What is the 2011-2019 Ford F-350 6.7L Power Stroke Turbocharger Bearing and Actuator Failure?

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.

What is the 2011-2016 Ford F-350 6.7L Power Stroke EGR Cooler Cracking and Coolant Loss?

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.

What is the 1999-2025 Ford F-350 Death Wobble - Violent Steering Oscillation?

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.

What is the 2003-2007 Ford F-350 6.0L Power Stroke Oil Cooler Plugging Leading to EGR Cooler Rupture?

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.

What is the 2008-2010 Ford F-350 6.4L Power Stroke Cracked Pistons at the Fuel Bowl Lip?

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.

What is the 2008-2010 Ford F-350 6.4L Power Stroke Radiator Plastic Tank Cracking and Repeat Failures?

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.

What is the 2011-2016 Ford F-350 6.2L Boss V8 Cam Phaser Rattle and Exhaust Manifold Studs?

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.

What is the 1999-2010 Ford F-350 Exhaust Manifold Bolt Breakage?

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.

What is the 1994-1998 Ford F-350 7.3L Powerstroke Turbo Pedestal O-Ring Leak?

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.

What is the 2008-2010 Ford F-350 6.4L Power Stroke Fuel Dilution of Engine Oil During DPF Regeneration?

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.

What is the 2003-2007 Ford F-350 6.0L FICM (Fuel Injection Control Module) Voltage Decay Causing Hard Start and Misfire?

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.

What is the 2003-2007 Ford F-350 6.0L Variable Geometry Turbo - Unison Ring and Vane Seizure from Soot and Rust?

The Garrett GT3782VA variable geometry turbocharger on the 2003-2007 6.0L Power Stroke controls boost by pivoting a set of vanes in the turbine housing, all tied to a single unison ring. Because the 6.0L routes heavy EGR flow and crankcase oil mist through the exhaust side, soot,… Repairs typically run $300-$2,200. Severity: medium.

What is the 1999-2016 Ford F-350 Dual-Rear-Wheel Rear Axle Bearing and Seal Failure on F-350 DRW (Dana 80 Full-Float)?

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.

What is the 1999-2016 Ford F-350 Cab Corner, Rocker Panel and Rear Wheel Arch Rust-Through?

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.

What is the 2003-2007 Ford F-350 6.0L HEUI Injector Stiction - Cold-Start Misfire from Varnished Spool Valves?

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.

Ford · Known Issues

1994-2025 Ford F-350 Problems: 21 Known Issues

1994-2025 model years · 430+ owner reports · Updated August 2026

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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), 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), 5R110W TorqShift Torque Converter Failure and Low/Reverse Planetary Pinion Walk-Out ($2,800-$7,000 repair), 6.0L Power Stroke Head Gasket Failure from Stretched Torque-to-Yield Head Bolts ($4,000-$9,000 repair), . at .

Frequently Asked Questions

What are the most common Ford F-350 problems?

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, Death Wobble - Violent Steering Oscillation. Of these, 11 are rated critical and should be addressed promptly.

Is the Ford F-350 reliable?

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 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 5R110W TorqShift Torque Converter Failure and Low/Reverse Planetary Pinion Walk-Out 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 and 4R100 Automatic Transmission Failure Behind the 7.3L - Mechanical Diode and Torque Converter. 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-350 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.

What year Ford F-350 is the most reliable?

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.

All 21 Known Issues

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Frequently Asked Questions

What are the most common Ford F-350 problems?

Is the Ford F-350 reliable?

How much does it cost to fix common Ford F-350 problems?

What year Ford F-350 is the most reliable?

6.7L Power Stroke Turbocharger Bearing and Actuator Failure#

6.4L Power Stroke Cracked Pistons at the Fuel Bowl Lip#

7.3L Power Stroke Camshaft Position Sensor Intermittent Failure and Stalling (Recall)#

6.0L Power Stroke Head Gasket Failure from Stretched Torque-to-Yield Head Bolts#

6.2L Boss V8 Cam Phaser Rattle and Exhaust Manifold Studs#

7.3L Powerstroke Turbo Pedestal O-Ring Leak#

6.0L Variable Geometry Turbo - Unison Ring and Vane Seizure from Soot and Rust#

6.0L Power Stroke Oil Cooler Plugging Leading to EGR Cooler Rupture#

6.4L Power Stroke Radiator Plastic Tank Cracking and Repeat Failures#

5R110W TorqShift Torque Converter Failure and Low/Reverse Planetary Pinion Walk-Out#

4R100 Automatic Transmission Failure Behind the 7.3L - Mechanical Diode and Torque Converter#

6.7L Power Stroke EGR Cooler Cracking and Coolant Loss#

6.4L Power Stroke Fuel Dilution of Engine Oil During DPF Regeneration#

Death Wobble - Violent Steering Oscillation#

6.7L Exhaust Gas Temperature Sensor Failure Causing Commanded Engine Shutdown#

6.0L FICM (Fuel Injection Control Module) Voltage Decay Causing Hard Start and Misfire#

Frame-Mounted Fuel Pump Driver Module Corrosion on Gas Super Duty#

Exhaust Manifold Bolt Breakage#

Dual-Rear-Wheel Rear Axle Bearing and Seal Failure on F-350 DRW (Dana 80 Full-Float)#

Cab Corner, Rocker Panel and Rear Wheel Arch Rust-Through#

6.0L HEUI Injector Stiction - Cold-Start Misfire from Varnished Spool Valves#