Ford · Known Issues
1994-2025 Ford F-350 Problems: 21 Known Issues
1994-2025 model years · 430+ owner reports · Updated September 2026
All years · All trims · All engines
Choose the year and equipment for your written issues and visual request.
1994-2025 model years · 430+ owner reports · Updated September 2026
All years · All trims · All engines
Choose the year and equipment for your written issues and visual request.
Interest applies to the selected vehicle and configuration; it is not a reservation. Voting stores a first-party identifier for up to 180 days to prevent repeat votes. No account or email is needed. Clearing cookies or using another device may count separately. Privacy
Visual coming soon
Your interest helps us choose what to build next.
Visual Known Issues · Coming soon
$4.99/month plus taxes at launch · No payment today
Choose a year to request this visual. Trim and engine are optional; omitted trim is Not specified.
According to Au7o's analysis of 430+ owner reports, the 1994-2025 Ford F-350 has 21 documented known issues, with 11 rated critical. The most serious are 6.7L Power Stroke Turbocharger Bearing and Actuator Failure ($500-$3,500 repair), 6.7L Power Stroke EGR Cooler Cracking and Coolant Loss ($1,500-$3,500 repair), 5R110W TorqShift Torque Converter Failure and Low/Reverse Planetary Pinion Walk-Out ($2,800-$7,000 repair), 4R100 Automatic Transmission Failure Behind the 7.3L - Mechanical Diode and Torque Converter ($2,500-$6,000 repair), Death Wobble - Violent Steering Oscillation ($200-$1,500 repair), 6.0L Power Stroke Oil Cooler Plugging Leading to EGR Cooler Rupture ($1,200-$3,000 repair), 6.4L Power Stroke Cracked Pistons at the Fuel Bowl Lip ($8,000-$20,000 repair), 7.3L Power Stroke Camshaft Position Sensor Intermittent Failure and Stalling (Recall) ($40-$250 repair), 6.0L Power Stroke Head Gasket Failure from Stretched Torque-to-Yield Head Bolts ($4,000-$9,000 repair), 6.4L Power Stroke Radiator Plastic Tank Cracking and Repeat Failures ($700-$1,800 repair) and 6.7L Exhaust Gas Temperature Sensor Failure Causing Commanded Engine Shutdown ($200-$800 repair). The most commonly reported issue is 6.7L Power Stroke Turbocharger Bearing and Actuator Failure with 230 owner reports. Across all issues with published estimates, repair costs range from $40 to $20,000. DIY maintenance guides at au7o.io.
Don't see your problem? Describe your symptoms to get a diagnosis, or get a full repair guide.
According to Au7o's analysis of 430+ owner reports, the 1994-2025 Ford F-350 has 21 documented issues. The most frequently reported are: 6.7L Power Stroke Turbocharger Bearing and Actuator Failure, 6.7L Power Stroke EGR Cooler Cracking and Coolant Loss, 5R110W TorqShift Torque Converter Failure and Low/Reverse Planetary Pinion Walk-Out. Of these, 11 are rated critical and should be addressed promptly.
The 1994-2025 Ford F-350 has 21 known issues documented across 430+ owner reports. 11 issues are rated critical: 6.7L Power Stroke Turbocharger Bearing and Actuator Failure and 6.7L Power Stroke EGR Cooler Cracking and Coolant Loss and 5R110W TorqShift Torque Converter Failure and Low/Reverse Planetary Pinion Walk-Out and 4R100 Automatic Transmission Failure Behind the 7.3L - Mechanical Diode and Torque Converter and Death Wobble - Violent Steering Oscillation and 6.0L Power Stroke Oil Cooler Plugging Leading to EGR Cooler Rupture and 6.4L Power Stroke Cracked Pistons at the Fuel Bowl Lip and 7.3L Power Stroke Camshaft Position Sensor Intermittent Failure and Stalling (Recall) and 6.0L Power Stroke Head Gasket Failure from Stretched Torque-to-Yield Head Bolts and 6.4L Power Stroke Radiator Plastic Tank Cracking and Repeat Failures and 6.7L Exhaust Gas Temperature Sensor Failure Causing Commanded Engine Shutdown. 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-350 issues range from $40 to $20,000, depending on the specific problem and whether you choose DIY or professional repair. The most critical issue, 6.7L Power Stroke Turbocharger Bearing and Actuator Failure, typically costs $500-$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-350. 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 1994-2025 Ford F-350 with 21 documented issues documented across 430+ owner reports.
The 6.7L Power Stroke turbocharger's variable geometry vanes stick from soot buildup, and the turbo actuator motor fails, causing limp mode and reduced power. Extended idle time and short-trip driving accelerate soot accumulation on the VGT vanes. Repairs typically run $500-$3,500. Severity: high.
The 2011-2016 F-350's 6.7L Power Stroke uses a dual EGR cooling arrangement - a primary cooler plus a secondary cooler section - and both are subjected to thermal cycling between roughly 1,200 F exhaust gas and 200 F coolant. Repeated expansion and contraction fatigues the cooler… Repairs typically run $1,500-$3,500. Severity: high.
The 5R110W TorqShift used in 2003-2010 F-350s has two documented failure modes that matter to heavy-duty owners. The stock torque converter uses a stamped-steel shell and a single-disc lockup clutch that is marginal behind a loaded F-350, particularly a dually pulling a gooseneck… Repairs typically run $2,800-$7,000. Severity: high.
The 4R100 four-speed automatic fitted to 1999-2003 F-350s behind the 7.3L Power Stroke is the weak link in an otherwise durable driveline, and F-350 duty cycles - fifth-wheel and gooseneck towing near a 20,000 lb-plus combined weight - expose it. Two failure patterns dominate own… Repairs typically run $2,500-$6,000. Severity: high.
After hitting a bump at highway speed, the front end enters violent steering oscillation (death wobble) that requires slowing to a stop to recover. Caused by worn front-end components: track bar bushing, ball joints, tie rod ends, or steering damper. Repairs typically run $200-$1,500. Severity: high.
On the 2003-2007 6.0L Power Stroke used in the F-350 Super Duty, the engine oil cooler is a stacked-plate unit with very small coolant passages that sits in the valley of the block. Casting sand left from block manufacture plus silicate dropout from degraded Ford Gold coolant pro… Repairs typically run $1,200-$3,000. Severity: high.
The 2008-2010 6.4L Power Stroke in the F-350 uses a piston with a re-entrant combustion bowl whose lip is a known stress riser. Under the high cylinder pressures the twin-sequential-turbo 6.4L makes, and especially on tuned trucks or trucks that see repeated in-cylinder post-inje… Repairs typically run $8,000-$20,000. Severity: high.
The 1999-2003 F-350 with the 7.3L Power Stroke uses a camshaft position sensor at the front of the engine to time injection. The original black-bodied sensor fails intermittently, most often when it is damp or heat-soaked, cutting injection and stalling the engine without warning… Repairs typically run $40-$250. Severity: high.
The 2003-2007 6.0L Power Stroke in the F-350 uses torque-to-yield head bolts in a high-cylinder-pressure engine with relatively few fasteners per cylinder. Under repeated heat cycles, and especially with the elevated cylinder pressures that come from towing at weight or from any… Repairs typically run $4,000-$9,000. Severity: high.
The 2008-2010 F-350 with the 6.4L Power Stroke uses a plastic-tank/aluminum-core radiator that has a well-documented pattern of splitting where the core is crimped into the tank, and of the tanks themselves cracking. The upper radiator support is thin enough to let the core flex… Repairs typically run $700-$1,800. Severity: high.
On 2011-2012 F-350s with the 6.7L Power Stroke, the exhaust gas temperature sensor mounted downstream of the diesel particulate filter can lose its sensing function. The powertrain control module interprets the bad signal as an exhaust overheat event: the driver gets a warning me… Repairs typically run $200-$800. Severity: high.
The 6.2L gas V8 in the F-350 develops cam phaser rattle on startup as the phaser locking pins wear. Additionally, the exhaust manifold studs break due to thermal cycling, causing an exhaust leak. Both issues worsen progressively. Repairs typically run $500-$2,500. Severity: medium.
The 6.0L Power Stroke's Fuel Injection Control Module sits on top of the driver-side valve cover and must deliver a 48-volt pulse to fire each HEUI injector. The module is heat-soaked in that location and its internal power supply degrades over time; it is also killed outright by… Repairs typically run $350-$1,100. Severity: medium.
The exhaust manifold bolts on the 6.0L and 7.3L Power Stroke diesel engines break due to thermal cycling, causing exhaust leaks with a ticking noise especially on cold starts. Broken bolts are very difficult to extract. Repairs typically run $300-$1,200. Severity: medium.
The turbo pedestal gasket and o-rings on the 7.3L Powerstroke are a common failure point, causing oil and exhaust leaks. The exhaust back-pressure valve (EBPV) in the pedestal can also stick or fail. Repairs typically run $200-$600. Severity: medium.
To regenerate the diesel particulate filter, the 2008-2010 6.4L Power Stroke injects fuel late in the exhaust stroke through the main injectors rather than using a downstream dosing injector. A share of that fuel washes down the cylinder walls and ends up in the crankcase. Owners… Repairs typically run $150-$2,500. Severity: medium.
F-350 dually trucks run a full-floating Dana 80 rear axle whose hubs carry adjustable tapered inner and outer bearings with a seal riding on the innermost part of the spindle. Unlike a sealed unit bearing, this design is a maintenance item, and the loads a DRW F-350 carries - a p… Repairs typically run $300-$1,200. Severity: medium.
The 1999-2016 Super Duty cab has a double-wall rocker and cab-corner structure that traps water and road debris and rots from the inside out. On the F-350 the pattern is worse than on lighter trucks for two structural reasons: dual rear wheels throw far more salt spray and grit u… Repairs typically run $800-$4,000. Severity: medium.
Gasoline F-350s of this era (5.4L Triton V8 and 6.8L Triton V10) use a Fuel Pump Driver Module bolted directly to the steel frame rail behind the rear axle, where it takes the full spray of road salt and water. The aluminum module against the steel frame sets up galvanic corrosio… Repairs typically run $200-$700. Severity: medium.
The 6.0L Power Stroke uses hydraulically actuated, electronically controlled unit injectors (HEUI) that are fired by high-pressure engine oil. Oxidized oil leaves a varnish film on the injector spool valve, and when the engine is cold that film creates static friction (stiction)… Repairs typically run $900-$4,500. Severity: medium.
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.