2003 FORD F-350 SD Engine And Engine Cooling Problems

I WAS HAULING A LOADED HORSE TRAILER AND HAD JUST MERGED ONTO THE HIGHWAY. AS I WAS TRYING TO ACCELERATE, THE ENGINE WAS "CATCHING" AND WOULDN'T LET ME ACCELERATE PAST 35 MPH AND WAS REVVING VERY HIGH AND WOULDN'T SHIFT UP INTO THE NEXT GEAR. IT FINALLY STALLED AND COMPLETELY SHUT OFF IN THE MIDDLE OF TRAFFIC AND I HAD TO COAST TO THE SIDE OF THE ROAD WHERE WHITE SMOKE STARTED POURING OUT FROM UNDER THE HOOD. MY ENTIRE RIG - TRUCK, TRAILER AND HORSES, HAD TO BE TOWED HOME AND THEN THE TRUCK TOWED TO THE MECHANIC. HE FOUND THE ENGINE RUNNING POORLY, AND FOUND LOW COMPRESSION ON CYLINDERS #3 AND #8. HE FOUND LOW OIL PRESSURE AND WHEN HE REMOVED THE OIL PAN FROM THE CHASSIS, HE FOUND PISTON MATERIAL IN THE OIL PUMP. HE REMOVED THE ENGINE AND FOUND THE PISTONS IN CYLINDER 3 AND 8 MELTED DOWN. HE HAD TO BORE OUT AND HONE ALL THE CYLINDERS, REPLACE ALL 4 VALVES IN CYLINDER #3 HEAD, REPLACE ALL PISTONS, REPLACE THE MAIN BEARING AND ROD BEARING, UPDATE THE OIL COOLER AND REPLACE 8 PISTONS AND 6 HEAD GASKETS. WHEN HE PUT IT ALL BACK TOGETHER AND TEST DROVE IT, HE FOUND AN EXHAUST LEAK FROM THE EBP SENSOR AND TUBE. THOSE HAD TO BE REPLACED. BEFORE ALL THIS HAPPENED, I HAD NOTICED THAT THE ENGINE SEEMED TO BE "SKIPPING" WHEN I WAS HAULING MY HORSE TRAILER. IT ONLY HAPPENED WHEN I WAS OVER 55 MPH AND IT ONLY HAPPENED WHEN I WAS HAULING. I HAD TAKEN THE TRUCK TO THE MECHANIC BEFORE THE BIG BREAKDOWN (DESCRIBED ABOVE) AND HE COULDN'T FIND ANYTHING WRONG. I THINK THAT IS BECAUSE HE WAS NOT HAULING A TRAILER AND THAT'S THE ONLY TIME THE PROBLEM OCCURRED. THE TOTAL BILL FOR ALL THESE REPAIRS IS $6400.00 AND I HAVE BEEN TOLD THAT FORD WILL DO NOTHING TO HELP ME. *JB

Mileage: 55,708

TL* THE CONTACT OWNS A 2003 FORD F-350 SD DIESEL. THE CONTACT STATED THE VEHICLE EXPERIENCED A BLOWN HEAD GASKET. THE DEALER REPLACED THE MOTOR BUT THE FAILURE RECURRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE BUT DENIED ANY ASSISTANCE WITH REPAIRS TO THE VEHICLE. THE VEHICLE WAS NOT REPAIRED. THE FAILURE MILEAGE WAS 25,000 AND THE CURRENT MILEAGE WAS 150,000. ..UPDATED 11/28/12 *BF THE CONSUMER STATED WHEN THE HEADS CRACKED IT PUSHED WATER IN THE FUEL AND DESTROYED THE FUEL PUMP, INJECTORS, AND TURBO. UPDATED 11/29/12

Mileage: 25,000

SPARK PLUG EJECTION FROM 2003 FORD F-350 SUPER DUTY ENGINE: TRITON 5.4L V8 DATE OF FAILURE: 03-10-11 MILEAGE OF TRUCK: 139414 THIS INCIDENT HAPPENED WHILE TRAVELING ON A STATE HWY51 NEAR POSTVILLE, IA EJECTION OF SPARK PLUG FROM NUMBER 7 CYLINDER ON 5.4L V8 ENGINE. DAMAGE TO CYLINDER HEAD OF ENGINE AND SPARK PLUG COIL. THIS IS A WELL MAINTAINED 2003 F-350, SPARK PLUGS REPLACED AT A FORD DEALER 01-19-09: 109156 MILES. *TR

Mileage: 139,414

SPARK PLUG BLEW FROM ENGINE ON 2003 FORD F-350 5.4 TRITON ON MAY 10TH 20010. ON FREEWAY APROX.65MPH. CANNOT RE-INSTALL PLUG DUE TO THREAD DAMAGE. *TR

Mileage: 165,000

FORD F350 EQUIPPED WITH 6.0L DIESEL ENGINE EXPERIENCED STALLING WITHOUT WARNING WHILE DRIVING AND/OR WHILE APPLYING BRAKES. THIS LOOKS TO BE THE SAME ISSUE THAT AFFECTED VEHICLES IN THE 2004-2005 RECALL. ICP SENSOR LIGHT IS LIT AND MOST LIKELY WILL NEED TO BE REPLACED. SEPARATE OR RELATED ISSUE? : ENGINE WILL "REV-UP" WHILE DRIVING AND PRODUCE ACCELERATION WITHOUT GAS PEDAL BEING APPLIED. ENGINE WILL REV-UP AND/OR IDLE HIGH WHILE IN PARK AND WHEN STOPPED/BRAKES APPLIED. *TR

Mileage: 90,500

VEHICLE STALLS - SURGES - RUNS ROUGH - PROBLEM HAS EXISTED SINCE NEW - HAVE TAKEN TO FORD GARAGE AND THEY HAVE NEVER FIXED TO LAST. *TR

Mileage: 25,000

WE WERE USING OUR FORD F350 DIESEL (6.0 MOTOR) WITH 63,000. WE WERE GOING 70 MPH ON THE INTERSTATE PULLING A LOADED 5 HORSE TRAILER WHEN THE TRUCK WOULD NOT ACCELERATE, 15 SECONDS LATER ENGINE CUT OFF. WE WERE IN THE LEFT LANE AND HAD NO POWER TO STEER OFF THE ROAD AND COULD NOT COME TO A FAST STOP BECAUSE OF THE WEIGHT OF THE OF HORSE TRAILER. WE HAD TO COAST APPROXIMATELY 100 YARDS AND PULL OFF ON THE LEFT SIDE BECAUSE TRAFFIC WAS TOO HEAVY AND GOING TO FAST TO LET US OVER TO THE RIGHT SIDE. TRUCK WOULD NOT START AGAIN. HAD TO BE TOWED OFF THE INTERSTATE AND HOME. TOOK IT TO THE REPAIR SHOP AND WAS TOLD THE ENGINE LOCKED UP AND NEEDS TO BE REPLACED AT A COST OF $7500 TO $10000. I CHECKED ON WARRANTY AND BECAUSE IT IS A 2003 IT IS EXPIRED. CALLED FORD AND WAS TOLD THERE WAS NO RECALLS. IT WAS EXTREMELY DANGEROUS SITUATION AND CAN NOT BELIEVE THAT WERE IS NOT SOME TYPE OF DEFECT IN THE ENGINE. *TR

Mileage: 63,000

2003 FORD F350 HAS PROBLEMS WITH THE FUEL INJECTORS, TRANSMISSION AND AN OIL LEAK. *NJ THE CONSUMER STATED THE VEHICLE LOST POWER AND WHITE SMOKE EMITTED FROM THE TAILPIPE. HE ALSO NOTICED A DELAY OF ENGAGEMENT FROM DRIVE TO REVERSE AND THE FUEL GAUGE WAS STUCK. THE NUMBER 8 INJECTOR HAD FAILED, THE TRANSMISSION NEEDED A NEW PART AND THE FUEL GAUGE NEEDED A NEW SENSOR. IN THE FALL OF 2008, THE VEHICLE DEVELOPED AN OIL LEAK. IT WAS DISCOVERED THAT THE ICP SENSOR (INJECTOR CONTROL PRESSURE) WAS THE PROBLEM. IN MARCH 2009, WHILE TOWING A TRACTOR, THE TRUCK LOST POWER AND AGAIN IT EMITTED SMOKE AND THERE WAS A HARSH JERK. IT WAS DETERMINED THAT THE ENGINE FAILED AGAIN. THE NUMBER 1 AND NUMBER 3 INJECTOR HAD FAILED AND THERE WAS A NEW OIL LEAK. *JB

I SMELLED HINT OF RAW FUEL WHEN THE ENGINE WAS WARM FOR 1-2 MONTHS PRIOR TO THE OBVIOUS PROBLEM. 3-4 WEEKS PRIOR TO PROFESSIONAL INSPECTION THERE WAS WHITE SMOKE OUT OF THE EXHAUST FOR 1-2 MINUTES. THIS SMOKE WAS ASSOCIATED WITH ROUGH IDLING THAT WHEN AWAY COMPLETELY UNTIL THE NEXT COLD START UP. THE PRECIPITATING EVENT FOR PROFESSIONAL INSPECTION WAS RAW FUEL SPRAYING ONTO THE TRAILER THAT WAS BEING PULLED. INSPECTION REVEALED RAW FUEL POOLED ON THE HORIZONTAL ENGINE SURFACES AND RAW FUEL IN THE COOLING SYSTEM. THIS WAS VERIFIED BY MANUFACTURER'S DEALER SERVICE DEPARTMENT AND FOUND TO BE A LEAKING FUEL INJECTOR CUP. IT WILL REQUIRE CHANGING ALL THE FUEL INJECTOR CUPS. THE DEALER SERVICE AGENT REPORTED THAT THIS SAME PROBLEM HAS BEEN SEVERAL TIMES IN THESE PARTICULAR MODELS. IT IS USUALLY A WARRANTY ITEM. THIS HAS NOT BEEN REPAIRED YET AS THIS VEHICLE'S WARRANTY HAS EXPIRED BY TIME LIMIT BUT NOT MILEAGE. THE MANUFACTURER HAS DENIED ANY OBLIGATION TO HELP RESTORE THE VEHICLE TO SAFE OPERATION GIVEN THAT IT SEEMS TO RUN UNIMPAIRED FROM A PERFORMANCE STANDPOINT. *TR

Mileage: 95,300

2003 FORD F-350 V10 EJECTED A SPARK PLUG FROM THE #3 CYLINDER. *TR

Mileage: 68,000

I'M SURE I HAVE THE SAME PROBLEM. I HEARD A TICKING NOISE ALSO, THEN MY TRUCK STARTED TO MISS UNDER LOAD. UNABLE TO DETERMINE WHICH CYLINDER IS THE PROBLEM, SOUNDS LIKE ALL MY BE BAD AT SOME TIME. FORD HAS TO BE AWARE OF THIS PROBLEM, NOT TAKING THE BLAME IS AN EXAMPLE OF HOW THEY RUN THEIR BUSINESS. OOOHHHH WAIT THEY ARE GETTING READY TO GO UNDER. WONDER WHY???? *TR

Mileage: 58,000

2003 FORD F350. DIESEL 6.0 LITER. HARD TO START EVEN WHEN WARM OUT, NOW IS NOT STARTING AT ALL, HAVE HAD THE SAME OIL LEAKS, AT SPEED OF 55 TO 60 JERKS HARD AND HAS EVEN STALLED WHILE DRIVING. JUST A FEW OF THE PROBLEMS AND WE KEEP SPENDING MONEY TO HAVE FIXED AND THEY JUST RECUR AGAIN. BEEN READING PEOPLE HAVE BEEN HAVING THE SAME PROBLEMS AS US. FORD IS NOT DOING ANYTHING TO FIX THIS. *TR

Mileage: 40,000

I HAVE A 2003 FORD F350 KING RANCH WITH A 6.0L DIESEL MOTOR. THE TRUCK HAS HAD A VARIETY OF SOFTWARE FAILURES WITH RESPECT TO THE PCM FOR THE MOTOR WHICH HAS RESULTED IN THE MOTOR COMPLETELY AND INSTANTANEOUSLY SHUTTING DOWN OR CATASTROPHIC FAILURE OF THE TURBOCHARGER RESULTING IN THE TURBO OVER BOOSTING AND BLOWING UP THE INTERCOOLER OR NO PSI OUT OF THE TURBO LEAVING ME AND MY FAMILY STRANDED TWICE IN THE MOUNTAINS PULLING A FULL TWO HORSE TRAILER (6,500 POUNDS). VEHICLE HAS BEEN INTO BAKERSFIELD FORD, VISALIA FORD, RANCHO FORD FOR SERVICE. PCM SYSTEM WAS ALWAYS REFLASHED AND REPAIRS MADE UNDER WARRANTY UNTIL THE MOST RECENT TURBOCHARGER FAILURE 09-28-2008. THE VEHICLE WAS 5 MONTHS OUT OF WARRANTY AND THIS FAILURE COST ME $2,700. TODAY 10-6-2008 THE PCM LOST ALL ITS MEMORY AND I AGAIN LOST POWER ON THE FREEWAY AND WAS NEARLY HIT BY MULTIPLE VEHICLES TRYING TO GET TO THE SIDE OF THE ROAD AND OFF THE FREEWAY. THIS WAS FIVE DAYS AFTER GETTING THE TRUCK BACK FROM FORD. A PROCESS WAS WENT THROUGH AT FORD TO RE-LEARN THE "TURBO STRATEGY" AND THE TRUCK WAS RETURNED TO ME WORKING FINE. *TR

Mileage: 38,942

TL*THE CONTACT OWNS A 2003 FORD F-350 SD. WHILE THE CONTACT WAS EXAMINING HIS VEHICLE, HE NOTICED OIL SPOTS ON THE FLOOR OF THE GARAGE. THE VEHICLE WAS TAKEN TO A LOCAL MECHANIC AND THEY DISCOVERED THAT THE OIL PAN WAS EXTREMELY RUSTED AND THE VEHICLE WAS SERVICED FOR THE FAILURE. THE VEHICLE HAS NOT BEEN DIAGNOSED BY THE DEALER. THE CURRENT AND FAILURE MILEAGES WERE 61,800.

Mileage: 61,800

FORD MOTOR COMPANY PUT OUT DEFECTIVE COOLANTS ON THEIR 6.0L DIESEL ENGINES. I HAVE/HAD 2003 F350 KING RANCH TRUCK WITH 67,000 MILES. FORD WARRANTIES DIESEL ENGINES TO 5 YEAR 100,000. ON JUNE 24, 2008, I WAS DRIVING WHEN MY TRUCK OVERHEATED. I PULLED OFF THE ROAD AND CALLED FORD NORTH SCOTTSDALE. THEY SAID THAT THE EJR COOLANTS ARE NOT GOOD ON THOSE TRUCKS AND MOST LIKELY IT GAVE OUT. THEY TOLD ME TO GET IT TO THE NEAREST DEALERSHIP. I DROPPED THE TRUCK OFF AT BELL FORD IN ARIZONA ON TUESDAY JUNE 24 TO LEARN THAT MY WARRANTY EXPIRED MAY 28, 2008. I GOT DIAGNOSTICS DONE AND THE HEAD GASKETS BLEW. BELL FORD SAID THEY BLEW BECAUSE THE COOLANT WENT OUT AND BLEW OUT THE WATER, WHICH OVERHEATED THE COOLANTS. WE CONTACTED FORD MOTOR COMPANY AND THEY HAD 2 CST (MARK & STEVE) "RESOLVE" THE DISPUTE AND SAY THEY CANT HELP US. I SPECIFICALLY ASKED, THAT WHY WOULD THEY NOT RECALL A PART THEY KNOW IS NOT EFFICIENT? THEY DID NOT GIVE ME AN ANSWER. AFTER DOING MORE RESEARCH, I HAVE SINCE LEARNED THAT THIS IS A VERY COMMON PROBLEM WITH THE 6.0L. I AM LOOKING AT $4300 JUST FOR THE HEAD GASKETS AND THEN PLENTY MORE IN LABOR CHARGES. THIS DOES NOT EVEN INCLUDE GETTING THE COOLANT FIXED. WILL I EVER BUY FORD AGAIN? MOST LIKELY NOT. THEY CANT STAND BEHIND THEIR PRODUCT OR HELP THEIR CUSTOMER. THIS IS A TRUCK THAT HAS BEEN BABIED AND UP TO DATE FOR ALL MAINTENANCE. AND NOW ITS DESTROYED. *TR

Mileage: 67,000

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. *TR

Mileage: 67,000

I RECENTLY EXPERIENCED SEVERE SURGING AT IDLE, MAKING THE VEHICLE JUMP FORWARD, ROUGH ACCELERATION, AND COMPLETE STALLING AT VARIOUS SPEEDS. TOOK VEHICLE TO DEALER FOR REPAIR. THEY REPLACED THE ICP SENSOR, AND THE ICP WIRING HARNESS (WHICH WAS BURNT AND SHORTING OUT), AND CLEANED INJECTORS = $1348.00 THIS IS THE SAME ISSUE THAT FORD RECALL NO. 05S34 ADDRESSES ON THE SAME TRUCK, SAME ENGINE (6.0), BUT ONE YEAR NEWER. FORD DID NOT RETURN OLD PARTS TO ME AND I FAILED TO ASK FOR THEM. I AM CONVINCED THAT THE SHORTING OUT OF THE ICP HARNESS, LIKE THE PROBLEM IN #05S34, CAUSED THE SENSOR TO FAIL. *TR

Mileage: 58,000

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. *TR

Mileage: 84,000

OUR COMPANY HAS PURCHASED A 2003 FORD F350 IN JULY 2003 IT HAS 18,000 MILES ON IT AND HAS HAD 3 TURBO'S INSTALLED IS RUNS ROUGH LACKS POWER AND CONTINUES TO HAVE PROBLEMS WE DO NOT DRIVE THE TRUCK OFTEN BUT IS RUN DAILY. I CAN'T IMAGINE THE PROBLEMS WE WOULD HAVE IF DRIVEN 500 MILES A WEEK . MY CONCERNS ARE WHAT WILL HAPPEN WHEN THE WARRANTY RUNS OUT AND I NEED TO PAY 1500 FOR A TURBO OR NEW ENGINE OR INJECTORS. *TR

Mileage: 2,289

TL*THE CONTACT OWNS A 2003 FORD F350 SUPER DUTY. THE CONTACT RECEIVED A RECALL NOTICE FROM FORD IN MARCH OF 2006 REGARDING EMISSION. THE RECALL REPAIR WAS PERFORMED ON THE VEHICLE, BUT THE FAILURE STILL OCCURS. THE DEALER AND MANUFACTURER STATED THAT NOTHING COULD BE DONE BECAUSE THE DEFECT IS COMPUTER RELATED. THEY STATED THAT THEY WERE WAITING FOR A NEW RE- FLASH TO BE DEVELOPED FOR THE DEFECT. THE RECALL NUMBER WAS UNKNOWN. THE CURRENT MILEAGE WAS 30,000 AND FAILURE MILEAGE WAS 10,000.

Mileage: 10,000

DRIVING IN TRAFFIC, TRUCK STARTED CUTTING OUT COULD BARELY GET TO THE SIDE OF THE ROAD, SWAPPED IN MY SPARE CPS AND TRUCK STARTED RIGHT UP AND I DROVE AWAY WITH NO PROBLEMS. *TR

Mileage: 45,000

DT*: THE CONTACT STATED WHILE DRIVING 60MPH ON THE INTERSTATE, THE CHECK ENGINE LIGHT ILLUMINATED FOLLOWED BY THE VEHICLE OPERATING AT A REDUCED SPEED. THIS WAS INTERMITTENT IN NATURE. THE VEHICLE WAS PULLED OVER WITHOUT INCIDENT. AFTER TURNING OFF THE IGNITION FOR A MOMENT, THE ENGINE RESTARTED WITHOUT FURTHER INCIDENT. THE VEHICLE WAS INSPECTED BY A DEALER WHO DETERMINED THE ENGINE COMPUTER NEEDED TO BE REPROGRAMMED. AFTERWARDS, THE ENGINE STALLING PERSISTED. THE MANUFACTURER WAS ALERTED.

Mileage: 110,000

THE ENGINE OF A 2003 FORD WENT OUT AND WAS REPLACED WITH A NEW ENGINE BY THE FORD DEALER SHIP. A FEW DAYS AFTER WE GOT THE TRUCK BACK IT WAS DRIVEN APPROX. 600 MILES, PULLING A TRAILER, WHEN THE ENGINE BEGAN TO BACK FIRE AND SPUTTER GOING DOWN THE INTERSTATE. THE TRUCK WAS PULLED TO THE SIDE OF THE ROAD AND SHUT OFF. THE ENGINE WAS CHECKED FOR ANY VISUAL PROBLEMS AND THEN STARTED AGAIN. AFTER IT WAS RESTARTED THE ENGINE BEGAN TO PICK UP RPM. AT THAT POINT THE EGNITION WAS SHUT OFF AND THE KEY REMOVED. THE ENGINE CONTINUED TO RUN! THE ENGINE CONTINUED TO INCREASE IT'S RPM UNTIL I THOUGHT THE ENGINE WOULD BLOW UP. I TOLD MY GRANDWON WHO WAS TRAVELING WITH ME TO HIT THE DITCH AND I TRIED TO REMOVE THE BATTERY CABLES. I FINALLY HAD TO LEAVE FOR FEAR THE ENGINE WOULD BLOW UP IN MY FACE. THE ENGINE DID BLOW BUT NO FIRE WAS STARTED. I TOWED IT TO THE FORD DEALERSHIP AND WAS TOLD THAT THE PROBLEM WAS MOST LIKELY THE TURBO THAT WENT OUT WHICH CAUSED THE ENGINE FAILURE. WE ARE NOT HAVING IT FIXED AND IT HAS NOT AS YET BEEN DETERMINED IF THE ENGINE IS COMPLETELY RUINED. IF IT IS, THE TURBO CAUSED THE FAILURE AND WE ARE BEEING TOLD THAT THE WARRENTY ON THE NEW ENGINE WILL NOT COVER THE DAMAGE. THE CONCERN IS THE RUN AWAY ENGINE. SHOULD THE IGNITION SWITCH NOT ALWAYS SHUT OFF THE ENGINE? WHAT WOULD HAVE HAPPENED IF THIS HAD BEEN IN GEAR AND THE TRUCK, PULLING A TRAILER, HAD BEEN RUNNING DOWN A CROUDED INTERSTATE? THE DEALERSHIP IS TREATING US FAIRLY ON THE TRADE IN BUT WE FEEL LIKE THIS IS A DEFECT SOMEWHERE ALONG THE LINE WHEN A TRUCK IS OUT OF CONTROL.

Mileage: 144,000

MY 2003 F 350 W/6.0 DIESEL FORD IS VERY UNSAFE STALLING SOME TIME NO POWER. *JB

2003 FORD F350 CREW CAB TRUCK WITH 6.0 DIESEL POWERED ENGINE LOOSES POWER WHILE DRIVING ON THE HIGHWAY. CAUSE: FUSE #22 BLOWS AND THE ENGINE SHUTS DOWN. THIS HAS HAPPENED TWICE IN A NINE MONTH PERIOD - LAST INCIDENT WAS ON DATE BELOW. TRUCK PURCHASED JUNE 30, 2003 AND HAS APPROXIMATELY 18,000 MILES ON IT. *JB

Mileage: 17,700

I WAS TRAVELING DOWN RTE 37W IN TOMS RIVER NJ WHEN A LOUD "BOOM" OCCURRED IN MY ENGINE FOLLOWED BY A CONTINUOUS LOUD "TICKING" SOUND. I HAD MY VEHICLE TOWED (2003 FORD F-350) TO THE LOCAL FORD DEALERSHIP FOR INVESTIGATION. AFTER SPEAKING WITH LEAD TECHNICIANS AT FORD, I WAS INFORMED THAT THIS IS A VERY COMMON ISSUE WITH FORD MOTORS AND THEY ARE SURPRISED THIS HAS NOT BEEN RECALLED. MY SPARK PLUG WAS EJECTED OUT OF THE CYLINDER HEAD DUE TO LACK OF THREADING WITHIN THE CYLINDER HEAD. THIS WILL COST APPROX $4000.00 TO REPAIR THIS. I HAVE CONTACTED FORD DIRECTLY AND THEY CANNOT ASSIST ME WITH THIS REPAIR AND DO NOT RECOGNIZE THIS TO BE A PROBLEM WITH FORD MOTORS. I STARTED DOING MY OWN RESEARCH ON THIS ISSUE VIA INTERNET AND HAVE COME ACROSS HUNDREDS OF CASES AND COMPLAINTS OF THIS ISSUE HAPPENING WITH FORD ENGINES. THERE IS EVEN A CLASS ACTION SUIT THAT IS IN THE WORKS OUT OF CALIFORNIA. SOME OF THE LINKS CONTAINING THIS INFORMATION CAN BE FOUND HERE: HTTP://WWW.CONSUMERAFFAIRS.COM/AUTOMOTIVE/FORD_SPARK.HTML HTTP://WWW.TWOGUYSGARAGE.COM/FORUM/ARCHIVE/INDEX.PHP/T-7423.HTML HTTP://WWW.JASPERENGINES.COM/PDF/4.6_&_5.4_STRIPPED_THREADS.PDF THIS IS A VERY SERIOUS ISSUE AND VERY COSTLY TO REPAIR. THIS IS ALSO VERY COMMON AMONGST FORD TRUCK MOTORS. IF YOU LOOK AT THE LINKS I HAVE PROVIDED ABOVE OR EVEN DO A SEARCH ON SPARK PLUG PROBLEMS WITH FORD VEHICLES, YOU WILL SEE HOW OFTEN THIS OCCURS BUT FORD FAILS TO PROVIDE ANY ASSISTANCE WITH THIS MATTER. *JB

Mileage: 93,450

2003 FORD F-350 6.0L DIESEL. VEHICLE RAN ROUGH LOST POWER. 3 INJECTORS BAD THE FIRST TIME, 2 BAD INJECTORS TWO OTHER TIMES BEFORE ENGINE BLEW AT 41000 MILES. HAS HAD NUMERUS INJECTORS CHANGED, AND MANY OTHER EQUIPMENT FAILURES. WAS AT THE DEALER SHIP FOR OVER 5 WEEKS GETTING ENGINE REPLACED. WE JUST PREVIUSLY HAD THE TRUCK AT A DEALERSHIP FOR OVER 15 DAYS AND THEY COULD NOT DIAGNOS THE PROBLEM WE WERE HAVING OF LOSS OF POWER.*AK

Mileage: 23,671

TOOK TRUCK IN TO GET COMPUTER UPDATES (132000 MI). DEALER DISCOVERED 12 QUARTS OF FUEL IN CRANKCASE. HAD TO GET INJECTOR SEALS REPLACED ($1200). I KNOW OF AT LEAST 4 OTHER OWNERS OF THIS MODEL TO HAVE THIS PROBLEM. IN AUGUST 2004 HAD TO HAVE FRONT END REBUILT EVEN THOUGH I HAD DONE REQUIRED MAINTENANCE ($450)VEHICLE LOST POWER (12/20/04)(182000 MI). STOPPED TO CHECK FOR PROBLEM. ENGINE RESTARTED. I SHUT IT OFF AND TRIED TO RESTART. IT WOULD TURN OVER BUT NOT START. HAD TOWED TO DEALER. THEY HAD 20 DIFFERENT CODES COME UP ON COMPUTER DIAGNOSTIC. AS OF 12/28/04 IT STILL WILL NOT START AND DEALER STILL HAS NO IDEA WHY. MOST RECENT ESTIMATE FOR THIS REPAIR AT LEAST $1200 AN HAVE NOT BEEN ABLE TO WORK SINCE BREAKDOWN. *JB

Mileage: 182,000

I WAS DRIVING MY 2003 F-350 SRW 6.0L PSD FOR ABOUT 15 MINUTES AFTER STARTING WHEN I STALLED WITHOUT WARNING. I WAS TRAVELING ON THE HIGHWAY AROUND 45MPH WHEN THE TRUCK JUST SHUT OFF AND DUE TO NO POWER STEERING I WAS UNABLE TO PULL OF TO THE SIDE OF THE ROAD. ALSO THE TEMP AT THE TIME WAS AROUND 20 DEGREES F. AFTER MANY ATTEMPS TO RESTART THE ENGINE I WAS HELPED TO PUSH THE VEHICLE OFF TO THE SIDE OF THE ROAD WHERE IT SAT FOR ABOUT 45 MINUTES AND AFTER A FINAL ATTEMPT IT STARTED AS NORMAL AND HAS BEEN RUNNING FINE SINCE. I TOOK IT TO THE DEALER THE NEXT DAY AND THEY SAID THERE WAS NO PROBLEM WITH THE TRUCK. I AM NOW AFRAID TO DRIVE THINKING THAT IT MAY STALL AGAIN IN HEAVY TRAFFIC AND CAUSE A CRASH.*AK

Mileage: 22,450

2003 F350 SUPER DUTY 6.0 DIESEL REPEATED INSTANCES OF FAILURE TO ACCELLERATE CONDITION IS INTERMITTENT AND OCCURS WITHOUT WARNING. WE'VE MADE SEVERAL ATTEMPTS TO REPAIR THE CONDITION WITH THE DEALER STARTING IN 2/04 AND CONTINUING TO PRESENT.*AK

VERY ROUGH IDLE. *AK

Mileage: 16,857

EXCESSIVE BLACK SMOKE AND LACK OF POWER ON ACCELERATION. FUEL ECONOMY IS WAY DOWN. I TOOK THE PICKUP TO SIERRA FORD IN BISHOP CA. THEY KEPT THE PICKUP FOR TWO DAYS AND DID NOT HAVE THE PARTS TO FIX THE PICKUP, IN FACT THEY HAD TO TAKE PARTS OFF A DIFFERENT PICKUP AND PUT THEM ON MINE FOR ME TO GET HOME TO FRESNO CA.I TOOK THE PICKUP TO FREEDOM FORD TO BE FIXED WHEN I GOT HOME . BOTH DEALERS SAID THE TURBO WAS BAD.*AK

Mileage: 25,462

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.*AK

Mileage: 27,671

TRANSMISSION FAILURE, NO EVENTS LEADING UP TO THE FAILURE. BACKED TRUCK UP AND THEN WENT TO PULL FORWARD TRUCK WOULD NOT MOVE. REPLACED OIL PUMP, GEARS, FILTER & GASKET. 28,330 MILES ON TRUCK. *LA

Mileage: 28,330

THE PROBLEM IS CALLED DEAD PEDAL. WHEN YOU STEP ON THE GAS PEDAL YOU GET NO RESPONSE AT ALL UNTIL YOU LET OFF THEN THE TRUCK LUNGES FORWARD USUALLY LEAVING HALFWAY IN A INTERSECTION. HAPPENED ON 6-26-03 AGAIN, LEAVING ME IN INTERSECTION WITH SEMI APPROACHING AND VEHICLE PULLED UP BEHIND ME, FORTUNATELY THE SEMI HAD ROOM TO STOP. DEALER HAS TRIED TO FIX THIS BUT HAS NO IDEA WHATS CAUSING THIS. AFTER LOOKING INTO THIS ON FORDTRUCKS.COM/FORUMS I FOUND I'M NOT THE ONLY ONE WITH THIS PROBLEM.

Mileage: 9,000

6.0 LITRE DIESEL ROUGH IDLE, DEAD ACCELERATOR AT TIMES, LOW POWER, EXCESSIVE SMOKE, POOR FUEL MILAGE 8 TO 12 MILES PER GALLON. HAVE 30,000 MILES ON VEHICLE, POOR ENGINE RESPONSE WHEN COLD, ENGINE WARNING LIGHT COMES ON, HAS BEEN TO SELLING DEALER FOUR TIMES FOR REPAIRS, RE-FLASH OF COMPUTER FOR UPDATED INFO FROM FORD BUT PROBLEMS TILL PRESENT! DEALER HAS HAD VEHICLE FOR THE PAST FOUR DAYS ,SAID ITS FIXED! PICKED UP LAST NITE, ALMOST DID NOT MAKE IT HOME! THEY NOW HAVE BACK TO LOOK AT..HAVE BEEN AROUND DIESELS FOR THE PAST THIRTY YEARS; THIS ONE IS A DUD!! MOST ALL PROBLEMS STILL PRESENT, NOW FUEL ODOR IN CRANKCASE, DEALER DID REPLACE I.P.C. SENSOR AND DOWNLOADED LATEST CALIBRATIONS TO NO HELP!

Mileage: 29,900

6.0 LITRE DIESEL ROUGH IDLE, DEAD ACCELERATOR AT TIMES, LOW POWER, EXCESSIVE SMOKE, POOR FUEL MILAGE 8 TO 12 MILES PER GALLON. HAVE 30,000 MILES ON VEHICLE, POOR ENGINE RESPONSE WHEN COLD, ENGINE WARNING LIGHT COMES ON, HAS BEEN TO SELLING DEALER FOUR TIMES FOR REPAIRS, RE-FLASH OF COMPUTER FOR UPDATED INFO FROM FORD BUT PROBLEMS TILL PRESENT! DEALER HAS HAD VEHICLE FOR THE PAST FOUR DAYS ,SAID ITS FIXED! PICKED UP LAST NITE, ALMOST DID NOT MAKE IT HOME! THEY NOW HAVE BACK TO LOOK AT..HAVE BEEN AROUND DIESELS FOR THE PAST THIRTY YEARS; THIS ONE IS A DUD!! MOST ALL PROBLEMS STILL PRESENT, NOW FUEL ODOR IN CRANKCASE, DEALER DID REPLACE I.P.C. SENSOR AND DOWNLOADED LATEST CALIBRATIONS TO NO HELP!

Mileage: 29,900

THE TRUCK WILL NOT DRIVE STRAIGHT. THE TRUCK WANDERS ON THE ROAD. THERE IS APPROXIMATLEY 2 INCHES OF "PLAY" IN THE STEERING. FORD CALLS THIS NORMAL AND CONSISTANT WITH OTHER "LIKE" VEHICLES. IT HAS BEEN TO THE DEALER AT LEAST 3 TIMES, MAYBE 4. I'VE LOST COUNT. THE FACTORY "REP" SUPPOSEDLY HAS DRIVEN THE VEHICLE AND SAID IT'S NORMAL. I'VE HAD THE MOTOR PROBLEMS LIKE THE CONCERNS I'VE READ ON THE INTERNET, BUT THE DEALER HAS CORRECTED THOSE. THIS VEHICLE DOES "HAUL THE MAIL", BUT I PURCHASED IT TO PULL MY TRAVEL TRAILER. BUT, BECAUSE I CAN'T "SAFELY" KEEP IT BETWEEN THE LINES, WITH OR WITHOUT THE TRAILER, I DON'T FEEL SAFE HAVING MY FAMILY IN THE VEHICLE.

Mileage: 100

CONSUMER STATED VEHICLE CUT OFF 3-4 TIMES WHILE DRIVING ON THE HIGHWAY. EACH TIME HE TOOK VEHICLE TO THE DEALER/MECHANIC THEY REPLACED A PART OR DID SOME ADJUSTMENTS, AND CLAIMED IT WAS REPAIRED, BUT THE PROBLEM RECURRED. *AK

MY 6.0L FORD DIESEL WILL NOT ACCELERATE PROPERLY AND IS A DANGER TO MY AND MY FAMILY. BY FAR I AM NOT ALONE AND YOU CAN GET MORE INFORMATION BY LOGGING ON TO THEDIESELSTOP.COM AND LOOK IN THE 6.0L FORUM.

Mileage: 1,600

MY 2003 F-350 SUPER DUTY 5.4, WITH 3,500 MILES HAS AN ENGINE KNOCK ON COLD START-UP.THE DEALER HAD THE TRUCK FOR A WEEK, AND SAID THIS IS NORMAL.I TOOK AN OIL SAMPLE, AND HAD IT TESTED, AND WAS TOLD THE SAMPLE HAD TO COME FROM A HIGH MILEAGE MOTOR,THE SAMPLE SHOWS TRACES OF BEARING MATERIAL.THE DEALER SAYS THIS IS NORMAL FOR "BREAK-IN" OIL.I THINK THERE IS MORE WRONG, AND DON'T WANT TO RUIN IT.THIS IS A $30,000 TRUCK, AND I CAN'T SEE TEARING IT UP.*AK

Mileage: 2,700

DANGERIOUS WHEN PULLING OUT IN TRAFFIC! FLAT SPOT IN LAUNCH!*AK

Mileage: 1

THE ENGINE STALLED WHILE DRIVING AND IT TOOK OFF REALLY FAST FROM A COMPLETE STOP. THE VEHICLE WAS TAKEN TO THE DEALER ON 8/5/2003. THE DEALER DID NOT IDENTIFY THE PROBLEM TO THE CONSUMER. WHEN PICKING UP THE VEHICLE FROM THE DEALER THE VEHICLE STILL HAD THE SAME PROBLEM. THE DEALER TOLD THE CONSUMER TO DRIVE IT FOR A COUPLE OF DAYS AND BRING IT BACK IF IT DOESN'T GET BETTER. PLEASE PROVIDE DETAILS. *PH

THE VEHICLE STARTED TO SHUT OFF WHILE DRIVING DOWN THE ROAD. THE VEHICLE WAS TAKEN TO THE DEALER ON FOUR OCCASIONS, AND EACH TIME THEY SAID THE PROBLEM WAS FIXED. THE VEHICLE WAS STILL AT THE DEALER AND NOT RUNNING. *MR *TS *JB

Mileage: 2,000

DEAD PEDAL. WHEN YOU STEP ON GAS PEDAL YOU GET NO RESPONSE UNTIL YOU LET OFF, THEN THE VEHICLE LUNGES FORWARD,USUALLY LEAVING YOU IN MIDDLE OF INTERSECTION. *JB-

Mileage: 11,000

NEW F350 DIELEL 6.0, CONTUNIAL INJECTOR PROBLEMS, RUNS ROUGH AND QUITS, TOWED 2X'S, SUCKING DIELES INTO OIL.*AK

Mileage: 3,330

STEERING BOX, OIL LEAK, BRAKE MASTER CYLINDER LEAK. *NLM

Mileage: 8

2003 FORD F-350 6.0 LITER ENGINE DIESEL RUNAWAY AFTER OWNING 13 DAYS. VEHICLE HAS BEEN OUT OF SERVICE AND AT DEALERS FOR OVER THREE WEEKS. *JB

Mileage: 3,300

CONSUMER STATES INTERMITTENTLY LOOSE THE BRAKE. NO POWER STEERING. DEALER NOTIFIED. PLEASE PROVIDE FURTHER INFORMATION.

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. *NLM

Mileage: 3,500

I HAD A BRAND NEW 6.0 POWERSTROKE SUPERCHARGER BLOW UP ON ME AND IT ONLY HAD 244 MILES ON IT. SO THE DEALERSHIP GAVE ME A NEW TRUCK. THEN THE NEW TRUCK HAD THE SAME PROBLEM AT 8,000 MILES AND IT WAS THE SUPERCHARGER TO BUT IT ALSO BURNT AN INJECTOR OUT AND TOLD ME I NEEDED A NEW ENGINE AND FORD WAS NOT GOING TO COVER IT UNDER WARRANTY BECAUSE IT HAD AN AFTER MARKET PART ON IT, EVEN THOUGH I HAD THE SAME PROBLEM IN THE FIRST TRUCK ,BUT FIRST TRUCK DID NOT HAVE THE AFTERMARKET PART ON IT . SO I SHOULD NOT BE LIABLE FOR IT. *NLM

FORD F350 CREW CAB WITH 6.0-LITER DIESEL ENGINE. THE TURBO RANDOMLY SHUTS DOWN AND THE VEHICLE WILL NOT ACCELERATE OVER 45 - 50 MPH. THE ONLY TEMPORARY FIX IS TO TURN THE ENGINE OFF AND RESTART THE VEHICLE. MY SPOUSE WAS NEARLY REAR ENDED BY A HAY TRUCK WHILE TRYING TO GET ONTO THE HIGHWAY. THE VEHICLE HAS HAD THREE COMPUTER PROGRAM UPDATES - NONE OF WHICH HAS FIXED THE PROBLEM. FORD HAS NOW TOLD THE FLEET SERVICE DEPARTMENT THEY ARE AWARE OF THE PROBLEM BUT DO NOT KNOW HOW TO FIX IT. FORD DOES NOT HAVE AN "UPDATE" TO FIX THIS PROBLEM AND TOLD THE SERVICE DEPARTMENT TO RETURN THE VEHICLE TO US TO DRIVE UNTIL THEY COME UP WITH A SOLUTION. *NLM

Mileage: 4,000