the scheduled service? additionally, had it not blown out on its own, who knows what other damages would have gone unchecked. I have researched this particular defect on the web and have found not less than 100 people thus far with the exact same complaint. Additionally , I have found numerous people that this has happened to more than once on the same engine. I stopped researching because I feel this is suffucient supporting documentation of my complaint. If necessary, I will be happy to furnish this documentation for you. I have found this problem to be inherent in all v10 Ford engines since 1999. I have also found that Ford is aware of this problem and has issued a technical service bulletin to all of their dealerships describing this particular repair procedure.

Complaint regarding problems with Ford v-10 engine. The consumer started a petition with other Ford consumers who have experienced problems as well. Additional problems the consumer experienced were: brief tapping noise and a pop, then a loud noise like a manifold leak, the mechanic observed a spark plug had been blown out of the cylinder and the cylinder head had broken. The consumer's cell# 845 0 438-3527.

The contact states the head in the engine was defective and it blew the spark plugs into the fuel rail. The dealer was unaware of any problems and offered no free remedy. The manufacturer has not been contacted.

I have a 1997 Ford f250hd with the 5. 8l engine and 78,000 miles. I noticed an exhaust leak and decided to install exhaust manifold gaskets to cure the problem. However, when I started the job I noticed that there were broken exhaust studs that had broken flush with the head. After removing the manifolds from the heads I also found multiple cracks in the manifolds, one almost completely around the right manifold. After contacting the local Ford dealership I was told that the problem was a common one for my year and engine but was only taken care of while there was warranty. I was told that the casting for the manifolds for those years was weak.

See all problems of the 1997 Ford F-250 🔎.

I purchashed the 6 liter 2003 250 truck in may of 2003, and nothing but a nightmare ever since. It has already had a cracked exhaust manifold which was causing poisonous fumes to enter the cab, the dealer fixed it and said it happens. Well it only had 5,918 miles on it. I bought this new truck so I wouldn't have to be taking it to be fixed all the time. Well since that day in may the truck has been in the shop 3 times for no power, poor gas milage, surging and bucking while in the tow / haul feature. And all they do is re-program it and say that is the problem. Well I disagree and I feel this truck is unsafe and is a time bomb waiting to happen. I feel that someone needs to start a class action lawsuit against Ford or they need to step up and stand behind their supposed quality and make the customers happy and safe. Henry Ford would be disgusted if he were alive today,that whoever is the careless individuals in charge are allowing this truck to remain on the road. Does Ford need another firestone on their hands before they see what is going on . I sure hope that someone doesn't lose a family member before something is done. I can say that I will never purchase a new Ford vehicle again please someone help us, before its to late. Thank you.

VIN # 1fmsu41px3ec31720 5/3/03 recall 03b06 6/4/03 air conditioner failure 6/17/04 air conditioner failure , ac blend door binding ,plenum defective,had to remove dashboard to repair 6/18/03 4x4 failed to engage, faulty gem module 6/18/03 oil leaking at rear of motor, rear main seal failure, still leaking to date 11/6/03 water seperator failure, perform recall 03e04, perform recall 03l12 1/14/04 rear heater leaking , rear heater core failure, replace fuel manifold,because fuel seperator light still warning 2/27/04 rear main seal leaking/ no repair offered 3/11/04 rear main leaking / no repair offered 5/17/04 air conditioner failure,faulty line conection/rear main still leaking 6/10/04 rear main still leaking /no repair offered 8/5/04 recall 04s15 peformed/ turbo failure, unrelated to recall 8/13/04 rear main still leaking/ no repair offered 9/15/04 rear main still leaking / no repair offered/power loss since turbo replacement.

Problems with oil pan, brakes, transmission and exhaust manifold. The front end casing cracked. The oil pan, brake and transmission lines rusted out. The bolt heads rotted off from the exhaust manifolds, and the heads cracked as a result. The rear end cap rusted along with the pollution control valves. The left front tire tilted as a result in a cracked front end housing leaving a 1" gap. A front tire alignment was needed.

Exhaust manifold bolts breaking and not gasket on exhaust manifold.

See all problems of the 1996 Ford F-250 🔎.

I purchased a new Ford f250 super duty truck in may, 2001. I almost immediately smelled exhaust fumes coming from underneath the front of the truck- fumes which smell much like that of a lawn mower. The exhaust coming from the end of the tailpipe did not have this smell. After 6 months, I brought the truck back to the service department in my place of purchase, bill marsh Ford in newtown, PA. The shop foreman denied smelling any fumes and, without having looked underneath at the exhaust system, stated that there was nothing wrong with my truck. A year later I returned for the same problem. I had him document this visit, but not the first one. Their consensus remained the same. For the first time the other day, I crawled under my truck while it was running, seeking an exhaust leak. And that's exactly what I found. Recently, my truck's warranty has expired and I still have this problem. Today, bill marsh Ford service has looked at the problem based on what I found. I now have an appointment with them to have the defective part of the exhaust system replaced. While it is one thing to have to pay for something that they could have fixed when it was new, or that should have been put together right and tested at the factory, I have a bigger concern. I feel this is a safety hazard, since the exhaust fumes come into the truck through open windows and the vents. It is also an environmental issue since the leak is in front of the catalytic converter. I cannot see how I was allowed to drive under these conditions after I reported smelling the fumes, or how the truck was even allowed to pass inspection if the exhaust system was completely checked. Now that I have identified the source of the problem which has plagued my truck from day one, and the service department has admitted that there is a correctable problem, I wish to pursue any further action necessary for such a case. Thank you!.

When traveling about 30mph on highway there is a noise coming from exhaust system pipe . Dealership is aware of problem.

See all problems of the 2000 Ford F-250 🔎.

A rattling or knocking noise emitting from the engine area. Noise is extremely noticable when the engine begins to labor. I have been told it could possibly be caused from a poorly designed "y" pipe.

The exhaust pipe heat shield was in contact with the metal transmission fluid tube from the transmission to the radiator. Over a period of time the shield wore a small hole in the tube, resulting in a pinhole, which caused the transmission fluid to be released under pressure directly onto the exhaust pipe.

Consumers vehicle will not pass future vehicle inspections because exhaust pipe exits on the side (design).

When turning on the air conditioner or heater strong diesel fumes enter the passenger cabin. Dealer will replace the flex pipe on the back of the engine from the manifold.

Vehicle fails to stop properly when brakes are applied. Would shake and vibrate badly. Took vehicle to dealership, mechanic noticed rotors were warped, which caused the braking problem. Had them replaced after 10,000 miles. Engine stalls and oil leaks from the turbo into the inter cooler. Transmission does not shift. Tires began to bulge out, consumer did not specify kind of tires. Electric window motor failed. Seals are out on the front axles and they were just replaced two months ago. Air filter system is inadaquet for this size of engine and has to be replaced every 2 to 3 thousand miles.