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According to Au7o's analysis of 5,800+ owner reports, the 1990-2025 Ford F-250 has 6 documented known issues, with 3 rated critical. The most serious are Front Ball Joint Premature Wear and Failure ($500-$1,600 repair), Recall 11V385000: Corroded Fuel Tank Straps on Salt-Belt 1997-1999 F-250 (Under 8,500 lbs GVWR) and Death Wobble - Front End Oscillation ($200-$1,500 repair). The most commonly reported issue is Front Ball Joint Premature Wear and Failure with 5,800 owner reports. Across all issues with published estimates, repair costs range from $200 to $2,500. DIY maintenance guides at au7o.io.
All 6 Known Issues
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5,800 owners
The Ford F-250 Super Duty (1999-2016) is notorious for premature front ball joint failure, a well-documented issue across all Super Duty forums. The heavy front-end weight from diesel engines (7.3L, 6.0L, 6.4L, 6.7L Power Stroke) combined with coil spring or leaf spring front suspension designs puts excessive stress on the upper and lower ball joints. RepairPal estimates ball joint replacement between $585 and $1,640 depending on model year. The 2005-2016 models with the coil spring front suspension appear most affected. Symptoms include clunking over bumps, loose steering feel, and uneven front tire wear. In severe cases, a completely failed ball joint can cause the wheel to tuck under the vehicle, resulting in loss of steering control. NHTSA has investigated ball joint complaints on various Super Duty model years. SuperDutyPSD.com provides a detailed ball joint replacement procedure documenting the issue.
Common Symptoms
Clunking or knocking noise when turning or going over bumps
Steering feels loose or wanders
Uneven or accelerated front tire wear (inside or outside edge)
Creaking noise from front suspension
Vehicle pulls to one side
Steering wheel vibration at highway speeds
Visible play when rocking front wheel by hand (jack test)
Front end feels unstable over rough roads
How to Fix
Replace upper and lower ball joints as a set on each affected side. OEM ball joints are adequate for stock vehicles, but heavy-duty aftermarket options (Dynatrac Free-Spin, Synergy, or Dana/Spicer heavy-duty) last significantly longer for trucks used for towing or off-road. RepairPal estimates $585-1,640 depending on model year and shop. DIY cost is approximately $300 in parts. Always perform a front-end alignment after ball joint replacement. Inspect tie rod ends, wheel bearings, and track bar bushings at the same time - these related components often wear together.
Medium Confidence5,800 owner reportsLast reported by owners Feb 2026Reviewed Feb 2026
NHTSA recall campaign 11V385000 covers 1997-1999 Ford F-250 pickups rated under 8,500 lbs GVWR, built between June 20, 1995 and August 4, 2004, that were originally sold in or are currently registered in the road-salt states: Connecticut, Delaware, Illinois, Indiana, Iowa, Kentucky, Maine, Maryland, Massachusetts, Michigan, Minnesota, Missouri, New Hampshire, New Jersey, New York, Ohio, Pennsylvania, Rhode Island, Vermont, West Virginia, Wisconsin, and the District of Columbia. On these light-duty F-250s, prolonged exposure to road deicing chemicals can corrode the metal straps that hold the fuel tank up against the frame. If one or both straps give way, the tank can drop far enough for the fuel lines to pull free of it, and in some cases the tank can end up dragging on the ground. Either outcome can leak fuel and create a fire hazard. This was a very large campaign: roughly 1,100,000 vehicles across all of the models it covered, which also included the F-150, the F-150 Heritage and the Lincoln Blackwood. Note that the recall applies only to the sub-8,500 lb GVWR version of the 1997-1999 F-250, so heavier Super Duty trucks of the same era are outside its scope.
Common Symptoms
Smell of gasoline or a visible fuel leak under the truck
Fuel tank hanging low, sagging, or scraping/contacting the ground
Visible corrosion or a broken metal strap holding the fuel tank to the frame
Fuel lines pulled loose or separated from the tank
How to Fix
The remedy is free at any Ford or Lincoln dealer. The dealer replaces the fuel tank straps with straps that have improved corrosion protection. Early in the campaign, when new straps were in short supply, dealers were authorized to fit a cable support under the existing strap as an interim repair, or a steel reinforcement over the existing strap as a permanent repair. Because coverage on this truck depends on GVWR, build date and where the vehicle was sold or is registered, run your VIN at nhtsa.gov/recalls to confirm whether your particular F-250 is included and whether the work has already been done.
The solid front axle suspension is susceptible to death wobble triggered by hitting a bump at highway speed. Worn track bar bushings are the most common root cause, compounded by worn ball joints and tie rod ends.
Replace the track bar and bushing as a first step. Inspect and replace ball joints, tie rod ends, and steering damper as needed. Perform a front-end alignment.
Glow plug failure is common on 7.3L diesel engines, causing hard cold starts. The glow plug relay (solenoid) also fails, preventing power from reaching functional glow plugs. Broken glow plug tips can also fall into the cylinder.
The 6.2L Boss V8 engine develops a knocking/ticking noise on cold start due to worn cam phasers. The phaser solenoids can also fail. The noise typically goes away once oil pressure builds but worsens over time.
Replace cam phasers and phaser solenoids. Update to the latest phaser design. Change oil regularly with 5W-20 to maintain proper phaser operation. Consider installing an oil catch can.
According to Au7o's analysis of 5,800+ owner reports, the 1990-2025 Ford F-250 has 6 documented issues. The most frequently reported are: Front Ball Joint Premature Wear and Failure, Recall 11V385000: Corroded Fuel Tank Straps on Salt-Belt 1997-1999 F-250 (Under 8,500 lbs GVWR), Death Wobble - Front End Oscillation. Of these, 3 are rated critical and should be addressed promptly.
Is the Ford F-250 reliable?
The 1990-2025 Ford F-250 has 6 known issues documented across 5,800+ owner reports. 3 issues are rated critical: Front Ball Joint Premature Wear and Failure and Recall 11V385000: Corroded Fuel Tank Straps on Salt-Belt 1997-1999 F-250 (Under 8,500 lbs GVWR) and Death Wobble - Front End Oscillation. Prospective buyers should inspect for these issues and factor potential repair costs into their purchase decision. Regular maintenance following the manufacturer's schedule helps prevent many common problems.
How much does it cost to fix common Ford F-250 problems?
Repair costs for known Ford F-250 issues range from $200 to $2,500, depending on the specific problem and whether you choose DIY or professional repair. The most critical issue, Front Ball Joint Premature Wear and Failure, typically costs $500-$1,600 to repair. Au7o provides step-by-step DIY maintenance guides that can help reduce repair costs.
What year Ford F-250 is the most reliable?
Reliability varies across model years of the Ford F-250. Based on documented issues, problems are most commonly reported in earlier model years. Au7o recommends checking the specific known issues for your target year before purchasing, and having a pre-purchase inspection performed by a qualified mechanic. Our known issues database covers the 1990-2025 Ford F-250 with 6 documented issues documented across 5,800+ owner reports.
What is the 1999-2016 Ford F-250 Front Ball Joint Premature Wear and Failure?
The Ford F-250 Super Duty (1999-2016) is notorious for premature front ball joint failure, a well-documented issue across all Super Duty forums. The heavy front-end weight from diesel engines (7.3L, 6.0L, 6.4L, 6.7L Power Stroke) combined with coil spring or leaf spring front sus… Repairs typically run $500-$1,600. Severity: high.
Content on this page was compiled with AI assistance using NHTSA complaints, TSBs, owner reports, and public automotive data. While we strive for accuracy, this information may contain errors. Always verify repair procedures and specifications with your vehicle's service manual or a qualified mechanic.
What is the 1997-1999 Ford F-250 Recall 11V385000: Corroded Fuel Tank Straps on Salt-Belt 1997-1999 F-250 (Under 8,500 lbs GVWR)?
NHTSA recall campaign 11V385000 covers 1997-1999 Ford F-250 pickups rated under 8,500 lbs GVWR, built between June 20, 1995 and August 4, 2004, that were originally sold in or are currently registered in the road-salt states: Connecticut, Delaware, Illinois, Indiana, Iowa, Kentuc… Severity: high.
What is the 1999-2025 Ford F-250 Death Wobble - Front End Oscillation?
The solid front axle suspension is susceptible to death wobble triggered by hitting a bump at highway speed. Worn track bar bushings are the most common root cause, compounded by worn ball joints and tie rod ends. Repairs typically run $200-$1,500. Severity: high.
What is the 1990-1998 Ford F-250 7.3L Diesel Glow Plug and Relay Failure?
Glow plug failure is common on 7.3L diesel engines, causing hard cold starts. The glow plug relay (solenoid) also fails, preventing power from reaching functional glow plugs. Broken glow plug tips can also fall into the cylinder. Repairs typically run $200-$800. Severity: medium.
What is the 1990-1998 Ford F-250 7.3L IDI/Powerstroke Injector Failure?
The 7.3L diesel engines (IDI pre-1994, Powerstroke 1994+) experience injector failure causing rough running, hard starts, and excessive smoke. The IDI injectors are simpler mechanical units; Powerstroke uses HEUI hydraulic electronic injectors. Repairs typically run $800-$2,500. Severity: medium.
What is the 2011-2025 Ford F-250 6.2L Boss Cam Phaser Knock?
The 6.2L Boss V8 engine develops a knocking/ticking noise on cold start due to worn cam phasers. The phaser solenoids can also fail. The noise typically goes away once oil pressure builds but worsens over time. Repairs typically run $800-$2,500. Severity: medium.
