What are the most common Ford F-250 Super Duty problems?
According to Au7o's analysis of 8,120+ owner reports, the 1999-2025 Ford F-250 Super Duty has 7 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, 4 are rated critical and should be addressed promptly.
Is the Ford F-250 Super Duty reliable?
The 1999-2025 Ford F-250 Super Duty has 7 known issues documented across 8,120+ owner reports. 4 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. 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 Super Duty problems?
Repair costs for known Ford F-250 Super Duty issues range from $100 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.
What year Ford F-250 Super Duty is the most reliable?
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 7 documented issues documented across 8,120+ owner reports.
What is the 2011-2019 Ford F-250 Super Duty 6.7L Power Stroke EGR Cooler Clogging and Failure?
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.
What is the 2011-2016 Ford F-250 Super Duty 6.7L Power Stroke CP4 High-Pressure Fuel Pump Failure - Catastrophic Fuel System Contamination?
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.
What is the 2011-2014 Ford F-250 Super Duty 6.7L Power Stroke Early-Generation Turbocharger Failure (2011-2014)?
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.
What is the 2003-2007 Ford F-250 Super Duty 6.0L Powerstroke EGR Cooler Rupture and Coolant Leak?
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.
What is the 2015-2022 Ford F-250 Super Duty 6.7L Power Stroke DEF/SCR System Failure - P207F and P20EE Codes?
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.
What is the 2011-2022 Ford F-250 Super Duty 6.7L Powerstroke Exhaust Manifold Stud Failure?
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.
What is the 1999-2025 Ford F-250 Super Duty Steering Damper Failure and Shimmy?
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.
