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Ford F-Series Powerstroke Diesel Problems

KCRamKCRam Mt. Arlington NJPosts: 3,516
Exclusive discussion for the Powerstroke engine, and the older 6.9 and 7.3 "pre-Powerstroke" diesel engines as well.

kcram - Pickups Host


  • Has anyone else had head gasket problems with your 05 powerstroke?
  • my 05 powerstroke is experiencing leaks from both head gaskets. the dealer says he will not cover the repairs because I have an after market exhaust system. He is trying to charge me $8000 to replace both head gaskets and the turbo. I reported the problem I was having with overheating while towing my 5th wheel before the aftermarket exhaust and the shop just claimed that the coolant level was low. my truck only has 19000 miles.
  • wpalkowskiwpalkowski Posts: 493
    Did you do any other mods to the engine besides the exhaust?
    (Did you chip it, or add propane, or nitrous?) If you have any of these things and especially if you tow heavy, your exhaust temperatures can shoot up real hot, real fast, and exceed their normal operating range. I think if the exhaust gas temps go over something like 1200 or 1300 degrees for an extended period, then you can damage the turbocharger and associated gaskets.

    If you only have the exhaust mod, I don't think it alone would cause the damage, but the dealer is probably thinking what I outlined above. Also, how heavy is your 5ver? And do you tow it through the mountains? IT can put a lot of stress on the engine.

    Do you have a pyrometer to measure the exhaust temperature? It's good insurance to protect your diesel. That way when you're pulling a big hill with a heavy load in tow, you can monitor the turbo temperature, and back off on the go-pedal if you see you're getting too hot.

    Another tip is if you've towing hard with your foot into it and the engine is really hot, don't shut it down as soon as you pull off the highway ramp. Either drive it a few miles at city traffic speeds, or let the truck idle for at least 5 minutes so that the turbo heat can dissipate. If you're turbo's glowing red hot and you shut off the truck, it will cause the oil in the turbo bearings to break down and cause premature failure of the turbo bearings.

    As far as the current may want to try a different dealer for service as some are more lenient about mods than others. Do you have any documentation for the earlier overheating problem. A paper trail would help tilt things in your favor
  • Hi,
    I have a 2004 F350 6.0 Power Stroke Diesel.
    Scenario: In May 06 i noticed antifreeze leaking in front of the truck so i took it to the dealer they replaced the hose. In June 06 smelled coolant leaking again and didn't notice any on the ground and the dealer replaced the clamp and hose. In July 06 I continued to have this problem and took it back to the dealer and they replaced the coolant bottle cap after it continued to leak. In Aug & Sept 06 it was leaking again, they ran their inspections and now they are telling me i need a new fan clutch. I've spent time and money dealing with these folks and was wondering if anyone else was having this issue.
  • ldqldq Posts: 1
    I have 51,000 miles on a Ford super duty six speed. I have had constant problems with the clutch slipping, and am looking at replacing it for the 4th time. I have pulled my horse trailer a total of 65 times in 7 years. Ford offers no help. I don't "off road" or abuse this truck in any way. Any thoughts would be appreciated.
  • hi this is brad i don't owen a 6.0 power stoke. i have heard from the local ford dealer's and friends say that 6.0 shouldn't idle for long periods of time becasue it will clog the egr inter cooler. and you also have to drive them like you stoled it
  • It's called wet stacking. Normal diesel idle rpms are too slow, if you idle too long, your exhaust temperatures stay at nominal operating temperature and you get crud buildup. I thought it was more of an issue in the old 7.8L Powerstroke than in the 6.0L.

    Ford sells an option - Automatic Idle Controller - keeps engine idling around 1200 rpm, engine runs hotter and prevents wet stacking.
  • tom007tom007 Posts: 40
    I have a 99 powerstroke with 275,000 miles on it, just recently, Diesel fuel started leaking from a small tube on the front right side of the engine. Sometime it won't leak for days, then it might leak about a half pint out while it is sitting and idling, I don't think it leaks when I am driving it because my mileage has not changed.

  • i have a 2000 superduty and it was leaking fuel all last week from a small overflow drain which is viewable from the left front wheel well. i replaced valave behind the fuel filter and that solved the problem. i got the piece from the local ford dealer and the guys in parts said it is a very common problem in these trucks. so i am sure hat is the same problem that you are experiencing.
  • kwk3kwk3 Posts: 3
    While in the mountains for Thanksgiving my 2004 6.0 started leaking fuel early in the mornings when I started up and let it run to warm up at idle. The leak ia a fast drip coming from the engine but without removing stuff to see better I can't see where it's coming from. The leak stops after a short warm up drive. If this means anything the air temp was in the low 20s and altitude was 7000'. I have 30K miles, been in the same environment several times and never had any problems before this.
    Any one have any ideas?

    Thanks, Kenny
  • I have a 2000 F350 Super Duty 7.3L. I live in alaska, just came back from being away for a little while and cannot get the truck to start. I had it turning over fro a little while, but then i noticed some smoke and the smell of electrical coming from the passenger side of the engine. I checked it out and couldnt find anything, then tonight while i was trying to get it started it wont even turn over now, justs clicks when i tturn over the ignition. I have checked the batteries and they are both charged. Does anyone have any answers or suggestions for me on this.
  • kwk3kwk3 Posts: 3
    Dealer says it's the injector pump (no other details) and I have to wait about two weeks before they can get to it. Good news is that it's covered under warranty.
    Also, while my truck continues to run fine, for now, a customer brought his truck in last night barely running. He shut the engine off and the dealer couldn't get it started 'till this morning. Same problem and they've had four trucks in the last month, all with about 30K miles with bad pumps.
  • orvin1orvin1 Posts: 2
    Recently, after having several injectors, injector module and accelerator module replaced I noticed a tapping noise. I was told that this is a lifter tap. What solutions are available. Can the lifter be adjusted or does it have to replaced. What $ figure can I expect?
  • I have an F-350 7.3L Diesel that I just changed the glow plugs and the batteries in. The truck started up right after that ran the day. Then the next morning I went to start it and it will not start and has not started for a week now. Also when the key is turned on now the wait to start light also does not come on. Does anyone have any idea what might be the problem?
  • jeff72jeff72 Posts: 2
    I have a '97 f-350 7.3l diesel
    On a cold start up it idles rough and has a "miss" until warmed up. I was told these trucks have a common problem with the fuel injector wires causing this problem...but I can't find any info about this.
  • Check the glow plug relay?
  • jeff72jeff72 Posts: 2
    the problem is after it has started and is idling....didn't think the glow plugs could be a problem at that point?. Anyway, the relay is new as well as the plugs
  • it will turn over and can be pull startred but will not start on its own.
  • My 1997 F350 power stroke diesel quit the other day on the way to work but after a little while started up again. We changed the fuel filter but on the way home it quit again. After sitting for a little bit it cranks right up and runs good for about 15 minutes then shuts off. What could be wrong with it.
  • For a year, our truck has had a cough to it when you accelerated. Now, it is choking and you have to hold the accelerator down to try and keep it running. Sometimes it just quits and if you let it sit for about 5 minutes, it will start up again. We have spent A LOT of time and money at Ford Dealerships only to come away with the same problem. Any help would be a blessing.

  • i've had several hundred dollars worth of work performed on my 1995 F250 7.3 in the last few weeks. although i had some ancillary issues corrected, my truck still stops intermittently. if i'm driving on the highway it will jerk as if momentarily the fuel is interuppted. i've been told i need to clean the water separator but don't have a clue where that is. also, both mechanics simply scratch their collective heads and say, "gee...we just don't know what's wrong". can i bleed the fuel line?
  • KCRamKCRam Mt. Arlington NJPosts: 3,516
    Definitely sounds like a fuel delivery issue. I'd check around for dealers with Powerstroke specialists, and have the pumps and injectors thoroughly checked.

    kcram - Pickups Host
  • proamproam Posts: 2
    i have an 04f350sd 6.0psd this truck had had all the problems garbadge do not buy one. bought brand new been in the shop three weeks i am a mechanic and the problems this truck has seen are horrible like below me 2 articles down bad head gasket come on i yhave 34,00 miles and now antifreeze is coming out the passenger side toprear of the block $40,000 truck bad head gasket,granted the truck pushes alot of boost but these problems should be worked out before marketed i know personally three people that have the same truck and there heads have lifted to 3 people with brand new trucks same yeay same problem two are 04s and 1 05 my truck is bone stock, oil,both fuel filters chandged every 3,000 miles the other 04 my buddy is bone stock same problem and the 05 has banks kit and 8,000 miles and his lifted but he also granted beats the ford outta it let me tell you i drive slow and cautious and this truck let me down
  • my truck has been in for warranty 3 times. recently for over 2 months. drovee it home yesterday and still has shimmy while driving and injector problems. my warranty almost up and i have had no explanation from ford.ITS A LEMON!!!RIGHT?
  • Keep all of your receipts from the previous attempts at repair. You'll need them if you try to have your truck declared a "lemon"
  • Hi
    Sound as though you may have a cam timing sensor problem,
    Powerstroke common. Sensor is located left side of engine just above and behind harmonic balancer. This sensor can give false sense that pump and cam are not in time. Check Ebay for Price Usually $40.00 to 60.00. If this works keep one in the glove box for a spare. You will see picture on Ebay of What to look for.
  • jssmitjssmit Posts: 1
    Have a 2000 f350 7.3 diesel that stopped running as I was driving. Replaced cam shaft sensor and still nothing. Reprogramed computer from superchips towing back to original program and nothing. Fuel is coming from tank to filter not sure beyond that. It will attempt to turn over but no ignition of any type. Any ideas?
  • hbrumleyhbrumley Posts: 3
    You were right on the money. After spending close to $1,000 dollars at a local Ford dealership, we took the truck to a young(early 20's) powerstroke nut and he not only diagnosed the problem, but fixed it, added a glow plug relay to it and two new batteries for $400. After being told at the dealership it was the injectors and it would be $1,500 we were thrilled. THANK YOU for all your help.
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