Ford · Known Issues
1999-2025 Ford F-250 Super Duty Problems & Issues
1999-2025 model years · 8,120+ owner reports · Updated September 2026
All years · All trims · All engines
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1999-2025 model years · 8,120+ owner reports · Updated September 2026
All years · All trims · All engines
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According to Au7o's analysis of 8,120+ owner reports, the 1999-2025 Ford F-250 Super Duty has 20 documented known issues, with 13 rated critical. The most serious are 6.7L Power Stroke EGR Cooler Clogging and Failure ($800-$3,500 repair), 6.7L Power Stroke CP4 High-Pressure Fuel Pump Failure - Catastrophic Fuel System Contamination ($8,000-$15,000 repair), 6.7L Power Stroke Early-Generation Turbocharger Failure (2011-2014) ($2,500-$5,500 repair), 6.0L Powerstroke EGR Cooler Rupture and Coolant Leak ($1,500-$5,000 repair), 6.8L V10 and 5.4L Triton 2-Valve Spark Plug Ejection from Aluminum Cylinder Head ($300-$1,500 repair), 6.0L Power Stroke Engine Oil Cooler Plugging - The Root Cause Behind EGR and Head Gasket Failure ($900-$2,500 repair), 6.4L Power Stroke Fuel-in-Oil Dilution from DPF Regeneration - Rising Oil Level ($150-$900 repair), 7.3L Power Stroke Camshaft Position Sensor Failure - Sudden Stall and No Restart ($80-$300 repair), Speed Control Deactivation Switch Underhood Fire - Recall 07V-078 ($0-$0 repair), 6.0L Power Stroke Blown Head Gasket from Stretched Torque-to-Yield Head Bolts ($3,500-$8,000 repair), 6.0L Power Stroke STC Fitting Failure on the High-Pressure Oil Pump - Hot No-Start ($600-$1,600 repair), 5R110W TorqShift Torque Converter Failure and Debris Contamination ($2,500-$6,000 repair) and 6.0L Power Stroke HEUI Injector Stiction - Spool Valve Sticking on Cold Start ($2,000-$5,000 repair). The most commonly reported issue is 6.7L Power Stroke EGR Cooler Clogging and Failure with 3,450 owner reports. Across all issues with published estimates, repair costs range from $80 to $15,000. DIY maintenance guides at au7o.io.
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According to Au7o's analysis of 8,120+ owner reports, the 1999-2025 Ford F-250 Super Duty has 20 documented issues. The most frequently reported are: 6.7L Power Stroke EGR Cooler Clogging and Failure, 6.7L Power Stroke CP4 High-Pressure Fuel Pump Failure - Catastrophic Fuel System Contamination, 6.7L Power Stroke Early-Generation Turbocharger Failure (2011-2014). Of these, 13 are rated critical and should be addressed promptly.
The 1999-2025 Ford F-250 Super Duty has 20 known issues documented across 8,120+ owner reports. 13 issues are rated critical: 6.7L Power Stroke EGR Cooler Clogging and Failure and 6.7L Power Stroke CP4 High-Pressure Fuel Pump Failure - Catastrophic Fuel System Contamination and 6.7L Power Stroke Early-Generation Turbocharger Failure (2011-2014) and 6.0L Powerstroke EGR Cooler Rupture and Coolant Leak and 6.8L V10 and 5.4L Triton 2-Valve Spark Plug Ejection from Aluminum Cylinder Head and 6.0L Power Stroke Engine Oil Cooler Plugging - The Root Cause Behind EGR and Head Gasket Failure and 6.4L Power Stroke Fuel-in-Oil Dilution from DPF Regeneration - Rising Oil Level and 7.3L Power Stroke Camshaft Position Sensor Failure - Sudden Stall and No Restart and Speed Control Deactivation Switch Underhood Fire - Recall 07V-078 and 6.0L Power Stroke Blown Head Gasket from Stretched Torque-to-Yield Head Bolts and 6.0L Power Stroke STC Fitting Failure on the High-Pressure Oil Pump - Hot No-Start and 5R110W TorqShift Torque Converter Failure and Debris Contamination and 6.0L Power Stroke HEUI Injector Stiction - Spool Valve Sticking on Cold Start. 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.
Repair costs for known Ford F-250 Super Duty issues range from $0 to $15,000, depending on the specific problem and whether you choose DIY or professional repair. The most critical issue, 6.7L Power Stroke EGR Cooler Clogging and Failure, typically costs $800-$3,500 to repair. Au7o provides step-by-step DIY maintenance guides that can help reduce repair costs.
Reliability varies across model years of the Ford F-250 Super Duty. 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 1999-2025 Ford F-250 Super Duty with 20 documented issues documented across 8,120+ owner reports.
The EGR (Exhaust Gas Recirculation) cooler on 2011-2019 6.7L Power Stroke diesel engines is prone to clogging with soot and eventually failing, particularly on trucks used for highway driving, light loads, or trucks that idle extensively. The EGR cooler recirculates cooled exhaus… Repairs typically run $800-$3,500. Severity: high.
The 2011-2016 6.7L Power Stroke uses a Bosch CP4.2 high-pressure fuel injection pump that is fundamentally incompatible with North American diesel fuel specifications. US diesel fuel has lower lubricity than European fuel, and the CP4 pump relies on fuel for internal lubrication. Repairs typically run $8,000-$15,000. Severity: high.
The 2011-2014 6.7L Power Stroke uses a Honeywell DualBoost variable geometry turbocharger with ceramic bearings that proved unreliable in real-world use. The ceramic bearings fail prematurely, especially under hard towing use or when oil change intervals are stretched. The variab… Repairs typically run $2,500-$5,500. Severity: high.
The 6.0L Powerstroke diesel in 2003-2007 F-250s is infamous for EGR cooler failure. The cooler develops internal cracks that allow exhaust gas to enter the cooling system and coolant to enter the exhaust. This produces white smoke from the exhaust, coolant loss, and can cause hyd… Repairs typically run $1,500-$5,000. Severity: high.
The early 2-valve Triton aluminum heads used in the gas Super Duty carry only about four threads in the spark plug bore. Combustion pressure and heat cycling gradually pull those few aluminum threads until the plug backs out and is ejected from the head, often taking the coil-on-… Repairs typically run $300-$1,500. Severity: high.
The 6.0L's engine oil cooler is a coolant-to-oil plate cooler with extremely narrow coolant passages, and it sits first in the coolant path ahead of the EGR cooler. Casting sand, silicate dropout from the factory gold coolant, and general debris pack those passages solid. Once re… Repairs typically run $900-$2,500. Severity: high.
To regenerate the diesel particulate filter, the 2008-2010 6.4L injects fuel late in the cylinder rather than through a downstream dosing injector. That post-injection fuel washes down the cylinder walls and ends up in the crankcase. On trucks used for short trips or lots of idli… Repairs typically run $150-$900. Severity: high.
On the 1999-2003 7.3L Power Stroke the camshaft position sensor is the PCM's only engine-position input. When it fails the PCM no longer knows when to fire the injectors and the engine simply shuts off - often at speed, with no warning and no check engine light. It may restart af… Repairs typically run $80-$300. Severity: high.
The speed control deactivation switch threads into the brake master cylinder and is electrically live at all times, even with the key out and the truck parked. Brake fluid migrates past the internal diaphragm into the electrical side of the switch, where it corrodes and short cir… Repairs typically run $0-$0. Severity: high.
The 2003-2007 6.0L Power Stroke uses only four torque-to-yield head bolts per cylinder to clamp the cylinder heads to the block. Under high cylinder pressure - towing, hot ambient temperatures, a stuck VGT turbo, or any power tuning - the TTY bolts stretch, clamping load falls of… Repairs typically run $3,500-$8,000. Severity: high.
For the 2005 model year Ford revised the 6.0L's high-pressure oil pump and introduced a two-piece 'snap-to-connect' (STC) fitting on the HPOP branch tube. The two-piece fitting flexes with engine movement, wearing the internal seal and the locking ring until high-pressure oil lea… Repairs typically run $600-$1,600. Severity: high.
The 5R110W TorqShift automatic behind the 6.0L and 6.4L Super Duty trucks is a strong unit, but its stamped-steel torque converter with a single-disc lockup clutch is the weak link. Heat from towing, added horsepower, or fluid that was never changed cooks the lockup clutch lining… Repairs typically run $2,500-$6,000. Severity: high.
Each 6.0L HEUI injector contains two spool valves actuated by high-pressure engine oil. Oil varnish, coking and wear cause the spool to stick - 'stiction' - so the injector cannot respond to the FICM's command quickly enough. The signature is unmistakable to owners: a hard cold s… Repairs typically run $2,000-$5,000. Severity: high.
The Selective Catalytic Reduction (SCR) system on 2015-2022 6.7L Power Stroke trucks - which uses Diesel Exhaust Fluid (DEF) to reduce NOx emissions - is prone to failure, most commonly triggering DTC codes P207F (Reductant Quality Performance) and P20EE (SCR NOx Catalyst Efficie… Repairs typically run $3,000-$4,500. Severity: medium.
The Fuel Injection Control Module on the 2003-2007 6.0L steps 12 volts up to the roughly 48 volts the HEUI injector solenoids need. The module is mounted on the driver's side valve cover where it lives in constant heat and vibration, and its power-supply section degrades - almost… Repairs typically run $400-$1,200. Severity: medium.
When Ford moved the gas Super Duty engines to 3-valve heads for 2005, it fitted a long two-piece spark plug whose lower ground-shield section sits deep in the bore. Carbon packs the annulus around that shield, welding the plug into the head. On removal the plug shears at the join… Repairs typically run $400-$1,800. Severity: medium.
The 1999-2003 7.3L routes exhaust from each head to the turbo through two up-pipes sealed with crush-type 'donut' gaskets, one of which is buried under the engine in an awkward position. Constant heat cycling and expansion blow those gaskets out, so exhaust escapes before it reac… Repairs typically run $500-$1,500. Severity: medium.
The factory radiator on the 2008-2010 6.4L Power Stroke uses plastic end tanks crimped to an aluminum core. The crimps work loose and the tank-to-core seal separates, so the radiator begins seeping and then dumping coolant - typically down the driver's side. It is one of the most… Repairs typically run $800-$2,000. Severity: medium.
The 6.7L Powerstroke diesel engine exhaust manifold studs are prone to breaking due to thermal cycling. The extreme heat cycles of the diesel exhaust cause the studs to fatigue and snap, creating an exhaust leak at the manifold-to-head junction. This produces a ticking noise on c… Repairs typically run $500-$2,000. Severity: medium.
The factory steering damper on the F-250 Super Duty wears out and fails, leading to increased steering shimmy, vibration at highway speeds, and reduced ability to dampen road imperfections. The single factory damper is often inadequate for the weight and solid front axle of the S… Repairs typically run $100-$400. Severity: low.
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.