Gas Recirculation Valve (egr Valve) Problems of Ford F-350 - part 2

The contact owns a 2004 Ford f350. The contact was driving at approximately 40 mph when the vehicle suddenly began to shake and jerk forward. The vehicle was taken to a local mechanic who informed the contact that the egr cooler and three fuel injectors were the cause for the failure. The vehicle was repaired at that time. Later, the high oil pressure pump and oil cooler failed. The vehicle was awaiting further repairs at the time of the complaint. The contact called the manufacturer but was told that she would have to assume all repair costs at her expense. The failure mileage approximately was 121,000. The current mileage was approximately 130,000.

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2006 Ford F-350 6. 0 diesel cab and chasis -- egr valve 1st time fixed by Ford dealer no cost, egr valve 2nd time fixed at cost, egr valve 3rd time by-passed, 16 fuel injectors replaced. Delaminating gas tank, over a dozen fuel filters at $60,00 a pop, new fuel pump, new gas tank, 8 more new fuel injectors. Possible turbo issues and I may be forgetting something.

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The contact owns a 2006 Ford F-350. While driving approximately 65 mph the contact smelled a strong anti freeze odor in the vehicle. The vehicle over heated and stalled. The vehicle was taken to the dealer for diagnostic testing. The technician stated the exhaust gas recirculation system had to be replaced. After the vehicle was repaired the failure continued. The failure occurred three times. The vehicle was not repaired. The approximate failure mileage was 110,000.

The contact owns a 2004 Ford f350. The contact stated that smoke appeared from the egr cooler tube. She also smelled antifreeze in the cab of the vehicle. The vehicle was taken to the dealer and they stated that it was still safe to drive and to return if the failure worsened. Later, the contact noticed thick, black oil coming from the exhaust. The vehicle was taken to a repair shop and the mechanic replaced the egr cooler tube with a kit from Ford at the contact's expense. The failure mileage was 79,000. Updated 06/09/09.

2008 Ford f350 super duty. Attorney representing consumer writes in regards to engine problems, egr valves and high pressure fuel pumps failure that manufacturer has failed and refused to repair.

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The contact owns a 2006 Ford F-350. While driving approximately 60 mph, the exhaust pipe smoked and/or steamed and the engine overheated. The check temperature light illuminated on the instrument panel. The contact filled the engine with water and drove home. The dealer diagnosed that the egr cooler leaked; therefore, the egr cooler and the oil cooler needed to be replaced. The vehicle was not repaired. The approximate failure mileage was 84,000. The manufacturer was not notified.

2004 f350 6. 0 powerstroke boggs when taking off. Sometimes will act like you turned off switch when you push down the pedal there is no effect. Mostly when driving up the mountain its like it don't go past idle has not stalled yet. 8 injectors replaced front and rear injector harness replaced high pressure pump fuel mileage 13 mpg. Head gaskets replaced egr cooler rear main seal all under 65,000 miles.

The contact owns a 2005 Ford F-350 superduty. The contact stated that when driving, he experienced a total power loss. There was no acceleration capabilities. The vehicle would jerk, pop and crack at times in the motor area. The vehicle was taken to an authorized dealership several times where the egr valve was repaired, fuel injectors replaced, and cleaned the turbo component. The failure continued to occur. The vehicle was not repaired at the time of the complaint. The contact called the manufacturer who advised him to go to the dealership. The current mileage was approximately 75,000. The failure mileage was approximately 32,000.

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Tl-the contact owns a 2005 Ford f350sd. The contact stated when driving from a complete stop the engine power was significantly low and the vehicle responded as though it wanted to stall. The vehicle was taken to an authorized dealer on eight different occasions for the similar failure and repaired; however the failure continued. A diagnostic test was performed and detected trouble codes within the engine. Most recent the egr valve was replaced and the failure persisted after the repair. The manufacturer was notified of the continuous defect. The approximate failure mileage was 47,000. Js.

The contact owns a 2005 Ford f350. The motor in the vehicle constantly fails. While towing a fifth wheel at approximately 65 mph, the turbo charger blew out. The dealer installed a new turbo charger under warranty. Approximately three months later, the failure recurred and the motor overheated while driving approximately 65 mph. The vehicle was towed to a local dealer and they tested the motor and replaced two heads, the oil cooler, and the egr valve. The mechanic advised him to not use stretch volts to prevent the failure again. The contact was informed that non stretch volts would increase the chances of the failure not recurring because it was a better product than what the manufacturer used. The contact did not want to pay additional money for an aftermarket product because he believed that the products used by the manufacturer should work properly. After the repairs were made, the vehicle worked well for less then a month. The vehicle is not currently working. He attempted to turn on the vehicle, but there was no power to the motor. The vehicle will be returned to the shop for more repairs. The contact feels that this is a manufacturer defect that should be recalled. The failure mileage was 27,000 and current mileage was 30,000.

I purchased this truck in November 2004 with 42,000 miles. It now has 67,000 miles and blown head gaskets. The warranty expired on 28 may 2008 and I did not renew because there were no problems and it has such low mileage. On 24 June 2008 the head gaskets failed while hauling a horse trailer. Ford will not do anything and the cost will be in excess of 4,000 dollars. Evidently, there is a known problem about egr coolers leaking which would have caused the problem. This truck has been well maintained at a reputable dealer through the 3. 5 years that I have owned it. Is there any help that I can get or addresses where this complaint may be sent? I will never buy a Ford product again, and that is sad.

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Trailer break controller faulty, replace egr and injectors. 3/31/09~ replace egr cooler, gasket, fuel filters. 6/8/10~ icp sensor & connector faulty, cac hose leaking, injectors faulty, egr valves changed. 6/25/10~ 17 days later back again in shop for same issue. Truck runs then when you stop the truck in hot weather, it will not restart for about 1 hour. Truck needs to cool down before restarting. And no one can figure out what problem is and fix it correctly.

On 01-06-2008 I started to have significant problems with my 2004 Ford F-350. It has just over 41,000 miles on it. It was smoking and had significant loss of power problems while at low road speed. Problem would clear once truck was >40 mph in speed. Took it to local Ford dealer on 01-07-2008. Their investigation showed that the egr valve was sticking. The valve assembly had to be replaced. The service person stated that this problem is common enough that they are keeping a couple of extra egr valve assemblies in their stock room. I asked if there was any indication of a product recall in the works. He said that he did not know of one but that one might happen in the near future and that I should keep my invoice just in case. My question/concern(s) is this: how often or frequent should an egr valve stick and/or fail? if their failure rate is high (1 failure per vehicle every 50,000 or less) then shouldn't there be a redesign and recall to improve the performance and safety?.

Vehicle would not start,a/c , performance, engine light sluggish take off, performance, white smoke and egr leaking diesel fuel on top of motor, this truck has had two rebuilt engines upon the first 50,000miles. Engine covered in oil, fuel injector main problem started with overheating.

Vehicle would not start,a/c , performance, engine light sluggish take off, performance, white smoke and egrleaking diesel fuel on top of motor, this truck has had two rebuilt engines apon the first 50,000miles. Engine covered in oil, fuel injector main problem statred with overheating.

Vehicle had a stalling problem on accelleration. Vehicle idled fine, but frequently on acceleration from a stop after vehicle started to roll. Engine will misfire, shutter, or backfire for several seconds until clearing up. Also, vehicle misfired at highway speeds. Vehicle was taken to the dealer on several occations to find the cause of the problem, but they reported could not duplicate the problem. Dealer replaced several injectors and egr valve to no avail.

The contact owns a 2004 Ford f350. While at a stop light, the engine would rev. Depending on the contact's reaction time, the vehicle would move 4-5 feet. There were no warning indicators. The rpm would increase to 1,000. The dealer replaced the control module, three turbos, three egr valves, and the back pressure sensor. However, the failure continues. The failure mileage was 40,000 and current mileage was 61,000. Updated 01/11/08. Updated.

This vehicle has had numerous engine failures which I will list below. I spend alot of time in rural locations between 50 and 100 miles from any service facilities in all kinds of weather. Usually there is not any cell service available. It is only a matter of time before I or someone is stranded in bad weather because of the poor engineering on the 6. 0 liter diesel that Ford installed in my vehicle. This could well be life threatening and lead to death in the future. 6/12/06 turbo failure-covered by warranty by Ford - 20000 miles 7/15/06 recall on computer-covered by warranty by Ford- 21000 miles 4/8/11 egr cooler blew out- out of pocket cost $1703. 46- 90619 miles 8/28/12 injectors failed- out of pocket cost $2178. 09- 110732 miles 8/30/12 rear wheel seal and emergency brake failure- out of pocket cost- $703. 06- 111423 miles 10/12/12 turbo failure again- out of pocket cost $2577. 75- 113473 miles you can see the ongoing theme here and when I talk to Ford they say "sorry but we have no recalls and no customer service help at this time. " they need to take resposibility before something happens and it puts peoples lives at risk. As the owner of this vehicle I would like to be included in any class action lawsuits against Ford for not taking responsibility for the 6. 0 liter engineering disaster that they created. Hopefully someone will make them step up and provide the buyers of these engines the help they need and deserve.

I own a 2004 f350 super duty Ford 6. 0 turbodiesel. I have had to replace the egr cooler three times starting in 2006. The last problem I had started out like the egr cooler then I developed and oil lose the when I ask the diesel mech. I was told the it sounded like a head gasket. That same diesel mech. Informed me that in the last 5 years he himself had to repair literally hundreds of 6. 0 Ford diesels for the same problem. My problem is that the problems I had started after the warranty was out and I was unable to get an extended warranty on the 6. 0 engine due to what the warranty agent described as a major engine development flaw by the 6. 0 designers. Looking on the internet I have seen thousands of complaints for the same thing. Yet I have seen no help from Ford.

: the contact stated upon starting the vehicle the oil pressure dropped and the engine died. The vehicle was towed to an independent repair shop where it was determined the oil pump and the lower intake manifold gaskets failed. The oil pump is made of aluminum which influenced the integrity of the pump, and caused the pump to wear out prematurely. The dealer was alerted of the problem, prior to the independent repair shop making the repair. Updated 5/10/2006 - the vehicle leaked coolant which caused the vehicle to overheat but the temp gauge did not indicate that the vehicle was overheating. The coolant also flowed through the egr valve which caused lose of power.

Diesel smell in the cab of a Ford f350 truck with 6. 0 engine. This is the second instance of this in this truck. Both have been covered by warranty, but the first time was in may of 05 and the second time was Feb 06 is this going to happen again. The smell is sickening and if you do not open the windows eyes water,feel tired, sick to stomach, all not good for driving down the road (people really look at you like you are nuts when its 5 degrees outside and you are driving around with your windows open). This time it has been blamed on the exhaust manifold, the first time it was what they called the down exhaust pipe. I believe that there is a bigger problem which has to do with the 6. 0 engine. Too much pressure for the exhaust. The other problem is with the radiator hose. I have 46700 miles on the truck and the radiator hose has to be replaced due to rubbing on the power steering gear box, Ford will not cover this under warranty, even though they have come up with a new hose and new part number to stop this from happening. I have not been told if they are replacing the hose with the old style or the new style.

There have been approximately 15 incidentas were the vehicle has stalled, while being driven or when attempting to stop at a stop sign or turn. The vehiclehas two methods of stalling - the first method is be idling very rough - as if miss firing on a cylinder/ timing issues where it blows black smoke. The second method is if you are stopped with your foot hopefully on the brake - the vehicle will rev up and lurch forward - if on the brake it will sometimes then stall. The vehicle has been to the shop at least 4 times - with multiple incidents per visit, the shop had replaced the egr valve and had reprogrammed the pcm everytime in the shop. Which takes me back to lousy fuel economy and has not yet fixed the problem. I am not happy.

Pickup has loss of power and surging mostly when warm. The first trip to freedom Ford they replaced the egr valve. The second trip to freedom Ford they said they could only find normal surging the third time to freedom for the same problem they kept the pickup for 7 days and replaced the turbo again and the egr again.

Since new vehicle purchase, my Ford f350 diesel p/u experienced engine surging (200-250 rpm) while stopped with the automatic transmission in drive. The surge was significant enough to lurch the truck forward with the brake applied, such as at a stoplight. In several cases, I almost rear ended other vehicles before applying the brake hard enough to stop the truck from moving forward. I later learned to anticipate the surge using the brakes to minimize movement of the truck while stopped. My surging problem was confirmed on multiple occasions by technicians during test rides, but they could not duplicate the problem in the shop. In all cases, the first step was to reflash the ecm which masked the problem for several days while the truck relearned my driving habits and prevented a diagnosis. The engine had to be operated at full temperature in road conditions before the problem developed. In the shop, idling the engine to warm up to normal operating temperature was not sufficient to replicate the problem. Ford dealers made multiple attempts (10 or more) to diagnose the problem: replacing injector control pressure (icp) module, egr valve, and icp wiring connectors to no avail. The problem was finally diagnosed and corrected, out of warranty at approx. 44,500 miles, by replacing the engine wiring harness. I found a dealer who was willing to send a technician on a test ride with me and hook up an onboard computer laptop that identified the problem before reflashing the computer ecm. A number of surging complaints from other owners of Ford f350 are posted in online forums documenting similar circumstances and frustration. The incident date provided is the approximate date of the first occurrence. In my case, the surging occurred on a near daily basis, although intermittently, for 41000 miles of driving without any resolution from Ford. The engine wiring harness was replaced in Feb 2009 which corrected the surging in my truck. I paid a $100 deductible.

The contact owns a 2004 Ford f350. He stated that the egr valve cooler and head gaskets failed. The mechanic stated that electrolysis developed inside the engine and caused the failure. Each part has been repaired 2-3 times. He also noticed smoke coming from underneath the dashboard caused by melted fuses. The current mileage was 126,000 and the failure mileage was unknown. The contact stated that he noticed the failure at the time he purchased the vehicle.

While driving, t he vehicle stalled several times. The consumer would restart the vehicle while in motion. The brakes would go out when this would occur. The problem seemed to be resolved. The dealer replaced the egr valve (exhaust gas-recirculation). The vehicle idled erratically. The injector pressure regulator was replaced. The ebp sensor and the egr valve did not work properly and both were replaced. The ebp signal remained to fluctuate. Also ,the turbo charger was not working properly.

While driving vehicle stalled. Dealership indicated that this was due to a malfunction in the fuel injectors. The fuel injectors were replaced 8 times, and the egr valve was replaced twice.

Vehicle wont move, when temperature is below o degree. Has to wait about a minute to warm-up. Dealer has inspected the vehicle and could not duplicate or correct the problem. (diesel engine).