2005 FORD F-250 SD Fuel System, Diesel Problems

THE TRUCK STALLED AND SKIPPED ON THE INTERSTATE ALMOST CAUSING A COLLISION ON I 85. ACCORDING TO THE TECH THE FUEL INJECTION CONTROL MODULE GOES BAD IN ALMOST EVERY FORD F250 6.0 DIESEL ENGINE WHEN YOU HIT THIS MILEAGE. NOT SURE HOW WE CONTINUE TO GIVE FORD A PASS ON THIS COMMON ISSUE. *KB

Mileage: 117,000

THIS 2005 FORD F250SD I BOUGHT 3 YEARS AGO HAS BEEN NOTHING BUT TROUBLE. IN THE FIRST 2 MONTHS OF OWNING THE VEHICLE THE OIL SENSOR SWITCH WENT BAD LEAVING ME STRANDED TWICE. I FINALLY TALKED FORD INTO REPLACING THE SWITCH SINCE IT HAD ONLY BEEN 2 MONTHS FROM PURCHASE. THEN A YEAR LATER THE FUEL CONTROL MODULE THIS SITE SAYS IT IS A RECALL FOR THIS YEAR BUT FORD SAYS IT IS NOT. COST $1200 NOW AGAIN NOT EVEN 3 YEARS LATER THE OIL SWITCH BLEW OUT AGAIN. EVEN THOUGH A TRAINED FORD MECHANIC REPLACED IT. IT IS COSTING $1500 TO HAVE REPLACED. WITH ALL THE SAME COMPLAINTS WITH THIS MOTOR IT IS A WONDER WHY FORD HAS NOT MADE A RECALL. *TR

Mileage: 197,000

TRUCK BECAME HARD TO START THEN STARTED STALLING. SOON AFTER THE CHECK ENGINE LIGHT CAME ON. TRUCK WAS TAKEN TO FORD DEALER WHERE IT WAS COMPUTER TESTED AND INSPECTED. THE FICM (FUEL INJECTOR CONTROL MODULE) WAS REPLACED AND REPROGRAMMED THE MODULES AT A COST OF 1,253.67. *TR

Mileage: 56,751

TL* THE CONTACT OWNS A 2005 FORD F250 SD. WHILE DRIVING AT ANY SPEED, THE CONTACT STATED THAT THE VEHICLE WOULD STALL WITHOUT WARNING. THE VEHICLE WAS NO LONGER UNDER WARRANTY AND HAD NO RELATED RECALLS SO THE DEALER WAS UNABLE TO PROVIDE ANY ASSISTANCE. THE MANUFACTURER WAS CONTACTED BUT OFFERED NO ASSISTANCE. THE VEHICLE WAS TAKEN TO A PRIVATE MECHANIC WHO REPLACED THE FICM. THE CURRENT MILEAGE WAS 88,000 AND THE FAILURE MILEAGE WAS 85,000. UPDATED 04/06/11*LJ

Mileage: 85,000

2005 FORD F250 SUPERDUTY, WITH 6.0L POWERSTROKE DIESEL ENGINE. OWNED SINCE NEW. TRUCK CURRENTLY HAS 89,700 MILES ON ORIGINAL ENGINE. HAD TRUCK IN FOR SERVICE IN MAY 2010. HAD MAJOR ENGINE WORK DONE, TO INCLUDE NEW HEAD GASKET, EGR COOLER, OIL/FILTER CHANGE, AND FUEL FILTERS CHANGED. IN EARLY OCTOBER, BEGAN EXPERIENCING ISSUE WHERE TRUCK WOULD RUN VERY ROUGH FOR THE FIRST MILE OR FIRST 5 MINUTES, WHICHEVER CAME FIRST. AFTER THIS, THE ENGINE WOULD RUN FINE, UNLESS IT HAD BEEN SITTING AND GOT COLD. IN NOVEMBER, HAD VEHICLE BACK TO DEALER ASKING THEM TO DIAGNOSE THIS PROBLEM. THEY SAID THAT PER THEIR DIAGNOSTIC EQUIPMENT, I HAD AN UNDERPERFORMING FUEL PUMP, AND TWO(2) BAD INJECTORS. THEIR RECOMMENDATION: REPLACE FUEL PUMP AND FILTERS, AS WELL AS REPLACE ALL FOUR(4) INJECTORS ON THE ONE SIDE WHERE THEY IDENTIFIED THE PROBLEM. COST FOR REPAIRS, IN EXCESS OF $2100. I DECLINED THE REPAIR, AND HAVE CONTINUED TO DRIVE THE VEHICLE, DESPITE ROUGH RUNNING FIRST THING IN MORNING. TODAY, AFTER ONLY 13,000 MILES, I TOOK THE TRUCK TO A VALVOLINE SHOP TO HAVE THE OIL/FILTER CHANGED, AS WELL AS THE FUEL FILTERS. THE TECHNICIAN CALLED ME OVER AND SHOWED ME THAT THERE WAS A SIGNIFICANT NUMBER OF RUSTY METAL FLAKES IN THE MAIN FUEL FILTER REMOVED FROM THE FUEL PUMP. MY BEST GUESS IS THAT THERE WAS AT LEAST A FULL TEASPOON FULL OF METAL FLAKES THAT WERE VISIBLE, AND THAT DOES NOT INCLUDE ANY SEDIMENT THAT HAD ALREADY ESCAPED THE REMOVED FILTER. I HAVE READ IN NUMEROUS LOCATIONS, INCLUDING THIS SITE, WHERE FORD TRUCK OWNERS, ESPECIALLY THOSE FROM 2003-2005, ARE COMPLAINING ABOUT THE GAS TANKS IN THESE VEHICLES DELAMINATING AND CAUSING ALUMINUM OR RUSTY FLAKES TO BE PROPELLED THROUGH THE FUEL SYSTEM, IMPEDING THE FUEL FLOW, AND DAMAGING THE FUEL PUMP AND FUEL INJECTORS. THIS APPEARS TO BE THE CASE WITH MY VEHICLE. I DO HAVE A PHOTO AVAILABLE, AND CAN PROVIDE AN AFFADAVIT FROM THE FOLKS AT VALVOLINE. PLEASE ASSIST. *TR

Mileage: 82,000

MY 2005 FORD F250 DIESEL TRUCK STARTED HAVING PROBLEMS 2 WEEKS AFTER WARRANTY WENT OUT. THE STC(SNAP-TO-CONNECT) FITTING IN THE HIGH PRESSURE OIL PUMP(HPOP) HAS WENT OUT. IN THE STC FITTING AN O-RING BLOWS IN ALL THE 2005-2007 VEHICLES WHICH WHEN ENGINE IS WARM, IT WILL NOT START. AND MUST COOL DOWN IN ORDER TO START. FORD KNOWS OF THE PROBLEM AND HAS PUT TOGETHER A REPLACEMENT FOR $60. THE LABOR IS AN ADDITIONAL $1740. I CANNOT AFFORD THIS, PLEASE HELP ME. *TR

Mileage: 86,000

2005 FORD F250 SUPER DUTY / CREW CAB, 6.0 L DIESEL / 61,264 MILES. LACK OF PERFORMANCE(18MOS), INTERMITTENT ENGINE STUMBLING(6MOS), INTERMITTENT WHITE SMOKE DURING START-UP, HARD TO START DURING COLD TEMPS(12MOS), BLACK SMOKE DURING POOR PERFORMANCE AND STUMBLING(2MOS) AND FAILURE TO START. ENGINE DIAGNOSTICS CODES: P0261/264/267/270/273/276/279/282 AND P0611. TOWED VEHICLE TO DEALER FOR DIAGNOSTICS AND REPAIR. DEALER FOUND SAME DIAGNOSTICS AND REPLACED FUEL INJECTOR CONTROL MODULE (FICM). FICM NEEDED FOR $140 CORE CHARGE. WARRANTY 5YR/100K MILES 6MOS OUT OF DATE BUT UNDER MILEAGE - EXTENDED WARRANTY FOUND TO BE CONCURRENT WITH MANUFACTURES. FORD MOTOR CO. HAS LEFT DECISION TO COMPLETE AS WARRANTY REPAIR OR DEFER PORTION OF COST TO DEALER. *TR

Mileage: 61,264

THIS EVENT HAD NO WARNINGS LEADING UP TO THE FAILURE. THIS FAILURE OCCURRED ONCE AND WAS DEBILITATING. MY 2005 FORD F250 (6.0 DIESEL) SUFFERED A LEAK IN TWO ORINGS AND A CRACK IN AN OIL LINE IN THE HIGH PRESSURE OIL SYSTEM. THE RESULT WAS A VEHICLE THAT DIED AND WOULD NOT START. THIS VEHICLE ONLY HAS 40,000 ORIGINAL MILES ON IT. ONLINE RESEARCH HAS REVEALED THAT THIS IS A DESIGN FLAW IN THE 2004 & 2005 MODEL YEARS. FORD HAS ISSUED TSB'S ON THE PROBLEM HOWEVER NEVER NOTIFIED CONSUMERS OF THE DEFECT TO FOREWARN OR CORRECT THE AFFECTED MODEL YEARS. THE ENGINE HAS SENSORS THAT SHUT THE ENGINE DOWN AND PREVENT IT FROM STARTING WHEN OIL PRESSURE IS LOST FROM SUCH DEFECTS. MY VEHICLE WAS TOWED TO FORD, HOWEVER THE WARRANTY HAD EXPIRED IN DECEMBER 2009. I HAVE TRIED TO RESOLVE COST ISSUE WITH FORD TO NO AVAIL. I FEEL THIS DEFECT IN DESIGN WAS A KNOWN PROBLEM AND SHOULD HAVE BEEN ADDRESSED, ESPECIALLY WHILE THE VEHICLE WAS STILL UNDER WARRANTY. *TR

Mileage: 42,000

TL* THE CONTACT OWNS A 2005 FORD F-250 SUPER DUTY. THE CONTACT STATED THAT WHENEVER THE AIR CONDITIONER WAS OPERATED, HE COULD SMELL EXHAUST FUMES IN THE INTERIOR OF THE VEHICLE. THE FAILURE WOULD PERSIST WHETHER DRIVING OR SITTING IDLE. WHEN SITTING IDLE, THE SMELL WAS OVERWHELMING. THE CONTACT ALSO STATED THAT WHEN DEFROSTING THE WINDOWS IN COLD WEATHER, THE FUMES WOULD CAUSE THE WINDOWS TO FOG EXCESSIVELY. THE DEALER ADVISED THEY WERE AWARE OF THE FAILURE HOWEVER; THE CONTACT WOULD BE RESPONSIBLE FOR ANY REPAIRS. THE VEHICLE WAS NOT SERVICED. THE FAILURE MILEAGE WAS 60,000 AND THE CURRENT MILEAGE WAS 124,702. UPDATED 12/01/10. *LJ UPDATED 12/07/10

Mileage: 60,000

OCT. 20, 2009, TRUCK DIED WHILE PULLING 5TH WHEEL UP STEEP MTN. ROAD TO KENNEDY MEADOWS, CA. BAD SITUATION. AFTER 3 WEEKS IN FORD GARAGE, IN RIDGECREST, CA. SEVERAL PARTS REPLACED ALL RELATED TO THE HIGH PRESSURE OIL SYSTEM USED TO FIRE INJECTORS ON THIS 6.0 POWERSTROKE ENGINE. JAN 26, 2010. AFTER PULLING THE 5TH WHEEL FOR ABOUT 100 MILES THROUGH HEAVY TRAFFIC AND PARKING TRAILER IN MY DRIVEWAY, I CAME BACK LATER AND TRUCK WOULDN'T START. TOWED TO LAKE ELSINORE FORD AND THEY REPLACE THE OIL PRESSURE REGULATOR. THIS IS ALL OVER THE POWERSTROKE SITES ON THE NET. MY NEPHEW HAS HAD THE SAME PROBLEMS. FORD KNOWS THIS TOO. BOTH OF THESE INCIDENTS COULD HAVE RESULTED IN WRECKS, THERE IS NO WARNING, THE ENGINE JUST DIES. *TR

Mileage: 56,934

TURBO CHARGER FAILURE, FULL OVERHAUL (TWICE) BEFORE THE WARRANTY EXPIRED MAY 30, 2009 AT 46131 MILES, AND NOV. 13, 2006 AT 17362 MILES

Mileage: 46,131

TL*THE CONTACT OWNS A 2005 FORD F-250 SUPERDUTY. SPORADICALLY, THE VEHICLE EXPERIENCES A NO START CONDITION. ON ONE OCCASION, WHILE DRIVING 25 MPH, THE VEHICLE STALLED WITHOUT WARNING. THE VEHICLE WAS TOWED TO A DEALER AND THEY STATED THAT THE FUEL PUMP, TANK, AND INJECTORS NEEDED TO BE REPLACED AT THE COST OF $4,000 DUE TO CORROSION. THE TECHNICIAN ADDED THAT THEY RECEIVED NUMEROUS COMPLAINTS AND FAILURES WITH THIS PARTICULAR MAKE AND MODEL VEHICLE. THE MANUFACTURER STATED THAT THEY WOULD NOT ASSUME ANY RESPONSIBILITY FOR THE REPAIRS AND REFERRED THE CONTACT BACK TO THE DEALER. THE VEHICLE HAS NOT BEEN REPAIRED. THE FAILURE AND CURRENT MILEAGES WERE 23,000. UPDATED 04-17-09 UPATED 04/20/09.*JB

Mileage: 23,000

TL*THE CONTACT OWNS A 2005 FORD F-250 SUPERDUTY. SPORADICALLY, THE VEHICLE EXPERIENCES A NO START CONDITION. ON ONE OCCASION, WHILE DRIVING 25 MPH, THE VEHICLE STALLED WITHOUT WARNING. THE VEHICLE WAS TOWED TO A DEALER AND THEY STATED THAT THE FUEL PUMP, TANK, AND INJECTORS NEEDED TO BE REPLACED AT THE COST OF $4,000 DUE TO CORROSION. THE TECHNICIAN ADDED THAT THEY RECEIVED NUMEROUS COMPLAINTS AND FAILURES WITH THIS PARTICULAR MAKE AND MODEL VEHICLE. THE MANUFACTURER STATED THAT THEY WOULD NOT ASSUME ANY RESPONSIBILITY FOR THE REPAIRS AND REFERRED THE CONTACT BACK TO THE DEALER. THE VEHICLE HAS NOT BEEN REPAIRED. THE FAILURE AND CURRENT MILEAGES WERE 23,000. UPDATED 04-17-09 UPATED 04/20/09.*JB

Mileage: 23,000

MY 2005 FORD F-250 SUPERDUTY HAS HAD ON GOING PROBLEMS WITH THE TURBO AND INJECTION SYSTEM ON THE 6.0L DIESEL. INITIALLY THE DEALER "CLEANED" THE INJECTORS, THEN AT APPROXIMATELY 1000 MILES AFTER, AT 16K MILES THE FORD DEALERSHIP HAD TO REPLACE THE ENTIRE TURBO UNIT. I WAS TOLD I NEED TO DRIVE THE TRUCK DAILY, AND DRIVE IT HARD, ESSENTIALLY "BEAT ON" THE TRUCK IN ORDER FOR IT TO RUN WELL. I HAVE STARTED TO NOTICE A LOSS IN FUEL ECONOMY AGAIN AS WELL AS A DECLINE IN POWER. *TR

Mileage: 16,000

MY F250 SUPER DUTY TRUCK STALLS WHILE DRIVING, SPECIALLY AFTER TURNING CORNER. ALL 3 TIMES THE COMPLETE FUEL INJECTOR ASSEMBLY WAS REPLACED , 5/15/07, 12/15/07 & 8/15/07. HAD FUEL TANK CLEANED AND FOUND RUST REMAINS IN BOTTOM OF FUEL TANK. THE COMPUTER AND WIRE HARNESS HAD TO BE REPLACED 12/15/07. FUEL TANK RUSTS FROM INSIDE AND BLOCKS FUEL LINE FROM FUEL TANK AND WATER SEPARATOR AND CONSEQUENTLY STARVES INJECTORS FROM FUEL WHICH IS WHY THEY BURN UP. SEE WWW.FORDDOCTORSDTS.COM/ARTICLES/ARTICLE-07-07.PHP. EACH TIME I BRING IN THE TRUCK IT COSTS FOR A TRUCK WITH BETWEEN $1,000-$4,000 WITH ONLY 110,000 MILES ON THE TRUCK. *TR

Mileage: 95,000

I HAVE A 2005 F250 DIESEL TRUCK. I WAS DRIVING ON I-95 WHEN I NOTICED FLAMES COMING FROM BEHIND MY CAB. I QUICKLY PULLED OFF TO THE SHOULDER AND TRIED TO EXTINGUISH THE FIRE BUT IT WAS TO LATE. THE FIRE BURNED THE TRUCK COMPLETELY. *NM

Mileage: 37,000