2003 Ford F-350 SD fuel system problems

Filed Jan 9, 2019 · Fuel system · 200,000 miles · GA

Fuel tank delamination leading to stalling and eventual replacement of the tank at my cost

Filed Dec 12, 2012 · Engine, Fuel system · 107,000 miles · WA

Vehicle was accelerating onto on-ramp to interstate 90 west bound at pines road in spokane valley wa. Vehicle was driven by my wife. At approximately 30 MPH their was a loud bang and noise that sounded like an exhaust leak. Vehicle was driven to the shoulder and shut off. My wife called me and I came to investigate what had happened. I turned the engine over and determined it was not an exhaust leak but that a spark plug had been blown out of the right side of the engine. It was the number 4 spark plug from the front on my v-10 gas engine. I located the bent spark plug at the approximate location of where the incident occurred. Other than being bent the threads on the plug were intact and did not appear to have been cross threaded. I had the plugs replaced at just over 100,000 miles as per the owners manual. I checked with the auto repair shop I used, (aafes auto hobby shop on fairchild afb), and informed them of what had occurred. They informed me that ford had a technical service bulletin on this very subject. This appears to be a manufacturing defect in that replacing spark plugs should not lead to an explosive event strong enough to dent my hood from the inside. I am now expecting to have 9 more little time bombs just waiting to go off under the hood of my truck. I am just thankful that my wife hadn't yet gotten up to the speed limit of 60mph.

Filed Jul 26, 2011 · Fuel system · 89,083 miles · CT

I had several breakdowns with my truck and had to have it towed twice. The first place it was towed to could not find the problem then after several more instances I had it towed to the dealership where I purchased the vehicle and they new the problem right away. The fuel tank delaminated and I waited two months for one because they were in production at a cost of $2000.00 to be repaired. This seems to be a wide spread problem with these trucks and it should be warrantied.

Filed Aug 11, 2010 · Fuel system · 150,000 miles · CA

On the ford f350 7.3 diesel, the clamp beneath the turbo holding the high pressure diesel fuel line in place is a poor design. The clamp appears to be aluminum with a rubber coating. The rubber coating wears away and the fuel line passes metal on metal through the clamp causing wear. In this particular case the pinhole leak in the high pressure fuel line caused by the wear created a mist of fuel to be blown on the hot turbo causing a flammable cloud of diesel. I immediately shut the vehicles ignition off and stood by with an extinguisher. This is going to happen again to somebody and needs to be repaired. Somebody is going to be injured or the vehicles engine compartment will catch fire. The fuel line needs to pass through a clamp of better design.

Filed Jul 7, 2010 · Fuel system · 73,530 miles · CA

Faulty ford fuel tank. Diesel tanks are delaminating, causing fuel line/filter to clog and vehicle not to run properly. 6/16/10 replaced fuel filter, ran for one day. Took truck to henry curtis ford on 6/17/10, they told us about delamination, not their fault. Charged us $909.28 to remove tank, clean and replace micron filter. Hcford says that the new gas tanks from ford are on back order, not available until approx. Sept 2010. On 6/30/10 truck runs improperly again,fuel filter clogged due to delamination, changed fuel filter. On 7/1/10 truck runs bad again, leave truck again with henry curtis ford with an odometer reading of 73812 and a 1/4 tank of gas. They called and said the fuel filter is clogged, they again want to pull the tank and replace the micron filter at a charge of $900 + only eleven days after they just did it. We declined, they charged us $122.00 and returned our truck with an odometer reading of 73896 and an empty tank of gas. When questioned hcford about odometer and gas they said they only drove truck 5 miles. No accountability. 100's of complaints on internet regarding delamination of ford fuel tanks. Please initiate a ford fuel tank recall.

Filed Nov 25, 2009 · Fuel system · 82,217 miles · MD

The fuel system of my 2003 ford truck corroded from the inside, contaminating the fuel which ruined the fuel pump, fuel filters and injectors. Everything needed to be replaced and repaired at the cost of $3000. Ford will not stand behind their product, they are aware of the problem. They claim it is a problem with the fuel itself. The replacement fuel tanks they sell to fix the problem begin corroding again within 3 months. This problem does not occur when plastic fuel tanks are used.

Filed Sep 16, 2009 · Engine, Fuel system · 63,000 miles · IN

We were using our ford f350 diesel (6.0 motor) with 63,000. We were going 70 MPH on the interstate pulling a loaded 5 horse trailer when the truck would not accelerate, 15 seconds later engine cut off. We were in the left lane and had no power to steer off the road and could not come to a fast stop because of the weight of the of horse trailer. We had to coast approximately 100 yards and pull off on the left side because traffic was too heavy and going to fast to let us over to the right side. Truck would not start again. Had to be towed off the interstate and home. Took it to the repair shop and was told the engine locked up and needs to be replaced at a cost of $7500 to $10000. I checked on warranty and because it is a 2003 it is expired. Called ford and was told there was no recalls. It was extremely dangerous situation and can not believe that were is not some type of defect in the engine.

Filed Sep 8, 2009 · Electrical, Fuel system · 100,000 miles · OH

Tl*the contact owns a 2003 ford f-350 sd. While driving approximately 40 MPH on normal road conditions, the engine stalled without warning. The contact was able to restart the vehicle and resumed normal operation; although, the failure recurred intermittently. An authorized technician stated that the failure was contributed to the injection control pump (icp); injection pressure regulator (ipr) and the wiring harness which were replaced on two occasions. The vehicle was also towed to an authorized dealer to have the transmission replaced. The cost to repair the vehicle was 3,400. The following day the alternator failed and the vehicle was towed to an authorized dealer. The contact had concerns of the safety risk involved. The failure mileage was 100,000 and the current mileage was 132,000.

Filed May 27, 2009 · Engine, Fuel system · NM

2003 ford f350 has problems with the fuel injectors, transmission and an oil leak. *nj the consumer stated the vehicle lost power and white smoke emitted from the tailpipe. He also noticed a delay of engagement from drive to reverse and the fuel gauge was stuck. The number 8 injector had failed, the transmission needed a new part and the fuel gauge needed a new sensor. In the fall of 2008, the vehicle developed an oil leak. It was discovered that the icp sensor (injector control pressure) was the problem. In march 2009, while towing a tractor, the truck lost power and again it emitted smoke and there was a harsh jerk. It was determined that the engine failed again. The number 1 and number 3 injector had failed and there was a new oil leak.

Filed Apr 9, 2009 · Fuel system · 125,000 miles · CA

7.3 ltr diesel engine has a metal fuel line strapped to engine block with metal clamp. The metal clamp eventually wears a hole in the metal fuel line and then diesel fuel is sprayed on to back of engine, starter and other electrical components. The metal fuel line and clamp is on the passenger side of the engine and attached to the back of the engine block. I would think there should be some kind of rubber insulation around the fuel line where it is held by the metal clamp. It is just a matter of time before every one f these 7.3 ltr engines will suffer this wear through of the diesel fuel line and spray fuel down the back of the engine and all over the starter and electrical components. It is a fire hazard in every vehicle using the 7.3 ltr engine. Web site forums are full on this exact same problem of wear through of the fuel line by the metal clamp holding it.