Ford F-350 Super Duty Problems

RepairPal has identified the most common problems with the Ford F-350 Super Duty as reported by actual vehicle owners. We'll tell you what the problem is and what it'll take to fix it.

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Known Problems

There is a technical service bulletin for the V8 engines regarding a possible problem with the spark plug being ejected from the cylinder head, damaging the threads in the spark plug hole. If the vehicle is under warranty, cylinder head replacement is recommended. If the vehicle is out of warranty, Ford authorized the use of a specific thread insert to repair the head.

Software enhancements are available to remedy inconsistency and confusion about the Diesel Particulate Filter (DPF) cleaning cycle - “Regeneration” mode. The Powertrain Control Module (PCM) will need to be reprogrammed to add several enhancements, including a more reasonable driving experience during the cleaning cycle and instrument cluster notifications of the cleaning status.

The high pressure diesel fuel injection pump may fail, resulting in a "no start" condition.

A coolant leak from the radiator can be caused by a defective thermostat bypass. This can cause pressure spikes in the cooling system, which leads to radiator failure. The thermostat assembly and radiator should be replaced.

A severe lack of power may develop because the hose from the turbocharger to the intake manifold can come loose, resulting in loss of boost pressure to the engine.

The cooler for the EGR valve can leak coolant internally, which causes white smoke to come from the tail pipe. Hot exhaust gases are cooled by the EGR cooler before being circled back into the engine.

The VGT solenoid can fail. The VGT solenoid receives signals from the engine control module to adjust the boost that the (variable geometry) turbo is generating. A defective solenoid can also create an overboost or underboost condition when driving.

Delamination of the diesel fuel tank can occur resulting in a loss of power due to debris clogging the fuel filters. In some cases the fuel injection pump and/or fuel injectors have also been damaged. Ford has issued a service bulletin (#19728) addressing this concern. This issue can affect all diesel F-350, F-450, F-550, F-650, and F-750 Super Duty models.

If the engine cranks but will not start, this may be caused by damaged wiring to the high pressure fuel pump. Wiring to the pump can be chafed, which causes the pump to stop working. The chafed wires will need to be accessed and repaired.

A leak in the exhaust down pipe and cause smoke to be seen around the front of the vehicle and engine compartment, and exhaust fumes in the cab. The exhaust down pipe should be replaced.

The rear sliding glass window may stop working, or binds in motion. The power slider cable binds causing slow, or no operation. The glass assembly will need to be replaced, the cable is included in the assembly.

Our technicians tell us the spark plugs in these engines can be very difficult to remove. Ford has issued a service bulletin (08-7-6) to address this issue, which includes a recommended procedure on how to remove the plugs. Failure to follow the recommended procedure can result in the one or more spark plugs breaking off in the cylinder head.

The recommend procedure is as follows. Using this procedure will greatly reduce the chance of breaking a spark plug.

1. Break the spark plugs loose when the engine is warm.
2. Turn each plug 1/8 to 1/4 turn and soak the treads with 1/2 to 3/4 teaspoon of Motorcraft Carburetor Tune-Up Cleaner or a quality penetrating oil. Do not try to remove the plugs at this time.
3. Let the threads soak for at least 15 minutes.
4. After the soak period, tighten and loosen each spark plug, working it back and forth until the turning effort is reduced. Then, you can remove the spark plug.

There are special tools available to remove the broken spark plugs and repair shops will often charge additional labor time, over and above the quoted spark plug replacement cost, for the removal of each broken spark plug.

If the driveline angle is out of adjustment, it can cause shuddering from the vehicle when accelerating from a stop. The driveline angle should be adjusted to reduce vibration in most driving conditions.