From
http://6literpowerstroke.flatratetech.com/
"Guys can you look up my vechical? Its an 03 Excursion. 1FMSU45P43EC23915. My truck has spent more time on the back of a tow truck then I have driven it this month. I can not even make it home from the dealership. Runs OK but dies and will not restart. Doesn't matter if running down the highway at 70 or at a stop sign. It's not fun to be in the fast lane and try to get over 5 lanes with no engine, no power brakes, and no power steering. Please help!!! Is there enough time in the shop to get Ford to do the buyback thing?"
"WHAT A DAY FOR ME. MY AREA FORD ZONE MANAGER HAS JUST TOLD ME OVER THE PHONE THAT THE POWER I HAD WHEN I BOUGHT THE TRUCK IN APRIL DID NOT EXIST ANYMORE.
HE STATED THAT I HAD 2 OPTIONS
1. IF I NEED MORE POWER & PEFORMANCE I SHOULD TRADE IN THIS TRUCK & BY WHAT EVER MAKES ME HAPPY
2 KEEP THE TRUCK & LEARN TO LIKE IT CAUSE THIS IS AS GOOD AS IT GETS. IT IS WITHIN FORD SPECS.
CLASS ACTION? I'M LOOKING FOR A GOOD ATTORNEY"
"I was one of the stupid one's. I bought one of the earliest 6.0's and has been nothing but problems. I have a 2003 F250 crew cab, short bed King Ranch. I have been through all of the typical 6.0 problems. I have had the PCM reflashed now 5 times if my memory serves me correctly. Most of my problems have been solved. The one issue that I still have is that if it is below about 50 degrees F, it smokes and knocks when started. It also runs really rough until it quits smoking. The smoke stops after a couple of minutes, but the knocking sound is noticeable until the vehicle has warmed up.
I use the block heater anytime it gets in the 30s or below. This morning it was -5F and even with the block heater plugged, and cycling the glow plugs 3 times before starting, it ran very rough.
Could the oil be one of the issues???? My local ford dealer said to use 15W40 year round. The last re-flash I had done was in early december.
Any help would be appreciated!!!
Sincerely,
Sorry I sold my 97 7.3"
"I have a 03 F-350 that was mnf'd late 2002. I've had numerous engine problems - 2 injectors replaced - 5 or 6 computer upgrades/flashes - speed control sensor replaced - wiring replaced - diesel fuel in the engine (confirmed by engine oil analysis). Just had the latest "flash" done and didn't even last one week - going back to the shop on Monday (8th or 9th time back for same problems). Truck has been exhibiting a major miss when towing or hauling heavier weights. At 1800 to 2200 rpms is when most prevelant. When you accelerate past 2200 rpms it seems to run better. Since the new flash I do not have as much torque or power when hauling heavier weights. Fuel economy very poor - lost 5 mpg since new. Dealer is at a loss for what to do...............can anyone please HELP ME !!!!!!!!!!!!!!!!"
"I have had it with Ford.
20K miles and they wouldn't give me a lowner when I showed up w/o an appointment. I just left it for them to fix when they could work it in.
Detuned is what I call it. I'll void the warranty if I chip or flash it but Ford soldl us HP and tork
and took it away to get them through the warranty period.
Also the sales manager thretned to call the police when I talked to a friend on the sales lot."
"Hello Guys, I ordered my 04 PSD on 7/14/03 and received it on 8/20/03. My problems started at about 500 mi and have continued ever since. The symptoms have been; stalling at idle, dead throttle pedal, racing tach, engine stumbling and dying at hiway speeds. The truck has been in the shop 4 times and is there now. It has had all the updated flashes, new ICP, all to no avail. I have had several 7.3's and have never had a problem. After spending nearly $40,000 and depending on this truck to make a living I can tell you that I am very disappointed that Ford would release a problematic vehicle such as this. The thing that cooks my goose is that I ordered an 04 and got an 03 motor and all it's problems. I hope all you PSD owners have better luck than I have. Thanks for listening. Tony I."
"What is the likelyhood of fuel being dumped into the crank case if your lose an injector?
I lost #4, and repair paperwork states: #4 INJ ELECT CAME OFF BODY.
Service advisor claimed that one of the bolts that held injector in was missing the bolt head.
They drain the pan "looking" for it, but I think it was drained because of fuel in the oil.
Can anyone look it up for me?"
"My F-250 was built during job #1 and I keep having recurring problems. In twice for the a/c (cool air comes out but does not cool cabin), 4th time in for a reflash. twice in for rear main leak, no low end power since the first recall, and dead pedal. Every once in a while, you step on the gas pedal and nothing happens. The turbo spools up, rpm's go up, but the truck only moves 1-2 mph (enough to get you in the middle of the intersection) and about 3-4 seconds later, it takes off like a rocket. My question is: Should I bear with Ford, or go to DSB and puch for an '04? I hear the '04's are'nt any better."
"My new F-250 6.0L, 3.73 LS rear end w/ 6 sp manual transmission is a dog at low RPM. Granted @ 1400 to 1600 when the turbo kicks in she cant'be touched. The old 7.3L IDI 4.10 LS rear end had more low in power."
"HAD ONE MELT #6 PISTON AND #8 GLOW PLUG OVER FUELED JUST A BIT I GOT THE NEW ENGINE TODAY FOR THOSE OF US WHO HAVE HAD THIS PLEASURE HOW MANY HOURS HAVE YOU BEEN GETTING"
"Everytime we fix one problem with 6.0L another arises. Fix one leaking injector and another will appear..Hydrolocked cylinders and vehicles towed back within 100 miles. 2 gallons overfilled crankcases every 2000 miles.
I'm a Senior Master with diesel and gas certifications. FOMOCO refuses to allow all 8 injectors to be replaced, but they require me to continually "patch" the vehicles and await their return. After sleepless nights, and another 6.0 being towed back to the shop today, is it possible the injector cups are dislodged or not sealed causing these problems?
Fuel pressurization tests have failed to isolate injectors leaking back UP through the top, but does isolate injectors leaking into the cylinders, and then during cranking fuel being sprayed out the glow plug hoes, but like I said fix one and another will start leaking."
"Had a 6.0 with a miss today.Cyl #1 low side open.Ohmed the injector and had an open circuit between pin 3 & pin 4.When I pulled the oil rail off the soloniod for #1 injector came with it.The two torx bolts retaining the soloniod to the injector were both broken.I found the head of one of the bolts laying on the head.Has any one else seen this?"
"Last week had the steering box replaced and the oil pressure regulator o-ring replaced. Crawled under the truck on Saturday and found a new oil leak near the oil pressure regulator. It looked like a the crankshaft seal was leaking. Just got back for my dealer and parts have been ordered to replace the crankshaft seal. Motor has 9500 miles on it . Wonder what going to start leaking next?"
"Last week had the steering box replaced and the oil pressure regulator o-ring replaced. Crawled under the truck on Saturday and found a new oil leak near the oil pressure regulator. It looked like a the crankshaft seal was leaking. Just got back for my dealer and parts have been ordered to replace the crankshaft seal. Motor has 9500 miles on it . Wonder what going to start leaking next? [Frown]
Skee"
"My engine has a date of 2/03. Have had two injectors replaced already. How do I get the service dept. or Ford to go ahead and replace the rest of them. So far no fuel in the oil (lucky I guess). Also Should it take them 4 days to replace 1 injector?"
"My engine has a date of 2/03. Have had two injectors replaced already. How do I get the service dept. or Ford to go ahead and replace the rest of them. So far no fuel in the oil (lucky I guess). Also Should it take them 4 days to replace 1 injector?"
________________________________
From
http://ford-trucks.com/forums/forumd...hp?forumid=107
"5449 miles build date was june 03, had 2 oil seals replaced in the first 2500 miles. gas milage was 16.4/18.8 ave when new and has consistantly gotten worse since now at 14.3/15.8 ave this is by math not the console and is a running ave of 3 tanks. other than that I love the way my truck runs and drives."
"At 550 miles returned to selling dealer for repair. Approx. $5000 (parts/labor) and 6 weeks later the vehicle still isn't "right" and I have invoked the Lemon Law and expect FMC to buy it back. Current mileage is about 660."
"First problem on the first 6.0 litre that we took delivery of on January 14/03 was at 1500 km. Second problem for that truck was at 2500km then approximately 4000 and 6000km. These were all IPC's (there were five new ones I think all coupled with re-flashes) EGR valve at 7200km. Then at 8000 km injectors etc. Sold truck at 9600km to a broker who shipped it to the US to be re-sold in early October and we replaced it with a late model 2003."
"4000 MILES - FORD REPLACED THE PASSENGER exhaust MANIFOLD, IT WAS WARPED. TODAY THE TRUCK GOES BACK IN FOR POSSIBLY THE DRIVERS SIDE MANIFOLD. ALSO TO FIND OUT WHAT REV CODE MY COMPUTER HAS LOADED."
"Current milage: 6500
since new: drone at 1750RPM under acceleration
3500 Rear main seal leak.
3800 Oct recalibration (flash) Fuel gauge inaccuracy, louder, fuel economy drop of 20% (16.5mpg all around to 13.1mpg), reduced acceleration, new vibration in exhaust."
" Has been in shop dozen times last time on 12/12/03 for reflash of Oct. flash. Helped but still not right. Mileage is down 40%, power is still off a little, but truck is better. Althought this morning, the truck would not start at 10 degrees F."
"I have a Exc built 01/03 bought 2/03 has been in and out starting in 3/03 for water sensor not accelerating,rough idle,injector pump failed and left me strolling at 11,000 miles pulled out of shop and had to be towed back 6 miles from the dealer ship . new injectors at 18000 miles(only two,only ones leaking) back at 20500 when dip stick showed about 3 quarts over full,3 more injectors,because the others are all good. At 25000 back in after noticing rise in oil again .Replaced all injectors now at 30000 miles the oil has disappeared off the stick and she smokes like my uncle don, pulls like a mule runs like the wind and currently blesses me with 16.5mpg best on highway 22.0 worst was my first at 13.5 Its been flashed every time a new one came out and milage hasn't been hurt.I just want my truck to be like my 2001 7.3 rock solid reliable."
"Hey guys, got exhaust fumes in the cab when the heater is on? Have your dealer check the Turbo "CAC" tubes and clamps. We have three of our trucks doing the same thing. These tubes and clamps crack causing exhaust to cirulate under the hood and into the fresh air vents. Voila, exhaust fumes in the cab. Ford supposedly is redisigning these now and the tubes are in short supply as they have been in big demand. We are waiting for all of ours to be replaced and in the meantime must live with the exhaust in the cab. Pretty deadly when it's -30 and your employees have to be in the truck for 12-16 hours per day. Don't know if these cracks can cause poor mileage and running or not but it would seem possible. Our dealer says it is a very common problem and new parts may not be available until the new ones are finished."
"2003 Excursion 6.0 4x4
Build 01/03
Bought 02/21/03
Mileage at purchase 35
Initial visit 03/04/03
Mileage 3198
Fuel mileage 13.5
oil change-smell of diesel in oil
Missing service ticket Mid April
Fuel mileage 16.5
won't accelerated from start ,reverse slow to engage-smell of diesel in oil
05/21/03
Mileage 6105
Fuel mileage 16.5
recall ICP sensor,flash pcm,oil change note smell of diesel in oil and raised level on stick
05/27/03
Mileage 7778
Fuel mileage 16.5
surging idle,harsh gear engagement,rear compartment carpetwet
08/22/03
Mileage 13572
Fuel mileage 16.5
tow in,no start,water in fuel light on won't go off
6 pages of tests etc etc
*********Ford makes PAYMENT on vehicle*************
09/26/03
mileage19791
Fuel mileage 16.5
left hand window innopperable,water in fuel light still on, smell of diesel in oil
10/03 missing ticket
Fuel mileage 16.5
replace right hand vent window motor
WAS JUMPED BY SERVICE WRITER FOR NOT GIVING ALL EXCELLENT MARKS ON SURVEY GAVE NOTHING LESS THAN GOOD.
11/19/03
Mileage 27750
Fuel mileage 14.5
Lots of diesel in fuel,water in fuel light remains on vibration on braking
12/29/03
Mileage30035
Fuel mileage 15.1
Oil level off dip stick ,Owner put 2 quarts in to get on stick,vibration on braking,leather peeling off steering wheel
All fuel mileage figured with calculator
Please help!!!!"
"2003 F250 Crewcab, 4x4, 6.0 auto
engine build datre 1/03, truck build date 4/03
Purchased 4/03
Initial reflash, no problems 3500 mi
October flash. Smoother idle, a little louder.
Rear main seal replaced 14,000 mi, no recurring problem
Center driveshaft bearing and rear pinion seal replaced 18,000 mi
Truck runs fine, 17 mpg average driving,
Last oil change 5 days ago, oil sent to Blackwell Labs for analysis, will update post when results arrive."
"I have had injectors replaced at 2000, 4000, and 6000 miles (approx). 4 injectors replaced so far, but am approaching 8000 miles on my 2003, 6.0l, F250."
"Build date 05/09/03 F350 6.0 PSD auto trans.lariat crew cab 4x4 dually 4.10 L/Slip diff.
purchased 05/31/03 @4 miles
1, Defect. steering box @ 108 Miles. 06/06/03
2, R/M oil leak @ 311 Miles. 06/16/03 (NOT REPLACED)
3, 5 leaking injectors @ 311 Miles. 06/16/03
4, Defect. posi rear end and replaced R/M seal @721 Miles 06/23/3
5, defect. vacuum pump @1,257 Miles 08/25/03.
6, defect. windshield @ 2,551 Miles 09/23/03.
7, Hard down shift in tow/haul mode/ R/M seal leaking @ 4,640 Miles 12/01/03.
8, recalibration @ 4,640 Miles 12/01/03. (after calibration)
engine start's slow after warm-up, went from avg.18 MPG to 10 MPG (manual calculations) loss of take-off power. very slight rough idle. (Nothing dealer can do)"
"2003 F 250 ex cab 6.0 L deisel, engine build date 02/03. 5k mile ICP chip changed computer flashed. went from 19/20 mpg to 16 mpg, towing was getting 14 dropped to 10 mpg complained right away. 8400 miles, lost #8 injector on vacation Flordia. Computer reflashed 10500 miles still no power and I did get 1 mile to gallon when not towing.(16000 k) trip to Alabama, truck stopped running 3 times.then no power like haveing a 4 cyclinder engine EGR valve, 5 engine codes 3 for erg and 2 unknown ? went to my dealership at home16400 miles, not egr valve, turbo ordered parts came in had to change a solinoid valve in turbo old reading 71% new one at 65% also changed intercooler hose at turbo.17500 miles no power no power runs fine with out load no power towing 5th wheel. Ford said it was OK, went home and brought 5th wheel back, showed tech no power, turns out there is 1.6 lbs of boost @ 3000 rpm, should be 22.5 or better. reflashed computer again left shop, tried to pass very lazy, went back to ford and they showed me boost working. went home call lomon law lawyer
new 2004 F-250 with everything except moonroof arrived today 12/30/04 and there going to put in a new Rhino liner install 5th wheel hitch and all trailer electrical, new mud flaps, new bug shild and moving stainless steel grill from 03 to 04."
"> 03 F250 4x4 Lariat Crew Cab
> Build date March-2003
> VIN - 1FTNW21P23EC81284
> Special Ordered - Centennial Edition
> Purchased April 17, 2003 @ 8 miles on Odometer
> Issue from beginning day: Intermittent loss of power - expected problem water in diesel
> First 4 weeks and 3 tankfulls of diesel from different station known to have good diesel. Intermittent problem became more consistent until high rpms resulted in 45 mph max.
> June 2003 - Threatened to go to the newspaper press about Ford and it's new 6.0L. Already spent a lot of money on diesel addatives to get the water out ... called BS on this one ... they can't fool me ... it's something much worse than water in diesel.
> Late June 2003 - (squeeky wheel gets the grease ... heavy griping paid off) Factory rep came to dealership, replaced a defective turbo sensor that came out in some of the very initial 6.0 L trucks. Since mine was special ordered back in February, I got one of the first 6.0 liter PSD's off the assembly line. ... Geez ... my luck.
> After turbo sensor fix, truck ran fine.
> July 2003 - Took truck over to a race-car shop and put it on a dynomometer to measure hp to the rear tires. RESULTS: 240 hp with only modification being 35" tires. Ford advertises 325hp to the flywheel. The difference from 240 to 325 is approximately 27% loss through drive-train. A little excessive I would say.
> August-December 2003 - Noticed that I'm filling up constantly, finally performed a 3-fillup MPG check. I'm averaging 11.02 by hand calculated method. Overhead LED is now reading 9.8 mpg."
"5500 miles on truck
replaced rear main seal
replaced frame mounted fuel sep module due to short at 5500miles
replaced key switch due to steering wheel jamming(ford bulletin)
reflashed because I had to(according to ford) and occasional burpty burp.
All problems other than fuel module where present at purchase with 200 miles on truck."
" '03 F-450 12/18/02 build date, purchased 5/28/03
7/24/03 4955 mi. replaced ICP (turbo sensor?)
7/24/03 4955 mi. recall 03B06 (reflash)
7/25/03 4987 mi. bad idle complaint, Everything ckd OK Could not duplicate. Told to wait for new reflash.
9/23/03 10989 mi. Continued serious idle and start-up problems. Told to wait for new reflash.
10/23/03 12520 mi. Continued serious idle and start-up problems.
Reflashed per TSB 03-20-12. Oil change, found #5 injector low and water in fuel light on after oil change. cleared codes and checked for loose connections.
10/31/03 12950 mi. While pulling trailer up long hill gradually started loosing power until truck was moving at walking pace on shoulder. Stopped and shut down engine. Restarted and ran great.
11/03/03 13160 mi. In for repair related to 10/31 incident.
replaced three injectors, both fuel pumps, FICM and PCM. Out of service for two weeks.
12/8/03 13327 mi. Truck cranks,no start. Still in shop as of this writing. Ford factory techs involved, but no answers.
12/17/03 Have initiated buyback. Ford says I need to be patient because of reduced staffing during holidays."
"2003 6.0 Litre S/n 1FTSW31P43EB58479 15,000 Miles. Just sent truck in to Ford for regular service. All updates done. Sent employees out to site. Truck died on highway again. No power, rough running etc. Possibly Turbo waste gate control which we have had trouble with when ambient temperature below 0. Third time down on the highway for this one. Saving grace is we actually have 8 of 13 that are running. Lucky us. Not all are 6.0 litre vehicles thank God. At this point we have 10 of the 6.0's and 3 of the 7.3's. Right now we would take all the 7.3's we could get to replace our 6.0's but I guess that's not an option. Even with all the problems witht the turbos, suspension, transmissions etc that the 7.3's had they usually would run. Talked to the service manager of the dealership we towed this one into today. He said he hasn't been able to sleep since the first 6.0 came back about a year ago. He says the '04's are a bit better and he can sleep half the night now. Great consolation I thought. We may have a lot more problems here because of the cold weather we experience in the winter time but that should never be an excuse. We have now been told that we must run 0W30 and a special fuel conditioner when ambient temperature is below -25. We were told last winter by Ford that no conditioner should be used and to stay away from 0W30. The service manager at the attending dealership today told me that the conditioner recommended by Ford was causing injector problems and really should not be used if you want the truck to continue to rum. He has seen fuel gelling and gumming of injectors with this conditioner in the 6.0 since last winter. He says they tried 0W30 last winter with no change in the problems encountered. One problem the cold weather seems to exacerbate is the Turbo Waste Gate Control. The dealership pulled one from a stock unit and got us on our way. Ambient temperature today was -28 but hey we buy diesels so they can be run 24 hrs a day in the cold. I think Ford forgot about many of the issues surrounding actual diesel truck operation and what these trucks are intended to be used for. Not just sitting in a grocery store parking lot and impressing the guy beside you. So far we haven't impressed anybody yet. Yesterday was coming back from the city and saw two flatdeck tow trucks with guess what vehicle on them? I dread the times when we actually have to travel with these trucks."
"03 250 XL PSD Build date 11/02 delivered 10/28/03 returned to dealer 12/01 with leaking injector (1779 miles on odometer)and fuel in the crankcase. Injector replaced and oil changed.
Mileage has been consistant @ 12.5 city/14 hwy. Dealer will not do a mileage check untill 5000 on vehicle. Currently running well with tendancy to make 'rattling' noise in high gear @1230-1260rpm"
'Lariat: Just got back from Calgary as the tow service dropped off the truck (16 hour return trip) I will try to do more research tomorrow. The truck does run but won't go over 30mph. Sounds like turbo. The '04's have a redesigned turbo. I can't believe it though as I just got a call from one of our other operators with a 6.0 litre and he figures the transmission is gone. This is a May 2003 build with 20,000 km. on it. He limped it back into camp but he doesn't think it willl make the trip tomorrow. So it's back to trying to line up a replacement vehicle and Roadside Assistance. "
"I have 03 F350 SD, don't know build date. Purchased 8/03. First problem at about 2 weeks. Replaced injectors at just over 2000miles. Has been in shop multiple times. Problems with suspension, fuel milage, check engine light, water in fuel light. Latest and worst problem bucking/ jerking condition in tow/ haul mode. This started at just over 5000 miles. As per oasis message number 17006 (from my dealer) no repair known at this time. My story reads as mr bad luck.6l. Dealer won't help. Ford doesn't seem to care. I depend on my truck for my livelyhood. Having to pursue legal channels. Any advice greatly appreciated. Can't believe we purchased $40,000 truck that my dealer says is unsafe to haul with and won't make good. I have owned a Ford diesel since I was 20 that I have used to haul with can't believe this!!!!"
"Guys: I see that some readers are saying that one in ten of the old style injectors failed and one in one hundred of the new styles are failing. So does that mean you would be happy with close to a ten percent failure rate of your truck for one problem? Over what period of time? One year, 10,000 miles or what? This seems like a perverse way of justifying a poor performance at best. Come on, we've already had 2 of our trucks with the new injectors fail due to injector problems. But I guess if you have 10 6.0 litre trucks then our odds are right on. We're not happy. Especially when bad injectors can create a dangerous situation with a runaway engine and have such a devestating effect on the rest of the engine (such as the tubo, charge air cooler, pistons etc.) With the cracking of the charge air cooler tubes causing exhaust fumes to enter the heater intake, and the injector problem which can cause a runaway why hasn't Ford issued a recall or at least sent out a warning? These are situations that all 6.0 litre owners need to be aware of. Ford is redesigning the charge air cooler tubes and obviously have chaged the injectors. They must know these situations can and have existed or they wouldn't be going through what looks like a hurried, adhoc design change of the 6.0 litre. It would be interesting to know exactly why they are disabling the pilot injection. It's not for better fuel economy that we're sure of."
"Tim Lamkin
3 bad C94's injectors @ 6,819 miles. 01/07/03
that's all of them, all C95's now"
"I just ordered a 2004 F350 with the 6.0 (ordered on 1-4-04)...this thread is scarring me. The last thing that I want with a brand new truck is reliability problems. However, I hate to change the order to the V10 because of the low MPG, shorter engine life, etc. Anyone else have the recent order jitters??"
"
June 03-350 crew cab-4x4-short bed
First 1000 miles had a loud pop, then brief flame out going up hill pulling trailer.Then engine light came on, started to get hot, backed out of it everything ok except engine light still on. Light off next morning but comes on 3 and off three more time on trip. Take to dealer, no codes thrown runs fine. Around 4000 miles pulling trailer, blow intercooler end off. Dealer fixes and flashes truck. Conplained to dealer about lost power. They reflash truck with 2nd flash, engine light keeps comming on. Changed out egr, or both sensors [havent got paper work on it yet]. Runs better but still not like when new. Smell exhaust more, and alot noiser than when new. Towed trailer first time since 2nd flash, could only pull hill at 55,pulled same hill before flash at 70 with some to spare, and mileage down to 7 pulling trailer,got about 91/2-10 when new,computer says 13 [first time i didnt use computer]Waiting for dealer to get 12-12 flash. Haven't taken mileage without trailer except with computer 13.5 best since flashes but dont think thats right? taking now will let you know."
"At exactly 5000 mi on the Odometer the engine started running rough. I was 1500 miles from home in nebraska. My cell phone would not pickup a signal. I limped into a Ford dealership in NE at closing time. I spent a week there. On initial inspection the technician blamed it on the CPS sensor. I asked him how he new that without doing anything but listening to it as it Idled normaly at the time he checked it. He said that he had just replaced one on a vehicle the other day with the same symptoms. Of course we had to wait for the sensor to show up. Guess what? I called the dealer and they said the engine had blown up. What? I rode down to the dealer to find the mechanic had drained 30 quarts of oil from the engine. I said you mean Oil and deisel fuel? He said yeah like maybe he hadn't thought of that. Well they found out about a service bulletin that required replacement of the leaking injector, turbo and EGR valve. I wanted to leave realy bad at that point so they fixed it. I am not sure what damage I may have incured in the incident but it cannot be the right thing to do if you operate an engine full of diesel fuel. I want to have a truck I can depend on. I want to know it will make it to 500,000 miles with resonable cost. I don't want to be stuck in the middle of anywhere without support. I don't want an engine that uses diesel fuel for a lubricant when the injectors leak. I want a new engine or a 500,000 mile guarantee. What's it going to be FORD?"
"engine build date dec 18, 02 huntsville plant
140 miles on del
2500 miles #8 injector not firing &replaced
currently on oct flash I think no other engine problems 6600 miles"
"Hi,
Well I'm happy with my truck when it runs right.
I have 35,000+miles, it's been reflashed 17 times, and milage is down to 15, when it was new out of the box it got 17.5 at 75MPH.
The reflash and in about a week and ahalf it goes back to the same old problems; smoke, gutless, rough idle-cold or warm, noisey, surges when cold, rear main leaks.
Help, where do I go to get Ford to buy mine back?"
"Issue #01
04 F250 4x4 Lariat Crew Cab
Build date 11/03
Purchased 12/19/03 with 18 miles on Odometer
Issue: Severe shake under acceleration, 12/27/03
Odometer when Problem noticed: 742 miles
Initial Fuel MPG: 7.2
Current MPG: Avg. 15.4 MPG
Problem resolved with replacement of injector #5
Current Odometer 823 on 12/31/03
Issue #2
04 F250 4x4 Lariat Crew Cab
Build date 11/03
Purchased 12/19/03 with 18 miles on Odometer
Issue: Loss of power when accelerating and rough idle at start-up, 01/09/04
Odometer when Problem noticed: 2273 miles
Initial Fuel MPG: 7.2
Current MPG: Avg. 15.7 MPG
Problem was not diagnosed
Current Odometer 2445 on 01/13/04"
"2004 F250 6.0 PSD 4X4 Crew Cab LB
10/02/03 motor build date
1900 miles- In shop for oil leak and to check for problem Stalling and no power ( Possible wire harrness) Will repost after I get it back from dealer.
I am picking up truck today they replace the following:
1: Cam Postioning Sensor
2: Rear Main Seal"
"04 F250 4x4 XLT Crew Cab LB (04' 6.0L PSD)
Build date 10/03
Purchased 12-27-03 @ 18 miles on Odometer
Issues: Engine cutting out & "resetting". sometimes on hard acceleration, sometimes starting from dead stop -- rather intermittant -- Dealer replaced crank position sensor and PCM with (supposed) most recent updates!
Odometer 563
Initial Fuel MPG: 12"
"2004 FX4 F250 Crew, Torque shift auto, Build date 8/12/03.Bought in oct.03. At 1400 miles I noticed the oil drip on bellhousing and had the dealer put the dye in. I also complained about strong exhaust fumes in the cab.I was told to bring it back at 3000 miles for the first oil change , and to verify the oil leak.At 3000 miles, Leak was verified and rear seal was ordered.I also had the latest flash that seemed to improve fuel mileage, But now it has dropped back to where it was at 16 mpg.I am still getting a puff of white smoke on a cold start, But it's not as big a cloud as before the flash. When I went to have the rear seal installed , I complained about the exhaust again. A leak was verified on the Turbo Inlet pipe. The rear seal was not installed at this time , because the exhaust parts were ordered and the Tech is waiting for the parts to do all the work at once. They say it will take about 4 to 5 days to do the job.They don't loan vehicles to drive while warranty work is being done. I am wondering how I will get back and forth to work during this time. I now have 4400 miles on the truck and still haven't had the first oil change because of the work that is waiting to be performed. My dealer says this is the first he has seen any of these problems. It's very hard to beleive him. He has about 6 new trucks being worked on everytime I have been by there. I am trying hard to love my Ford, But I am also thinking that Ford has used us all for a test bed."
"4705 miles
Rear main seal replaced (again was originally replaced at 22
miles)
Timing Cover seal replaced
2 injectors changed
4 other injectors were loose (how does an injector loosen up?)
exhaust smell in cab not fixed (dealership says it's not a problem)"
"Lower radiator hose replacement due to a minor leak at approximately 400 miles on my '04 X 6.0 PSD."
"2 fridays ago took a trip from Detroit to Akron OH and back.
Truck ran great and looked to be getting the best mpg yet. I had gotten back to Monroe Mi driving 80mph @ 2000rpm an the engine let go throwing a rod right out the oil pan. Truck only has 15,000 miles. "
" I had no problems until 12/25 and that is when it all started. With approx. 4100 miles, had to take to dealership to have the AGT Valve replaced (I think that is what it was called). The next day my Check engine light came back on with rough idle. Took it in next day and they replaced the EGR Valve. The very next day, Check engine light was back on. Waited 2 weeks and finally got it back to the dealership. With 5300 miles they replaced the EGR Valve again and I also had a complaint about a loud noise coming from motor after accelerating and taking my foot of the gas pedal...they said that is normal....but it doesn't do it on neighbors truck (same as mine). Well that trip lasted 2 days and check engine back on and so back to the dealership with 5390 miles. They replaced the EGR valve again and gave it back to me saying "This is normal for this motor". 3 days later (last saturday) check engine came back on and just received a call from dealership saying that code is for EGR valve but they believe the problem is more than the EGR valve. At this point very frustrated and do not know what to do, and is more frustrating when the dealership doesn't know what to do.
I do not know what is wrong but I am done with this one and am willing to try a NEW ONE."
" 6200 miles and just had my 1st injector go bad. i should get it back today. My truck seems to run great compared to comments that I am hearing. My milage could be better about 13/16. I told them not to reflash because it runs well and am not sure how much louder it will be without pilot injection."
"July Build '04/'03
Steering wander
Bellhousing leak at delivery
Low power, fuel mileage, noise and vibration since Oct. Flash
Replaced #5 injector - 5000 miles
Replaced Rear Main Seal - 5000 miles
Replaced Steering Box - 5800 miles
Took truck in on December 16 for oil leaks on both sides of engine with ~5800 miles
Shop foreman called December 23 and said that the oil was coming from inside the heads on both sides
The truck is still in the service department as I type this on January 20. Over a month in for service at a very large Ford dealer w/ a lot of diesel sales.
I have been approved for a replacement vehicle but I'm still not sure if I want to take another gamble. This has been a very bad experience. I liked the original truck with all the power, great fuel mileage, pilot injection, ... and now I'm not sure if I will ever be satisfied again.
Ford can do much better than this and I hope they prove it soon."
"09/02/03 Purchased truck Production date 07/03, 2003 Motor month 7/22/03 Huntsville plant. 45 miles on odometer.
09/11/03 MPG 13
09/18/03 report smell of exhaust through cab vents, 824 miles
told normal burn in smell
09/22/03 Diagnosed warped passenger side exhaust manifold.
10/28/03 Manifold replaced, flash loaded smell is less. Engine
seems louder. 1768 miles MPG is around 17 overhead
is displaying 16.1
11/20/03 Oil Lube Filter at dealer, also report smell again, dealer
reports no issues - miles=3907
12/04/03 Adjust rear passenger door, report smell told normal.
12/21/03 Drop off truck for exhaust odor through vents, want it
fixed miles=5515
01/05/04 Called Ford relations
01/21/04 Picked up truck again. All seems ok. Will monitor things.
Miles 5520
Parts replaced (2) w300012 n1818402c2-o ring
(1)3c3z*6k854*ca adpt & shld assy
(1) “ *da “
(1)9y439*ad hose assy egr cool out
(1)6n640*aa gasket exch man adpt
(1)9e933*aa gasket egr to thrtl body
(2) w300012 n1818402c2 o-ring
(1)3c3z*6a603*aa hos-crkc ven tub ext
Door ajar alarm on lights do not go out, replaced
4L3z*14018*aa
PCM Flash calibration is 307a-12A650-FTC version B29.1
Basically above parts were replaced to try and fix exhaust smell in the cab.
Tech states a EGR gasket was missing. Turbo inlet/outlet tubes and related parts were changed. Latest flash loaded, seems ok, Blue Puff in the mornings however still happens. Slight drift in steering not sure if worth complaining will check air pressure etc… 3 Weeks to do this work."
"I have a 2003 ford powerstroke. Build date is January 03. huntsville alabama plant. S/N 0025996. The first problem occurred on 15th of may. 2008 miles were on the truck. One of the fuel injectors went on it. actually cyl #5. They performed flashes and insatlled ONE new injector. Took 15 days.
After recieving the truck the was a spuratic rolling idle. It jerked at lights when at a stop ocassionally, I also had a dead pedle ocasionally (I would step on the gas and truck wouldn't respod for a few seconds) alot of smoking, running extremely rough, and fuel millage was at 11 miles to the gallon. my drive to work in 32 mile on a 45 and 55 mph roads.
Second trip was on 29 july, 03. 7290 miles. i took it in for the above reasons. said that i had to live with it until new flash comes along.
Third trip to the dealer was 19th of Jan, 04. 18983 miles. noticed a small amout of oil in the coolant resevoir, turbo started droning around 8500 miles. along with the above problems. decided it was time to take it in agian. just recieved it back today. alot of the above probelms seem to solved. unfortuatly the truck is louder than my 7.3 litre, power seems to be down, and shifitng is wierd havent put my finger on it yet! They said the turbo droan was normal and that i should put a additive in my fuel to help the smoking and rough idle out (LOL) will let you know if the milage is any better.
I am a loyal ford owner and understand the problems of intoducing a new motor. However i definalty didn't want to be the guniea pig for it. If you or anyone have any information that can help me get rid of this truck it would appreciate it. the dealer has been very helpful until i brought up that i wanted it bought back!"
"Ford F350 Lariet CrewCab 4x4 6.0 LB SRW Fully loaded
Build Date: Unknown
Purchase Date: May
1. Oil change/reflash 4000 miles during this time
I had clunk in tranny and minor cosmetic problems
After reflash, huge loss of power, white and black smoke at startup, dead pedal. Requested buy back at this time.
Truck would not start, towed from garage back to dealership.
2. 8000 miles truck reflashed by dealership and starting problem
resolved. During that time Ford engineers tested truck. The recomended all injectors be replace which was done.
Power came back. Engine made loud noise at idle. Black smoke persisted Gas milage droped from 19mpg hwy unloaded to 17mpg
still had some other drivablity problems and clunk in tranny.
Ford offered replacement truck. I wanted a Chevy but they would not by back the truck."
" i had one of the very 1st 6.0's in my area in '03.drove it 1500 miles and injectors and turbo went out twice in 200 miles. ford bought it back and sent me an '04. it has been worse and to date has been in shop for 5 weeks!!! yes ...put in shop 12-18-03. now is 1-27-04..."
"build date is 2/03 15059 miles I changed the oil. next morning my wife drove it 1/2 way to work called me and said it lost all power. we made it to the dealer 3 miles away they say #3 injector is bad. the only other problems are chugging on cold start up and once in a great while absolutly GUTLESS on cold take off (about the way a duraslack runs @ it's best).:-X01 the
truck goes back in tuesday feb.3 to have #3 injector replaced, after reading about the poor milage after the reflash I am going to ask them not to do the reflash!"
"04 F250 4x4 XLT SC LB Auto trans
Build Date: 10/03
Motor Date: 02 Oct 03
Purchased: 28 Oct 03
Issue: Engine dies (no warning, no stumbling, just dies)
Odometer at Initial Occurrence: 416 miles (rollback to dealer) One day at the shop (R/R wiring harness - Don't know if that's remove/repair or remove replace)
Died at idle in driveway 27 Jan 04
Died in traffic again 01 Feb 04 (Restarted after I pulled over and fought with the steering lock and switch)(Odometer @ 3589)
Current MPG: 15.25 (When it's running that is ......)
I went through hell with the 95 Ford I had. Traded for a 2000 Chevy 2500HD 6L. Ran great (except for lousy mileage) for 4 years. No pistonslap, no problems at all. Thought I'd come back to Ford. Didn't want a Dodge made in Mexico and the Chevy's were uuuuuuuugly. Now it begins again. I'm very irritated and I haven't had half the problems other have. Wake up FMC .... While you're at it, how about some real gauges! The Fords I had in the 70's were great. My nephew is still driving my 77 F-150 302 V8. He has over 200K on it."
"I called the dealer today, they are going to put dye in my engine to see just where the oil leaks are coming from.
They haven't figured out how they are going to stop the rear main oil leak, they've tried twice now.
Third time is a charm.
Nothing worse than having a brand new truck and all it does is leak oil and transmission fluid"
"I lost $3,100 plus 3 months worth of payments plus a new stainless Magnaflow exhaust system. I no longer own the '04 F250 with the '03 powerstroke. I now have an '04 2500HD with the Duramax. I know Chevy has had it's share of problems too, But at least they will give you something to drive when they have to keep your truck for a week at a time for warranty work. I guess you live and learn, But it sure is expensive. I'm glad it worked out for you racerwoman,I can identify with your situation."
"I just thought I would let all know that the '03 F-250 is no longer a part of my life!!! I now own a '04 F-250. I am keeping my fingers, toes, eyes, and everything else crossed that there will be no problems like before. The dealer worked me a deal to pay mine off and put me in a new truck for the same terms as before with nothing out of pocket. They finally realized it was un-repairable. I went in with this site as my ammunition! I want to say thanks to everyone who posts here. This place let me know I was not alone with all the problems with my '03. Have a great day!!"
"I even called the ford customer service to try and get a loaner vehicle for the 5 days they were going to have mine in the shop. They told me it was up to the dealer and not ford. I explained that when I took delivery of my truck, it had those factory defects. They should have at least been willing to stand behind their product to the tune of a loaner/rental vehicle. The dealer should have at least stood behind their customer as well. They acted like they were doing me some kind of big favor to just fix what was wrong with it when I drove it off the lot. They tried to say the exhaust smell in the cab would go away after it was broke in. They also said that it was the first time they had seen a rear seal leaking. I must have bought the only F250 they sold with the 6.0 powestroke!Yeah right! Sorry for the rant, But if I can discourage anyone from buying a truck at benson ford in Easley SC, I will do it."
"I bought a new 2003 6.0 F350 in June 2003, it was made in Feb of 2003 @ the Kentucky ford plant.
I bought the truck for a work truck........I haul pole barns. Since it was bought for a work truck I didn't want all the bells and whistles. It is an extended cab, flat bed, standard trans, XL.
I now have 75000 miles on it. Granted that is alot of miles but it is all hwy miles. At 18000mls it was @ the dealership and they replaced the #7 injector and cleared and reset the computer. The truck never has run right from day one........it has been gutless, has no low end power and idles real rough almost dying and sometimes would die.
We limped along with it until finally it gave out, breaking down and leaving us stranded 8 hrs from home. It broke down in Guymon OK 3mls from the ford dealership, but they would not get the truck in their shop to try to fix it.........said it would be a week before they could look at.........got the same story from 3 other dealerships close to Guymon. Finally got one that said they would get it in and look at, but I had to pay to have it towed 70mls south to TX (I was headed North to CO). They said that the high pressure oil pump had blown out the gaskets and seals. Took them a week to get that fixed. Went to pick it up (drove 8hrs) and when I got there they said it still wasn't running.......UGGHH!! So now they think it is injector problems.......replaced the 2,3&8 injector. Drove 8hrs to pick it up again....Got in the truck drove it a block went back told the service manager something was wrong, it was not running right, he got in and drove it (telling me oh it's probably just cold and hasn't got warmed up yet). we went about ten miles got on a straight stretch and he pushed it up to around 60mph and then........The transmission locked smooth up........bouncing us off the road!! I was not a happy camper. Then to top it off, the service manager drives the truck back to the dealership (5mls) with the transmission locked in low (the shifter was flopping around in neutral), it was grinding and making a god awful noise. So, we replaced the transmission, all this took a month.......I was losing lots of money! Before going to pick the truck up for a third time I asked the Service manager to check and make sure that no damage had been done to the rear end. I was told that he had indeed checked it out and there was no damage. I drove the truck the 8hrs home and it was making a noise.....AGAIN! Took it to a dealership at home and guess what.........The rear end was out!! After talking to the service rep for the dealership in TX, I was told that the service manager only checked the oil in the rear end!! So, we fixed the rear end. The truck made 4 1/2 hauls before breaking down in Springfield CO!! This time it was towed to Lamar to the Ford dealership where it stayed for a week and half. They could not figure out what was wrong with it. So, I hauled it home. Put it in the dealership here and they replaced the 1 and 7 injector.......this was the second time for the #7. Also a fuel pump, pcm module, gasket-rocker arm cover, mass air flow censor, idle censor and replaced the pinion seal and nut because the rear end was leaking. Another month later the truck is finally running, but I am scared to take it out again. I have been calling customer service and have gotten nowhere. The dealership the truck was bought at will not help in anyway. I have had a Service manager call and leave a nasty message on my phone because I reported his neglegance to customer service. I AM FED UP!! I will never buy another Ford. The customer service is seriously lacking. I am trying to get the truck bought back, but haven't had any luck so far. Next step is to hire an attorney. I have lost so much money with down time, hotel cost and repair cost it is unbelievable."
"In case you haven't been following I brought my truck in 3 weeks ago this coming Saturday for a bad vibration in the engine and blowing blue smoke. After a good amount of jerking around they decided to replace the oil burner. I was able to get into the shop tonight to see the engine and you wouldn't believe the damage. The #7 piston was near gone. There were parts missing out of it the size of a peanut M&M. If you've seen a diesel piston you know it's conical with a point in the middle, well the outer edge was gone in 3 spots and you could see the top ring which was also missing peices. The engine was still running when I brought it in by the way. So there is something to be said for the durbility. BUT, no here's the bad part. To swap the engine they had to pull everything out of the engine bay. I'm talking coolant lines, AC lines, electrical wires, etc., etc. So who knows what will work and what won't work when I get it back. Did I mention the magical 30 day mark will be this Sunday and they don't have the new engne yet? On top of that I was going to pull a camper to Daytona next Friday with this truck. What would you do? Oh yeah, I got someone to call me back from FMC HQ today. I'll certainly be on the phone with her tomorrow. Hey doesn't Big Blue own Hertz? Maybe they can get me a reliable Excursion to pull the camper to the 500.... sorry to ramble I'm just PO'ed...."
"I just had the second rear main seal replaced. I had the original replaced at 3800 and the second now at 7600 miles. The service people say the checked the crank end play, etc. and it is all okay. I have read a few other posts with similar problems. They ever go away? Other than the Oct flash and the rear mains, I like the truck but this is annoying."
"I have an '04 6.0 F350. Took delivery on 10/26. Truck leaked coolant in mid-December. Took it in they couldn't find the leak. Two weeks later it was the same thing. They swapped out the EGR cooler b/c it had a leak. Two weeks later the truck cooks jugs #7 and #3. Cracked both pistons and burned the rings off of #7. It's took 13 days in the shop for Ford to step up and replace the engine. As of today I'm looking at another 10 to get the replacement and get it in. With 23 days +/- for this visit and 7 days for the EGR replacement and 1 day for the witch hunt for the coolant leak I'll be at 31 days. Just over the 30 limit and the truck only is 3 months old (1 spent in the shop) and has 6100 miles. What do you think I should do next?"
"Hello everyone, This is my maiden post. Bought F-350 in August,truck was great. Then came time for first oil change. Went to dealer, they suggested flash. That was start of problems. Fuel milage dropped from 18 to 11 miles to gallon. Engine noise almost doubled. Strong diesel fume smell in cab. Noticeable loss of power. List goes on but I will quit. Flash fixed one problem, stopped disel fuel from getting into motor oil by disabling pilot injectors. Took truck back in for second oil change and to address some of the concerns I had been having on Dec. 9th. Keep truck for 3 days, said they could not duplicate customers concerns on every issue but one, was told to bring truck back when transmisson tech would be back. Sorry to say truck did not run long enough to make it back. On Dec.19th motor shut off and has not run again. I will be ordering new truck tomarrow Jan.20th as Ford has started buy back process. Got to love those Ford's to go through this. Good luck to all other owners with problems"
"Looking for some advise here folks. Rear main seal was replaced at 15,000 miles than again at 20,000 miles and now at 22,000 miles the dreaded stain/drop around the rear main seal has re-appeared. At no time has the leak been severe enough to drip onto the driveway.
Should I get it replaced again or just live with it?"
"I've been fairly satisfied with my 04 F250 w 03/6.0, Even when I discovered the rear seal leaking that famous little drip everyone is talking about.I had them put the dye in the oil at around 1400 miles, and last week I finally rolled 3400 miles on it and I took it in for it's first oil change, Which was not going to be free by the way. When they blacklighted the oil spot, They determined it was in fact a bonified oil leak. I set up an appointment with the service mananger to have it fixed, and he said it would probably be an all day job. So I left my truck with them and had to bum a ride to work, Since they don't have loaner vehicles and Ford doesn't reimburse on rentals(according to them). I had complained about the exhaust smell in the cab when I dropped my truck off for the rear seal repair. They found that the Turbo feed pipe has a leak and will have to be replaced. They are saying now , That it will be a 4 day job for the rear seal and the turbo feed pipe. The only part I have a real problem with , Is the fact that I have a 3 month old truck with 3400 miles on it and Ford doesn't reimburse for rentals or loan cars while warranty work is being done. I am flashing back to 1994 when I bought a new GMC Z71, and it had a Transmission cooler leak the first day I took delivery of it. Since I had bought it from a dealer about 100 miles from where I lived, They put me in a brand new 95 GrandAm for about a week, and then drove my truck to my workplace and picked up the grand am from me. Now that was service! Well, I can say I love my Ford, But I don't think Ford is too fond of me!"
"I had the #7 (anyone know which side of the engine it's on?) injector go bad on Sat and it blew smoke until I could get it to the dealer. They replaced the injector but can't get compression in the cylinder now. It's either top end or a ring they think."
"i've had my truck about a year. in the shop 15 times. rear seal once, oil still leaks, have the transmission out now along with engine, they say the "bed pan" is leaking. anyway, they are measuring some stuff in the engine and thinking of replacing the engine, but i was told it would be a refurbished engine. i've been without my truck 39 days today and counting in less than a year. i talked to the regional manager and he said no way ford would buy my truck back. i told him it would be a lemon under the TN lemon law. (30 days in one year in the shop). he said no way for me to let them repair it again. i told him i might get a lawyer and he hung up on me. needless to say i was a little perturbed. i called a lawyer today and hope to get this started next week."
"Hi,
Well I'm happy with my truck when it runs right. Mine was built Jan 5, 2003, one of the first ones
I have 35,000+miles, it's been reflashed 17 times, and milage is down to 15, when it was new out of the box it got 17.5 at 75MPH.
The reflash and in about a week and ahalf it goes back to the same old problems; smoke, gutless, rough idle-cold or warm, noisey, surges when cold, rear main leaks.
I have had it in the shop for the same problem 10 times, each time it runs good but not for long.
How many times must the truck go in the shop before it qualifies for the buy back?
Help, where do I go to get Ford to buy mine back?"
"I took my truck in today for recall o3eo3 expecting all to be fine--my engine build date is 5/27/03. Well, 3 hours later I call to hear that injectors 1 & 6 were sticking; I had complained to the advisor of a rough idle. End story-- 2 new injectors and a flash =$1362.79 courtesy of FMC. The dissapointing news, I have the C94 injectors--at least 6 more. Service advisor says, "Don't worry.... by 100,000 miles we'll have all injectors replaced". Well, that should make me sleep soundly tonight!!"
"2003 6L PSD LX-limited slip diff-Oct flash
Recently experienced roadside failure (engine quit running at hwy speed). After parking on shoulder engine would restart and run fine for a time, then repeat this scenario. Managed to run from Salinas to Santa Rosa, CA (200 m). Truck had 1100 miles on it at the time. Dealer found leaking injector. This had put enough fuel into the crankcase to induce a 'vibration' upon acceleration (the crank was litterally 'wallowing' in the oil-fuel mix!) This also created a very strong diesel smell in the climete controll system"
"Hello all. I am posting a question for my uncle. He purchased a F-350 with the 6.0 in Sept. It went in a few weeks ago at around 4000 miles with an oil leak. They put the dye in and found the rear main leaking, so they replaced the rear main and some kind of plate on the backside (I assume it is the metal plate that the rear main sits in). Now they say they have put it back together and it is still leaking. He is a little upset now that his truck has been in the shop (after dreaming for 10 yrs of owning a diesel) for a month now. What are the production dates that the 6.0 is experiencing these rear main leaks and is there a solution? They are at the point they want to replace the motor and he wants a new truck. Any help?"
"Hello, took delivery of a new 350 CC XL 6.0 11/24 and loved the truck. 12/24 it started shaking on highway (miss) pretty bad. Stopped immediately and drove home practicaly on idle 1/4 mile and had it towed to dealer. Result, injector #4."
"Hi all,
Well, my I took my truck (see sig.) to the local dealership today to have the water in fuel light fixed. Originally they said to switch gas stations, and if the light were to come on again, to have it fixed under warranty (by replacing the fuel pump) they said the Tec.'s issued an all-points bulletin about this issue. Well, all is well, the light goes on again, so I bought it back to have this fuel pump replaced "under warranty". I gave it to them at 9AM today, I get a call around 11AM saying that it leaked so much water, that they have to replace BOTH fuel filters, and this will cost me OVER $160. (including labor). Now I'm rip ___. To make a long story short, after talking with the service manager, because I felt they ripped me off, I paid the $167.00, and was on my way. The service manager said that if the light came on again, the would have to completely take off the gas tank, etc., and flush the whole thing out. This could take up to THREE days, and cost OVER $750 for labor! PLUS parts !! This truck is only 3 months old, and should NOT be going throw all the problem's I've stated. If the light comes on again, I'm DONE, I've having the dealer buy back the truck. I'm NOT investing near $1K to a BRAND NEW truck to have it "fixed". "
"This is a long story but I will try to make it short. I have been reading this forum since I first started having trouble. I am to lazy to post but think I owe the story. After 1000 miles I began pulling my 8000 lbs. plus boat. I could not believe the power. The truck just asked for more. At about 4000 miles it started. When towing it would not go over 55 mph with out missing. The dealer could not recreate the problem without the boat. 5 or 6 trips to the dealer and here are the problems: The injecters were bad, not one, but several; fuel oil in the crank case; the air flow sensor was changed; reflashed; re reflashed; now the truck lost power; lost fuel econ. ; romps when cold repeatedly even after siting for several min. ; left on the side of the road twice with the boat ; fuel injection pump changed; others problem I can't even remember.
Ford tried to get me to accept a "new engine" I refused and insisted on a buy back. The finally agreed and the 2004 is on order. Lemon law was applacable. The gave me a better deal than required by Lemon Law. I never threated them and I was never inpolite. But they never gave me B.S. They just tried to fix it and they couldn't. Do you think I should sell my 2004 the day I get or is the 2004 the truck I thought I bought in 2003?"
" I have had the same porblems with my truck since new. It now has 49000km on it. I has been in and out of the dealership for the past 6 months. The latest flash did help with the ruff start up. Here is the main problem: Highway driving between 80 and 120 kph when I start up a hill (small or large) the truck hesitates. It will keep doing it every 2-3 seconds untill is reaches the top of the hill or kicks down to the next gear. Every time it hesitates a puff of black smoke comes out of the tail pipe, and a knock comes from the engine. 4 different dealers have taken a try at fixing it, about 7-8 weeks in the shop since new (the fleet guy at Ford Canada directed me to each dealer). Today they said they have fixed the problem.... Needs 1 or 2 new injector(s). I am guesing the problem is not fixed because every other time the truck was in they said the same thing "It's fixed"... NOT. So anyone think bad injectors could cause this problem, and why did they not find this before??"
"I had to tow my baby 700 miles home and I just can not trust the my truck to go out of town. This was the second time it was towed in and the second time I was 600-700 miles from home and it dies and leaves me on the side of the road. two other times I was close and limped into the dealer. I wasent sure if I wanted to post this but I would like to here from some guys who did the buy back and get some advise. I must say I love my truck when it runs it is so awsome but when it dies there is no warning at all and it could be a real dangerous to die when towing on a small mountain road or in the fog I have been real lucky so far when it has died (15 times) I have had the room to pull off. The stange part is I had over 20k on the truck before the first time it died then it got a reflash in Oregon and drove home fine then died three more times and had to be towed in. My local dealer put in a new cam sensor and pcm, I picked it up on a friday at 5pm put about 50 miles on it and then sat morning (yes less than 24 hrs) I was towing my boat to the lake when it died right in front of my dealers driveway. By tuesday they had put in a new ficm and it has been great since 9-16-03 and about 6k mile and then I tow my 27' trailer through bad fog ( dont want to think about it dieing then) and get 700 mile from home and it dies again. I towed it all the way home to my local dealer on mon 11-24-03 and now they tink a new wire harness is the problem and so they when it gets here we will see. I will order another truck just like this one and move all my goodies to the new one so if any one can help with the buyback I would be real greatful."
"i have 2003 6.0 liter that has been nothing but small problems. it has been in for rough idle 4 or 5 times, finally was fixed. water in fuel light was on at @ 2000 miles, finally fixed at 33,000 with new fuel pump. bad battery cable, needed replaced. rear main was leaking at 20,000 miles they added dye and didn't see it, then at 27000 was leaking again (or still) replaced rear main. multiple times truck would not start. turned key over and just turned over for about 30 seconds twice and finally started. they couldn't find out why. at 29000 would surge at idle and they replaced rear speed sensor, it showed 20 mph when cranking.?? Took truck in at 32000 for oil change, they said i needed new fuel filter, transmission fluid change, air filter and oil change. quoted price was 350, was charged 550. air filter was $100. needless to say i was ****ed. they also replaced fuel pump b/c water in fuel light stayed on. Today at 35814 miles the rear main is leaking again. Ford has given me a 5yr/75000mile bumper to bumper but i want a new truck"
"I HAVE A 04 SUPER DUTY 6L. WHICH HAS GIVEN ME PROBLEMS FROM THE FIRST TANK OF FUEL. THE TRUCK STARTED SHAKING AND MISSING 5 MILES AFTER FILLING UP W/FUEL, THEN THE guageS RAPED RIGHT TO THE END AND THE TRUCK QUIT. AT FIRST I THOUGHT I GOT SOME BAD FUEL, BUT THAT WAS NOT THE PROBLEM, MANAGED TO GET IT TO A DEALER AND THEY CHANGED A SENSOR AND I WAS ON MY WAY, GOT 200 MILES DOWN THE ROAD AND IT DID IT AGAIN. THIS TIME IM IN THE MIDDLE OF NO WHERE @ NIGHT WITH NO SUPPORT SO I UNHOOKED THE batteries FOR 10 MINS AND AWAY I WENT, THE TRUCK WORKED GOOD FOR 2 DAYS, THEN STARTED ACTING UP AGAIN. TOOK TRUCK TO THE DEALER AGAIN, ( 3 TIMES NOW) THEY HAD THE TRUCK FOR 2 DAYS, THEY CHANGED A SENSOR AND MODULAR ON THE TURBO,SAID THE TURBO WAS STICKING, WORKING NOT WORKING, THEY CALLED AND SAID THE TRUCK WAS READY,WENT AND PICKED IT UP AND DROVE 4.6 MILES AND SHE QUIT AGAIN,(NOW IM MAD) TAKE IT BACK AND THEN THEY REPROGRAM THE COMPUTER, NOW THE TRUCK IS AS LOUD AS MY 2000 7.3L WHICH HAD 200000 MILES ON IT WITHOUT A PROBLEM TO SPEAK OF, IT WAS A AWSOME TRUCK. NOW THIS TRUCK SMOKES WHEN IT IS STARTED AND BURNS REALLY RICH ( U CAN SMELL THE DIESEL)PLUS IT IS REALLY HARD ON FUEL 10-12 MILES TO THE GALLON. THEN I TOOK IT BACK AND THEY SAID THE WHOLE TURBO WAS SHOT SO THEY CHANGED IT OUT ALONG WITH A COUPLE MODULES,SO FAR THE TRUCK HAS BEN RUNNING NOT TO BAD(FOR 4 DAYS NOW) OTHER THAN THE NOISE AND HARD ON FUEL, AND DOESNT SEEM TO HAVE THE POWER IT HAD BEFORE THEY ZAPPED THE COMPUTER UNTIL U GET THE RPM UP. THERE IS ALSO A FEW OTHER LITTLE THINGS THATS WRONG TO BUT THEY DONT BOTHER ME RIGHT NOW BECAUSE I JUST NEED THIS TRUCK TO RUN AND GET ME TO WORK ON TIME,ITS BEEN IN THE SHOP 6 TIMES IN 4 WEEKS, IM NOT SURE WHAT TO DO ANYMORE I CAN HARDLY DEPEND ON IT TO GET ME TO AND FROM WORK EVERDAY.SEEMS WHEN IT QUITS OR ACTS UP IF I UNHOOK THE batteries FOR A FEW MINUTES IT WORKS GOOD FOR AWHILE. I SURE HOPE THAT NO ONE HAS HAD THE PROBLEMS THAT I HAVE HAD BECAUSE IT IS EMBARRASSING TO ME AND TO FORD. THEY TELL ME THAT THE NOISE WILL BE THERE ALL THE TIME BECAUSE OF THE NEW PROGRAM WHICH IS NOT GOOD(THAT WAS THERE SELLING POINT)"
" I have a 03 F-450 that was purchsed by my employer last May on my recommendation. It has an early 03 build date and I have unfortunately experienced about every problem that seems to be common to this engine. I have had all the flashes, 3 new injectors and now had two incidents with cranks/no-start. Last time it was in the shop for 2 weeks while they sourced a new PCM after first replacing the FICM and the fuel pump. I had it back and drove it about a hundred miles and it left me stranded again. My employer counts on this truck as we cover a large geographic area and a loaner vehicle is not an option when you need a flat bed truck and pull a large trailer. I love the way this truck performs when it is working properly, but we can't tolerate this unreliability. I would appreciate any guidance on how to navigatethe DSB or buyback process so I can get a replacement."
"Would you get into bed with a whore with herpes, even if she said it wasnt contagious ? If not, then why would you buy a new Ford diesel ?? We have owned over 12 Ford diesel trucks, and while some were not perfect, we only had one 7.3 that blew injectors. The 6.0 litre just blows period. It is an amazing engine if only it ran for more than a few miles at a time. It is an absolute nightmare, and now we arent even getting out warranty covered anymore. It is easily the worst investment our company has made and the truck has already lost several thousand dollars in down time. Every new dealership we take it to claims to have fixed something, but it still wont start. We had to buy a
2004 Dodge because we could not own such an unrelible truck. It is hands down the worst engine ever produced on the market. Dont believe that they have been fixed. Ours had a new engine at about 3000 miles and several injectors changed since. Ford doesnt stand behind there warranty..Its a joke. Dont believe their lies. What do you think they will tell you, that they are still garbage ? Im sure some dont have all the bugs, but a ridiculasouly large majority do. Just go to any dealership and look at them lined up. If anyone knows of the number to try to get a recall, please let us know...we are already used to being put on hold for several hours and not getting any answers."
"I have 2003 6.0 ps. I runs great right now without any of the problems that people have posted in this site other than a small oil leak and a bad icp sensor. I am taking it in for an oil change so I thought I would look the truck over and see if it has any other issues. It now has onther oil leak looks like a rear main seal and also both exhaust manifolds are leaking. Is there a proper fix for the exhaust manifolds or will this happen again and should I let them do the latest reflash {i don't want to loose any power or mileage}. The dealer told me that they will not replace any of the injectors unless they fail I work out in the bush alot and there is no phone or towing service so if an injector goes I am sure that the turbo and the motor will be toast before I get out. any advice would be greatly appreciated."
" Three weeks ago my new 2003 F450 6.0 deisel with 13k miles died in traffic. Since then, Service mechanics, ford engineers, and the hotline hasn't been able to solve the problem. They've tried replacing fuel injectors, filters and even the computer module. I had installed a refridgerated 12 ft box on the unit and have had to rent a truck for the last three weeks which I think ford should pay for. The dealer tells me they are working with ford to resolve the situation but I want answers now! Any advise?"
"I first contacted the Dispute Settlement Board on 8/7/03 after a local Ford tech told me the performance was normal and I would have to live with it. My response to him was a little less than polite. The Ford engineer was out twice in an 8 day period in September. They reflashed twice and replaced a couple of injectors. Once the engineer said Ford couldn't fix it, attitudes changed. Ford charged a mileage allowance but paid full price for all the addons, ie hitch, tool box, aux fuel tank, etc. One admonition, save all receipts and be sure they have your name on them. I bought the aux fuel tank through a friend, the receipt had his name on it and that alone caused a couple of weeks delay. Anyway the new one was delivered to me on 11/7/03, three months to the day after the process was started. I dealt directly with the owner of the local dealership and he went out of his way to help in the process. The new F350 was built the 2nd week of Oct. and has the '04 engine."
"I have a 2003 F250 6.0 PowerStroke. At 2500 miles it blew 2 valves. Dealer said a bolt in the rocker arm assembly sheared, Took the dealer a month to get my truck back in service. I was told this was one of only 3 -4 occurences which did not make me feel any better. Any experience with this problem and/or the length of time to repair these 6.0's?"
"I just recently bought a 2003 6.0 L Excursion. At 700 miles it started shaking and smoking. The Dealer says the rocker arm assembly malfunctioned and they are in the process of removing the valve cover and repair.'
"Driving truck this morning, lost all power, 2nd, EGR valve went bad, last one was put in July 27. Are these a continuing problem. Just makes you totally sick to know that your truck with 7.000 is in the shop again, 18 1/2 days since May not counting this time, also when going around left turn, fuel light come on also will have to have that fixed also. Getting tired of all the problems with it."
There's alot more on thedieselstop if the above isn't enough dukie.
BTW GM changed the fuel filtration on the LLY ........................Huffdaddy...
Also the injectors look real easy to get at, not hidden under the valve covers!! I sure was impressed with the power of the LLY, it's awesome!!!! :D ...........Huffdaddy....
Brady 
Linear Mode
