Ford F-450 SD engine failure problems

Filed Nov 6, 2026 · Engine · NJ

I own a 2020 Ford F-450 equipped with the 7.3L Godzilla gasoline engine, currently with approximately 81,000 miles. The vehicle developed an engine misfire and illuminated check engine light. I initially brought the truck to an independent mechanic, believing the issue could be something minor, such as spark plugs. After inspecting the vehicle, the independent mechanic suspected a lifter failure and advised that the engine needed replacement. I then brought the truck to Chapman Ford for a second opinion. The Ford dealership identified low compression in cylinder 1 and also recommended replacing the engine. The engine has a ticking noise, and both repair facilities provided estimated replacement costs ranging from $15,000 to $17,000. Currently, the truck still starts, runs, and drives, despite the check engine light and diagnosed mechanical issues. I am concerned that continued operation could result in sudden engine failure or loss of power while driving, particularly because this is a commercial work truck used to transport materials and equipment. At approximately 81,000 miles, I believe this type of major engine problem is premature and raises concerns about the reliability and safety of the 7.3L gasoline engine. The estimated cost of replacement also places a substantial financial burden on my business. I recently became aware of the federal safety agency defect petition DP26-011 regarding reported failures involving Ford's 7.3L gasoline engines, including concerns about lifter failures and low oil pressure. I am submitting this complaint to formally document my vehicle's condition and request that the federal safety agency consider this case as part of its ongoing investigation into potential engine defects. I am concerned that other owners of similarly equipped vehicles may experience comparable failures, potentially resulting in unsafe driving conditions.

Filed Aug 18, 2023 · PA · fire

The contact owned a 2022 Ford F-450. The contact stated that while her driver was driving at an undisclosed speed, her driver smelled a burning odor and noticed smoke at the hood of the vehicle. The contact then stated that the driver then stopped and exit the vehicle when the vehicle suddenly inflamed. No injuries were sustained. A fire department was notified however, the vehicle had burned. A fire report was filed. Additionally, the contact stated that on several occasions, she attempted to start the vehicle however, the engine failed to engage. The contact also stated that prior to the failure, while driving at undisclosed speeds the vehicle stalled without warning. The undisclosed dealer was notified of the failure and an appointment was scheduled for the following week. The vehicle was not repaired. The vehicle was towed to a tow lot and deemed a total loss by the insurance company. The manufacturer was notified of the failure and the contact was advised to contact her insurance company. The failure mileage was approximately 17,000.

Filed Jan 9, 2019 · Engine, Fuel system · 15,000 miles · GA

Fuel tank delamination leading to blown engine x2 and fuel pump replacement x2. I use no additives and buy only commercial fuel almost exclusively in northeast georgia.

Filed Oct 4, 2016 · Engine, Steering · 28,900 miles · WY

Entered on 10/04/2016 at 2:45:07 pm edt (gmt-0400) by the federal safety [email protected]: sender name: sender email: subject: ford f-450 cooling system failure and engine problems comments: I purchased this truck new in 2008 and drove it cross country towing my 5th wheel. At 4,544 miles the radiator blew apart. (driving highway/towing) this was replaced under warranty after fighting with ford. At 6,065 miles I had another cooling system leak.(driving local) they had to replace the "small" radiator, the "fuel and turbo" cooler. At 21432 miles the power steering pump went and had to be replaced.(driving/towing/local) shop stated that "fluid was contaminated" (this truck has only been serviced by ford) at 22215 miles I had to have the left rear axle seal, brake pads and lower cac hose for turbo replaced.( driving highway/towing) now at 29,017 miles the radiator tanks have separated from the core and need to be replaced again along with the crank seal and another power steering pump.( combination, highway/local/towing? Not towing) I have checked with ford and their customer service department and they refuse to cover any of this, or any part, under warranty. I have also done research on these trucks having found many other owners having the same cooling system issues along with other issues that ford refused to cover. Please look into this issue, I think they need to have a recall on the cooling systems in their trucks. Thank you for taking the time to read this. I would appreciate a response. Check edmunds ford f-450 sd turbo diesel review, multiple complaints of cooling system failure, engine failure.

Filed Jan 29, 2015 · Engine · MN

2008 ford f450 crew cab. Consumer states car had two major mechanical breakdowns. *ta the consumer stated the turbo and engine blew out five days apart.

Filed Jan 6, 2015 · Engine, Transmission · 134,000 miles · OH

My 2009 ford f-450 truck currently is at my local dealer which is kerry ford in cincinnati with a bad motor and bad rear differential. The motor has one failed lifter and 2 failed rocker arms. The rear end has a bad pinion bearing which sent metal through the differential which destroyed the gears. The motor is a 6.4 liter powerstroke diesel and the rear end is a dana 110. The motor issues are common knowledge to both ford repair facilities as well as ford corporate offices. The rear end is also a known issue both which can be confirmed by any powerstroke certified mechanic. The motor issue was confirmed by 2 seperate shops to which I was suggested by my repair facility and mechanic to contact ford corporate for a "goodwill policy" to cover this issue even though it is currently past the written warranty due to the fact ford has covered numerous engine failures because of this inherent issue. The regional ford rep denied any assistance to this issue when even the dealer has said its common and should be addressed. Upon finding out the decision which took 2 weeks of my truck being in the shop I was advised to contact the corporate customer relations line which I did to try to talk to my regional manager but as per fords policy I cannot get a direct contact to any regional rep or anyone above this person. My dealership service manager states he cant even get a direct number to the rep himself so basicly ford insulates itself from any direct contact for a consumer to resolve any issues. I have numerous documented failures of this vehicle while under warranty when it has been maintained to the very best schedule. This issue is an inherent design flaw of this motor which shares the same valvetrain parts with the previous 6.0 liter powerstroke which is also doomed fleetwide with these same issues which as also highly documented.

Filed Sep 25, 2012 · Engine · 51,193 miles · AR

On september 12, 2012, my truck engine stopped working. The vehicle, (2006 ford f-450 superduty truck) was towed to a dealership, where I asked for a diagnostic test. The vehicle has 51,193 miles on it. Ford reported that the engine had a "catastrophic failure." the mechanic said he had never experienced such a problem and was puzzled. He said the engine literally blew apart sending fragments through the system, damaging other engine components. To repair the engine would cost me $14,000.00 dollars. I called ford's hotline to ask what could be done about the defective engine given the low mileage. I was told by ford they would not help in the repairs because of the time frame associated with the vehicle's warranty. However, the number of miles on the truck would have qualified the truck for warranty work had it been within the time frame. I filed a complaint with ford should a future recall be issued, but was told there would be no further action or assistance with the vehicle. While searching for a mechanic who could fix the truck, I found a number of local mechanics who were very critical of the 6.0 liter diesel ford engine. One particular mechanic told me that he currently had 7 of the 6.0 liter diesel engines he was working on that had similar issues. He mentioned one customer that had the same truck and year model as mine, but the truck only had 22,000 miles on it when its engine failed. Another local fleet mechanic told me that you could call "any diesel mechanic in arkansas" and they would tell you what a terrible engine the 6.0 liter ford diesel engine is. Given the information I discovered concerning the faulty engines, it is my firm belief that if the federal safety agency office conducted an investigation, they would find clear evidence that the ford 6.0 liter diesel engine used in a number of their truck models have numerous defects and serious deficiencies.

Filed Jun 17, 2010 · Acceleration, Engine · 25,000 miles · TX · crash · 1 injury

Have had acceleration issues with this ford f-450 since april of 2010, the first time the driver was able to stop the vehicle without incident but the engine blew up when he put it in neutral to stop the vehicle. It was at the ford dealership for 6 weeks, I retrieved the vehicle, while on the way home the engine failed again, it was towed back to the dealership. 1 week later I retrieved the vehicle again, 2 days after that the accelerator stuck once again while hauling a trailer loaded with a rental trencher. This time the result was a traffic accident that sent one of my employees to the hospital and caused major property damage, the vehicle was towed back to the dealership and has been there ever since. They have replaced the short block, injectors, and other various engine components.

Filed Oct 19, 2009 · Engine, Fuel system · NE

Ltr on behalf of constituent re 2008 ford f450 truck defective engine. *nj the consumer stated from july 12, 2008 to november 28, 2008 she experienced three failed engines. There was an unusual amount of heat in the engine compartment, enough to melt the wiring and cause smoke to come into the cab of the truck. On each occasion, that the engine failed, there was excessive looseness in the steering. On one occasion, the consumers son was driving the truck and all of a sudden, oil began blowing all over the windshield. The fuel pump also failed which was causing the steering and starter to lock up.

Filed Jan 12, 2009 · Engine · 18,900 miles · SC

Engine blew at 18,900 miles.