Engine Exhaust System Problems of Ford F-350 - part 1

The contact owns a 2016 Ford F-350. The contact stated that while driving at an undisclosed speed, the check engine warning light illuminated. The vehicle was taken to the dealer. The dealer diagnosed that the diesel exhaust fluid (def) reductant heater needed to be replaced. The dealer informed the contact that the VIN was not included in a recall. The vehicle was not repaired and remained at the dealer. The manufacturer was made aware of the failure and referred the contact to file a complaint with NHTSA. The failure mileage was approximately 52,500.

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At times and very frequently truck is losing power to accelerate, very slow to accelerate, will not go over 50mph. This happens everywhere doesn't matter the speed or location. When this happens the turbo psi reads 0, and you can't hear the turbo. A warning will come up that says the exhaust needs to self clean and drive to clean. Sometimes it will have thick smoke come out the exhaust that stinks. Sometimes the truck will shake violently when trying to accelerate or brake. Very dangerous when driving on the highway and the truck will not accelerate so that I can merge without being rear-ended. Sometimes it will loose all power so I have to let up on the gas and try again softly and it will slowly accelerate this has also happened at a traffic light that turned green for me, as I was entering the intersection I lost all power and was almost rear-ended. The first happened when I was trying to get into the right slow lane on the highway from being pulled over on the shoulder and as I stepped on the gas and the truck did not accelerate at normal speeds and I was unable to accelerate to speed in order enter traffic in time to not get rear-ended by the car coming up in the lane I was trying to enter thankfully the other driver switched out of that lane.

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Tl the contact owns a 2012 Ford F-350. While driving at unknown speeds, the vehicle went into power mode and lost power. In addition, the check engine indicator illuminated. The vehicle was towed to the local dealer (walts live oak Ford, 1109 ohio Ave n, live oak, FL 32064, (386) 362-1112) where it was diagnosed that the exhaust sensor needed to be replaced. The vehicle was repaired. The manufacturer was called, but failed to respond. The failure mileage was 150,000.

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Exhaust filter cleaning when that warning comes on my trucks engine is really rough and shakes. This is when driving to clear the exhaust filter.

While towing our fifth-wheel trailer with our Ford f350 drw truck, the diesel particulate filter (dpf) caught fire. While towing our fifth-wheel, we turned from the highway onto a city street in mesa, az. We heard a loud "pop" and thought we blew a tire. After pulling over and checking that all tires were fine, we continued on. We noticed reduced power to the truck and the turbo boost was zero. We pulled over again to look for signs of a problem. We looked under the hood and did not see any obvious hoses blown or issues. The truck was still running, so we continued on slowly as we were almost home. Near ellsworth/thomas road in mesa, I got a notice, "reduced engine power," as my 14yo son yelled, "there's smoke coming out of the truck. " we pulled over again and my wife and son saw flames shooting out of the tailpipe and the exhaust system was glowing red hot. The dpf was blowing flams out towards the ground. We emptied a fire extinguisher with no effect. Our trailer has a water hose so we sprayed water on it for about 10 min to cool it down and stop it from reigniting. We did not call police as my wife and I share nearly 40 years of law enforcement experience. We extinguished the fire and called for a tow. After $10,000 in repairs, we have received no response from Ford. We have not filed an insurance claim yet and are working to contact Ford again. Ford knows there is a problem with the def/dpf systems. Drivers have no instrumentation to see the temp readings on the four temp gauges along the exhaust system. How are there no error codes or notices when a vehicle is on fire??? my and my wife's experience handling emergencies prevented a total loss of our vehicle and potential death of our family. Pics attached. Pics of red hot exhaust are not our vehicle, but a vehicle that had the same issue. This is what ours looked like.

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Tl-the contact owns a 2014 Ford F-350. The contact stated that while driving at various speeds the engine lights illuminated. The vehicle was not towed. The vehicle was taken to the dealer spradley barr motors cheyenne 2200 westland rd, cheyenne, wy 82001 (307)-638-3335 where it was diagnosed with diesel exhaust fluid heater malfunctioning which needs to be replaced. The vehicle was not repaired. The manufacturer was made aware of the failure and informed the contact that there were no recalls under the VIN provided. The failure mileage was 88,000. Ck.

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At approx. 4600 miles the engine started to shake violently a couple of miles after the emission regeneration started. Ford has a service bulletin on this issue for f350 super duty trucks built in 2016. Apparently the computer increases the fuel in one side of the cylinder head in order to burn off the soot on the emission filter. This causes the engine to back fire continually. The first time it happened we thought that the exhaust fell off it sounded so bad. The shaking got to be so bad that we had to pull off to the side of the road and turn off the engine when it happens. The truck was in three times for service at 5985, 10669 and 15210. First, Ford did a software update. The second time it was in for repair, the dealer pulled off the cylinder head and replaced it. That didn't work either. Now, Ford has decided to replace the entire engine. It takes about 5000 miles for the issue starts happening, so we will see if the new engine does the same thing.

When 2016 F-350 sd pulling 18000 lb camper on interstate highway running 65-70 mph goes into exhaust cleaning mode, the vehicle speed drops to approx 45mph in short distance. Vehicle is acting like limp mode. No codes are present. When exhaust cleaning mode clears, vehicle resumes normal speed. This has happened twice in the last month. Ford tells me this is normal. Feel this is a major safety hazard when speed suddenly drops ~30 mph with chance of rear end collision. This problem has only happened when pulling 18000 lb camper. Have not seen problem with no load.

At times while driving at 45-60 miles per hour and while in 6th gear (automatic) after the "cleaning exhaust filter" message comes on when it cleans the exhaust twice within a 100 miles, the engine will shake and knocking/spiking noise after the second cleaning. This happens intermittently and I am unable to recreate the problem at the dealership. It doesn't happen all the time but when it does it feels like you have a loose wheel and it will jerking backwards and forth. Ford seems unaware of this problem and has no remediation on how to fix the problem. This started around 8000 miles the truck has 32,000 miles now.

The contact owns a 2011 Ford F-350. The contact stated that the engine warning light was illuminated. The vehicle was included in a recall involving the sensors with the exhaust system. The vehicle was repaired, but the failure recurred. The contact informed the dealer who scheduled another repair. The vehicle had not been repaired. The contact found that NHTSA action number: rq14005 (electrical system, engine, and engine cooling) directly related to the recalls received and included the vehicle's year, make, model, and engine referenced in the investigation. The manufacturer was not made aware of the failure. The NHTSA campaign number was unknown. The approximate failure mileage was 40,000.

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At times while driving at 50-55 miles per hour when "cleaning exhaust filter" message comes on, the engine will shake and knock violently. This happens intermittently and am unable to recreate the problem at the dealership. It doesn't happen all the time but when it does it feels like you have four flat tires and it is very violent. Ford said this is normal, I know it's not. We live on very narrow and winding roads in the mountains. I'm afraid that if this happens on snowy or icy roads conditions the vehicle will be very had to control. This has happened 4 times. The date below is the last time it happened, mileage was 6,865. This first happened at about 4500 miles. Seems to happen at about 400-600 miles.

During driving on highway, exhaust regeneration cycle activated, violent shuddering and clattering from engine for 2 minutes.

Engine stopped once in the road pulling a 40 ft. R. V. . Intermintley severe loss of power and trying to overheat. Comeing down a 7200 ft. Mountain I lost the r. V. Brakes,engine brakes & the tow haul mode (to help slow down) all I had was the truck brakes going around 80 m. P. H. By the time I got stopped all 4 wheels were smokeing cooking the related parts, rotors, brake pads, calipers,wheel bearings in my opinion. Later in a town going slow and stopping the brakes pulled violently to the right, a few more traffic lights then violently to the left. Failing to clean the diesel exhaust filter as needed. Sometimes the wipers come on one time when starting the engine. 3 attemps to fix the engine problems and in my mind it is not fixed yet, most of these problems happened at higher altitudes. All this information should be in the trucks black box, since I could have gotten killed twice I have not let the dealer have the truck again as it is running o. K. Now and I have ordered a new truck because I am afraid of this truck. The dates are approximate, the dealers and I have a copy of the repair attemps . I was on the same roads two years ago with a 2011 f-250 same engine and a heaver load and did not have any problems.

This is the third time that my truck has left me on the side of the road. Ford had a recall of all 2012 ambulance f350 because of this exact situation and is leaving the consumer to worry with it on their own. The actual problem is the egt sensor 13 and 14 in the exhaust system. These sensors continue to fail and all Ford can do is to keep my vehicle for 4-5 days and tell me that they cant find the issue and they replace the sensors (only to fail again in about a month). I can not drive this vehicle anywhere without the thought of failure. There is no way I can take this truck out of my normal around town area as if failure does occur, I am stuck. I am afraid that it is going to die on me in traffic and cause an accident or death of myself or a passenger. I have taken it to 3 different local dealers only to be told that they dont have a clue and know nothing of any other similar instances of this ever happening. (I can show you 50 cases online that have happened to other owners of the same vehicle) I am looking to get this taken care of as soon as possible as I am driving at $65,000 vehicle that I cant trust to drive across the state line. Any recourse that you can offer is very much appreciated as Ford is acting clueless to this ongoing issue. Thank you for your help.

Warning came on saying "stop safely now" and as I pulled to the side of the road the truck shut down and would not re-start. Luckily I was not on a busy road, pulling a trailer or out of cell range or there definately could have been a problem. Because there is no warning and the vehicle will not start again and these trucks are way to big to simply push off the road this is a very dangerous situation. After looking into the problem online I have discovered that this is and has been a problem on these trucks and now that I have been told that the replacement sensor is on national backorder and will take an undetermined amount of time to find, this is a very common problem. These are large truck and often are pulling large loads, this problem of a sensor that can completely shut down a truck leaving it stranded is a very dangerous situation not only for the driver but even more for the others on the road since it will be impossible for everyone to safely get out of traffic before the truck simply stops. There are 4 exhaust gas tempreture sensors on these vehicles, I had one fail causing the problem.

The contact owns a 2004 Ford F-350. The contact stated the exhaust system warning light illuminated and the engine loss power. The vehicle restarted. The contact mentioned that the failure recurred on several occasions. The contact referenced NHTSA campaign number: 07v139000 (power train). The vehicle was taken to a dealer. The technician diagnosed that the exhaust sensor needed to be replaced. The manufacturer was notified of the failure. The approximate failure mileage was unknown.

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Ford f350sd crew cab w/ 6. 7 diesel motor. . . Vehicle was being driven when suddenly warning message came across dash that vehicle was "shutting down" and to pullover vehicle immediately. Within 10 seconds vehicle began decelerating and came to a complete shutdown. It was very difficult to maneuver vehicle as power steering and everything stopped working. With wife in a panic, she barely got the truck off the highway, before complete shutdown of vehicle! called local Ford dealer, which did have the truck towed in to dealership, under Ford warranty. Truck was diagnosed as having a "faulty" exhaust sensor, gave estimate to fix of around $600. 00. Claims it was not part of the powertrain, so no warranty coverage of the costs of repair! totally frustrated with Ford for this incident and lack of support or concern for this failure, I appealed to their customer service dept. And basically got nowhere! now as I have done research on this issue, I find out that Ford has a recall generated #13v535000, on this very same product failure, with the exact same issue as our truck's failure. However, Ford only issued the recall for f350,450, &550's that were utilized in ambulance chassis. Our truck has a same build date as the recall indicates and every exact symptom that they cite in the recall letter and findings, yet Ford refuses to acknowledge that the same problem could have existed in the non ambulance f350's. I have only asked Ford customer service reps. For reimbursement of my costs for this repair, which was completed on 08/29/2013. They have refused to accept my claim! I find this ridiculous, and the safety issues of the problem were every bit as severe in this private situation as what may have been in an ambulance use situation. Please help, anyone at Ford should realize that the "faulty" sensors probably were placed on many other f350's built during that same timeframe.

Failure of flexible joint in the exhaust up-pipe creates a fatal safety hazard for all occupants of the vehicle. Exhaust gasses leak from the failed joint and enter the cab of the truck through the heater vents. This can cause the occupants to be overcome by exhaust gasses while driving, leading to a fatality. There have been several complaints identified in Ford blogs with regards to this and nothing has been done to correct this.

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The contact owns a 2012 Ford F-350 sd. The contact stated that while driving 75 mph, the stop vehicle now warning message illuminated. The vehicle also lost power. The vehicle was towed to a dealer, who performed a diagnostic test and advised the contact that the egt exhaust temperature sensor was defective. The dealer replaced the exhaust temperature sensor replaced. The failure mileage was 4,882.

The contact owns a 2008 Ford F-350 sd. The contact stated that exhaust fumes emitted inside of the vehicle. The vehicle was taken to the dealer who indicated that the exhaust filter was poorly designed. The vehicle has not been repaired. The manufacturer was notified of the defect. The approximate failure mileage was 120,000.

1. Severe engine rattle and then severe shaking of entire truck due to exhaust regenerative system. Truck becomes hard to control on highway and presents danger in heavy traffic situations. First incident was taken in for repair; second incident occurred approximately seven months later and was told by dealer service representative that in order for the exhaust regenerative system to work properly we had to watch for the "cleaning exhaust system" message to appear (which only flashes on for approximately 5 seconds and requires eyes off the road) and then drive an additional 20 miles at speeds above 50 mph for the regeneration system to complete. Unacceptable when living in an area where speed limit is 45 mph and there is only a distance less than 10 miles from one end of our town to the other. In other words, if we are pulling into our driveway and the message comes on, we are to not stop the truck and drive it for an additional 20 miles at 50 or more mph to complete the cycle. Video of one incident of the severe shaking is available if needed. 2. Hard washboard bouncing effect when operating vehicle at 45 mph. Went to the personal expense of ruling out tire issue. Cannot maintain vehicle at 45 mph.

Truck cut off . The exhaust sensor keep going out. This is the four time the sensor have gone out . Now the ac is out at 51000. Miles I buy a new Ford f350 about ever two to five years I have a lot of problen with this 2011 f350 my next truck may not be a Ford.

The truck has begun blowing white smoke while under acceleration. This is a very blinding smoke. I have found numerous other truck owners with the same 6. 4 l diesel engine experiencing the same issue. Ford has not offered a fix for this and say it is doing no damage to the engine. It has caused me to be pulled over by the police as it is that severe. I would like the truck fixed, a new exhaust system which works or I want Ford to buy the truck back for what I have in the vehicle. I should not have to drive a vehicle that is causing a safety issue for others. Ford will not help in this matter.

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Loss of coolant, white smoke exiting out of exhaust. Engine over heating. Can lead to blown head gaskets.

The contact owns a 2001 Ford F-350. The contact stated that the muffler brackets and exhaust manifold were corroded. The vehicle was taken to the dealer, but the manufacturer was not contacted. The vehicle was not repaired. The failure and current mileages were 42,328.

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The contact owns a 2009 Ford F-350 diesel. The contact stated the fuel fumes emitted into the vehicle whenever it was in the exhaust cleaning mode. On occasions, blue smoke also came out of the exhaust pipe. The vehicle was not taken to the dealer for diagnostic testing. The manufacturer was not made aware of the failure. The vehicle was not repaired. The failure mileage was 48,000 and the current mileage was 57,988.

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The contact owns a 2006 Ford F-350. While driving at an unknown speed, the contact stated that exhaust fumes were emitting from the exhaust manifold in front of the vehicle. In addition, the contact stated that there were exhaust fumes in the vehicle. The vehicle was not diagnosed or repaired. The manufacturer was notified of the failure. The failure mileage was 25,000.

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While driving my 2008 f350 superduty diesel powered truck at 45mph for approx 4 miles, received message "exhaust drive complete" immediately followed by "stop safely now" and complete powerdown of engine. The truck decelerated so fast that despite my flooring the throttle, the car behind me almost collided. The truck lost so much power that I could not safely pull off road and was in a rural area between two blind curves. The whole incident happened in less than 30 seconds and left truck completely vulnerable to whatever traffic conditions were at the time of incident. After getting over to side of road, truck stalled on slight rise and did not have the power to move, however when I shut truck down, my 5ft8in 200lb body was able to push the 8000 lb vehicle over the hump. Engine would not crank over after incident and was not allowed to restart until after the unit either cooled down or timed out (didn't try for 30-45 min later). By time tow truck arrived, unit would run but less than full power and check engine light was on. Truck was in shop serviced for faulty egr valve and had latest Ford recall for reprogramming completed less than 100 miles prior to incident.

1. Normal driving with normal scheduled maintenance. 2. Egr system: egr cooler, oil cooler, fan clutch, modulator valve, egr valve 3. Brought to Ford; replaced the above parts. Different style egr cooler old parts were taken by Ford.

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Issue 1 - fuel spilling out of coolant system. Fuel spilling onto exhaust components and coating engine and underside of vehicle. Created a fire hazard. Created an environmental hazard. This could have resulted in severe injury or death if a fire had started.

The contact owns a 2010 Ford F-350 sd. The contact stated that smoke was emitted from the exhaust as the vehicle went through regeneration. The contact was concerned because the smoke would block the roadway of the vehicles following behind him. The contact had been dealing with the issue since the vehicle was purchased. The manufacturer was contacted but provided no assistance. The failure mileage was 6,000 and the current mileage was 12,000.

My f350 crew cab has fumes that enter the cab of the truck when the exhaust system is cleaning. This has been happening for as long as I have owned this truck, you can't leave the windows up and breath because it is a health hazard. Sunbelt Ford in cordele georgia is aware of this problem as they have looked at the truck. I was advised that my truck is the only one that does this. I know there is a problem as I have been a satisfied Ford truck owner for years as well as using Ford trucks in my construction business and have never encountered this type of problem before. Please advise me in writing as I feel that Ford motor company has a problem.

08 f350 with 70,000miles on it. We tow a trailer daily with this vehicle. Approximately 10 times per day it states "cleaning the exhaust filter". On sept. 29, 2010, it said "cleaning exhaust filter and stop safely now" and shut off immediately. While I was in the middle of road. Luckily a friend was driving by and towed me out of the lane of traffic. Prior to this our vehicle had four radiators put into vehicle because plastic parts kept breaking. The exhaust sensor was replaced prior to this incident. The code for this was the exhaust sensor. If I was on four lane highway when the vehicle shut down I'd be dead. I didn't have any time to pull off road. Something must be done about this. Ford is not standing behind this. Truck is still at dealer. I've been without vehicle since sept. 29, 2010. They refuse to put truck back together. They stated that this would be warranty but Ford won't warranty and I won't pay what they are asking for something that is a frequent occurrence.

The contact owns a 2005 Ford f350 super duty. While the contact was driving approximately 35 mph, the engine loss complete power with the engine warning light illuminated. There was also a burning odor of coolant. The contact allowed the engine to cool; and was able to start the vehicle the following day. The vehicle was taken to an authorized dealer where the technician stated that the failure was contributed to the egr valves. The manufacturer was notified and stated that they the service warranty exceeded 30 days over the expiration and they refused to honor the repair under the warranty. An authorized dealer offered a fifteen percent discount towards the estimated repair cost of the vehicle which was approximately $4,000. The vehicle had not been repaired when the complaint was filed. The failure mileage was 41,800. The VIN was unavailable.

Information redacted pursuant to the freedom of information act (foia), 5 u. S. C. 552(b)(6) on 3/26/10 my 2005 Ford f350 6. 0 diesel started smoking from the exhaust while hauling horses to a show. I was approx. 70 miles from home. Had the truck towed into my local Ford dealer to find out that the egr valve went bad and also overheated my turbo. My truck has 58,000 miles and I purchased the esp 100,000 warranty however, they said my warranty expired on 3/21/10. The bill was $3900. And Ford is not covering it. Now I come to find out that this has been a huge issue for Ford & the repairs don't seem to hold either as most people have had this reoccur 2 or more times. This was not a problem I could have prevented in any way but a problem with the engine itself. What can I do & is there a recall? [xxx].