Four problems related to engine exhaust system have been reported for the 2003 Ford F-350. The most recently reported issues are listed below.
The truck (2003 F-350sd) lost all power while driving. The deal replaced the egr valve. The dealer said that this is a known problem with 6. 0l d motors. The egr valve will stop up and not allow the exhaust to escape.
Cracked "y" pipe is leaking diesel exhaust fumes into cab of truck. This occurred previously when the truck was under warranty back in 2004 but now it is not under warranty nor is there a recall. I have brought this up to several dealers in the area but unless it is under warranty they won't cover the repair. However, I feel it is a major safety hazard which I feel should be addressed immediately, as diesel fumes are linked to cancer or could leak to an accident if someone is overcome by the fumes, which could lead to a death. Please look into this hazard and let me know if you have any questions, I would be happy to answer. I do know from talking to mechanics that this does occur often in these trucks.
A bad odor was coming from inside of the vehicle through the vents. Exhaust system was causing the smell. On one occasion, consumer had to pull over to the shoulder because he became very ill. Dealer was aware of the problem.
Vehicle lost power (and never returned) while passing another vehicle on the highway. Check engine light came on after 20 miles of driving under the lost power condition. Took the truck to the dealer and they replaced the egr valve. This happened at only 3500 miles. I wish Ford would test their vehicles instead of having the consumer test them for them on the highways.