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Expensive Ford F-250+ Super Duty repairs by problem area

Engine (49%)

Transmission and Drivetrain (14%)

Brakes and Traction Control (13%)

Suspension and Steering (18%)

Electrical and Air Conditioning (5%)

Paint, Rust, Leaks, Rattles, and Trim (0%)

Other (0%)

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Chart based on 85 repairs.

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Ford F-250+ Super Duty repair cost distribution

$2500+ (43%)

$1000 - $2499 (57%)

$500 - $999 (0%)

$100 - $499 (0%)

< $100 (0%)

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Chart based on 68 repair trips. The repair cost chart excludes repairs made under warranty, do-it-yourself repairs, and repair trips that include maintenance.

59000 mi

US $1200

Replaced both batteries under warranty Replaced traction bar under warranty along with alignment. It's a known issue for all HD and Super Duty trucks. It's essentially a shock that goes bad and it exasperates the potential for death wobble.

66000 mi US $500	Resonator rear fitting broken
78185 mi US $2000	Replace front axle hub
89898 mi US $620	Shocks replacement

200000 mi US $1000	Condenser seized up - replaced
220000 mi US $1600	loose steering

59100 mi US $1500	calipers froze, overheated and destroyed disk, melted several parts
62000 mi US $1400	Fuel system cooler. Replaced twice due to fuel rail codes on check engine

80000 mi US $200	Rear backing plates rusted apart. Had to pull axles and replace plates, pads, axle seals
82000 mi US $1800	low pressure turbo leaking oil. Both up pipes broken, leaking at bellows

97340 mi C $3700	New front bearings(warranty),rotors,calipers,pads. Replaced 4 wheel drive actuator. New rear rotors, calipers,pads. Turbo sand blasted and a seal replaced under warranty.
106640 mi C $1100	Seized front caliper. Replaced both calipers, pads and rotors.
111600 mi C $100	EGR replaced under warranty

153000 mi US $1200	Problem: massive hesitation between half to full throttle. Solution (sort of): clean tank, flush lines, change all filters, flush engine lines. Still have very slight hesitation at full throttle.
161000 mi US $1870	Turbo not spooling properly and remaining hesitation. Turbo vanes behaved as though stuck open. Turbo replaced with exact replacement; sounds and operates correctly now. Still have minor hesitation issues but tired of throwing money at it.
168000 mi US $857	Hesitation required hunt and possible discovery of regulator issue. Replaced the fuel regulator and screen. Appears to have addressed hesitation issue. Edit: Nope, hesitation still there. When this truck works, it’s amazing... otherwise, I hate it and have lost all trust in it.
178600 mi US $1200	Full replacement of steering box, high pressure hoses, and power steering pump. Fixing slop in steering and loss of pressure at slow speeds. Reman steering box from autozone partially failed on first use and now waiting on Ford replacement. Currently driving truck with only 50 percent left turn capability due to work schedule.
198500 mi US $1150	Passenger side tie rod Believe it or not, the radiator fan pulley mount on the 2 yr old water pump spun on the shaft and was replaced. One idler pulley replaced, and a new wiring harness for the turbo control module.

73360 mi C $500	Wheel bearings replaced.
86800 mi C $1200	Replaced rear rotors, pads and calipers.
90520 mi C $499	Replace left front caliper and do brake service on all four.
94860 mi C $300	New Batteries installed

141000 mi US $4000	Replaced water pump. Also bulletproofed: 1. Head gaskets are replaced with late generation OEM gaskets. 2. The head bolts are replaced by ARP head studs. 3. The factory oil cooler is replaced with an upgraded unit. 4. The factory EGR cooler is upgraded or removed. 5. The turbo up-pipe is replaced. 6. All gaskets and seals are upgraded. The EGR cooler was leaking, the rest was preventive.
144000 mi US $1000	Replaced turbo.
152000 mi US $200	Driver upper ball joint worn. Replaced all ball joints.
154000 mi US $150	Hole in factory plastic intercooler pipe. Replaced with aftermarket steel unit.
159000 mi US $1300	Replaced turbocharger due to leaking seals.

78000 mi US $120	Failed starter, replaced starter
78700 mi US $400	FICM defective and replaced
82000 mi US $1120	failed tensioner and other pulleys, replaced, replaced water pump during the repair, fuel pump leaking, and repaired
85000 mi US $200	replaced starter

145000 mi US $3700	Install new long block assembly and replace transmission fluid and filters.
145200 mi US $800	Replace steering gear box and all four shock absorbers and left rear caliper and rear brake pads
147000 mi US $220	Cab corner and bottom of drivers door rust repair

92700 mi US $1200	Pulling hard right, extremely hot R/F wheel, diagnosis of clogged brake hose keeping R/F caliper piston from retracting. Replace hose and caliper and pads both sides. 55 miles later brake pedal went to the floor. Master cylinder replaced. Decided to replace rear pads at this time, since fronts were done and M/C replaced, so all brakes now new.
104000 mi US $625	Replaced alternator & battery
117000 mi US $260	Frayed harness intermittently shorting to ground. Harness replaced. Took some time to locate.

122000 mi US $800	Injector leaking diesel into coolant. Replaced all injectors.
122000 mi US $5000	Leaking fuel injectors. Previous shop had tried to fix, failed within 10,000 miles. Had to flush engine 4 times to clean system. Did regular maintenance as well.

135000 mi US $150	EGR Valve clogged and not functioning, replaced the part.
151000 mi US $4500	Fuel injector sticking, replaced all 4 on the 1 side.
150000 mi US $250	Oil cooler was partially clogged, indicated by ECT to EOT temperature difference of greater then 10, was around 20 at times. Bought a Fixur6 backflush valve, installed and back flushed the oil cooler. problem resolved. Have not had to do the back flush again, almost a year later.
158000 mi US $700	EGR Cooler coolant hose was leaking

110000 mi US $100	Replaced the thermostat
115000 mi US $900	Fan clutch stopped working. Had it replaced as well as serpentine belt.
117000 mi US $150	Had to replace the silicone rubber connectors for the intercooler
118000 mi US $5500	while towing truck would release pressure thru overflow cap. needed new head studs, head gaskets, and heads machined. turns out it is a somewhat common problem with these powerstroke 6.0 diesel motors.
132000 mi US $400	Power steering pressure hose was leaking and needed replaced.
135000 mi US $600	needed to replace the left exhaust manifold. problem was caused by a plug that had been placed in the manifold by the previous owner when an EGT sensor was pulled out prior to trading the truck in. That plug blew out after 10 years and required the complete manifold be replaced.

215000 mi US $158	Replaced faulty starter that was replaced 9 months ago New wiring harness for battery & starter
215700 mi US $1100	Complete brake job. Included pads, rotors, calipers, etc.
228000 mi US $2250	Defective injectors (2) and 1 glow plug, coolant system rehabbed
230000 mi US $260	Rebuilt starter had to be replaced, took a bit to figure it out.
232300 mi US $250	Cost for diag. EGR valve had carbon deposits causing it to stick open and excessive fuel called for with backfiring. The problem resolved itself, much to the surprise of the Ford dealer mechanic. Hasn't recurred since.
240000 mi US $360	Replaced worn tie rod ends
241000 mi US $4300	Oil pressure seal failed, egr valve rebuilt, lots of stuff done

154000 mi US $1140	Issues with oil coolers.... put the bullet proof kit on it. FACTORY CALIPER PISTONS ARE CERAMIC.... THEY LOCKED UP AND DAMAGE EVEN THE AXLE SEALS..... HAD TO BE TOWED, RENT ANOTHER TRUCK (THIS IS MY WORK TRUCK) ND PAID TO HAVE ALL FIXED.
234200 mi US $1700	Carrier bearings failed in the rear end.... damage to several components.. Replaced with a "junk yard" assemby (wheel to wheel) with 41,000 on it.
198300 mi US $7322	Head bolts, studs stretched.....

122000 mi US $175	Starter motor failed. Replaced with rebuilt unit.
124000 mi US $2800	High pressure fuel pump (which drives the fuel injectors) failed. Engine would not start/run. High pressure fuel pump, fuel pressure regulator valve, and dummy plugs replaced.
127000 mi US $1000	Oil cooler failed causing a cascading failure of the EGR cooler and head gaskets.

155000 mi US $300	replaced alternator
154400 mi US $2000	Blown head gaskets on 6.0L Ford, this is the second time that for this truck. Replaced head gaskets oil cooler, blue spring upgrade and cleaned sticking turbo veines. Plus a few upgrades, glow plugs, blue spring, updated FICM, revX, oil cooler.
162300 mi US $550	Replaced broken rear leaf springs

221700 mi US $1000	Oil cooler blew out on a 6.0 liter Powerstroke
257000 mi US $1600	Ball joints worn out
269000 mi US $300	Alternator failed. Replaced alternator. Starter not engaging the flex plate properly. Replaced with a starter for a 6.4l diesel
278000 mi US $6500	Replaced 4 of 8 diesel fuel injectors Replaced the FICM and main engine electrical harnesses due to wear and age

144000 mi US $900	Replaced fuel sender. Speed sensor was faulting occasionally....but was still working....codes came up multiple times, we decided to replace now rather than later, since we had it in the shop.
164000 mi US $1600	All 4 Speed Sensors replaced as well as a fan. Sensors were preventing Turbo from working properly by de-rating engine. Mind you, Ford would not help at all with this issue....it took a 23 yr old w/ perseverance to figure it out in 3 weeks

179800 mi US $500	The AC started blowing hot air after driving to the desert. The AC would switch between hot air then cool air but never cold. The AC was refilled and checked for leaks The torque converter went out. It was not locking up at highway speed. Purchased a refurbished converter on Ebay and had the dealership install it for me. My nieghbor is a mechanic there.
187000 mi US $1500	Had the steering gear box replaced. The up pipes were leaking. Had to take out old system and replace with bellowed up pipe to fix leak.
188300 mi US $500	Electronic shift on the fly 4WD not working. Took both front hubs apart and found driver side hub not sealing properly. Shift in the fly works with a vacuum. Instead of spending $500 to replace hub just plugged the hoses. Now must manually lock hubs.

182500 mi US $800	Electrical short in main fuse box, was literally melting any time the key was in the on position. Required replacing fuse panel and trailer system wiring harness.
197700 mi US $1450	Replaced Failing left wheel bearing. Replaced worn left front ball joint. Replaced left tie rod end.
204000 mi US $500	Replace alternator

119040 mi C $404	Replaced vehicle security module. Automatic lights, and door locks, not working and door ajar light stayed on even with doors closed. New security module cured the problem. Less than 1 hour labor.
143220 mi C $1600	Replaced fuel injectors. Bought Redwood premium injectors and had a local diesel shop replace them.

203700 mi US $200	replaced IPR due to failure, maintenance included resealing fuel bowl, replaced high pressure oil lines and oil change
213700 mi US $250	carrier bearing failed. Had drive line shop replace u joints and carrier bearing. rebalance shaft
222000 mi US $200	replaced intercooler boots due to oil saturation
224000 mi US $4800	transmission service revealed debris in pan. Replaced transmission
225000 mi US $2200	rebuilt rear differential due to bearing failure. Added a Detroit True Trac carrier to upgrade the OEM LS
231000 mi US $125	clock spring failed throwing code 32.
233700 mi US $200	aftermarket water pump failed...replaced with OEM part
237000 mi US $200	P1316 code and CEL on. Replaced UVCH and gaskets. Also replaced glo plug relay.
255000 mi US $500	replaced M/C, hydroboost, lines, rotors and pads due to wear and age replaced ICP sensor

Expensive Ford F-250+ Super Duty repairs by problem area

Ford F-250+ Super Duty repair cost distribution

2019 Ford F-250+ Super Duty 4-door

2015 Ford F-250+ Super Duty

2014 Ford F-250+ Super Duty 4-door

2011 Ford F-250+ Super Duty 4-door

2011 Ford F-250+ Super Duty 4-door

2011 Ford F-250+ Super Duty 4-door

2008 Ford F-250+ Super Duty

2008 Ford F-250+ Super Duty 4-door

2008 Ford F-250+ Super Duty 4-door

2007 Ford F-250+ Super Duty 4-door

2006 Ford F-250+ Super Duty

2006 Ford F-250+ Super Duty 4-door

2006 Ford F-250+ Super Duty 4-door

2006 Ford F-250+ Super Duty 4-door

2005 Ford F-250+ Super Duty

2005 Ford F-250+ Super Duty 4-door

2004 Ford F-250+ Super Duty

2004 Ford F-250+ Super Duty 4-door

2003 Ford F-250+ Super Duty 4-door

2003 Ford F-250+ Super Duty 2-door

2002 Ford F-250+ Super Duty

2002 Ford F-250+ Super Duty 4-door

2002 Ford F-250+ Super Duty 4-door

2001 Ford F-250+ Super Duty

2001 Ford F-250+ Super Duty 4-door

2000 Ford F-250+ Super Duty 4-door

1999 Ford F-250+ Super Duty 4-door

Ford F-250+ Super Duty Expensive Problems

116000 mi US $5700	Transmission had worn parts which required replacement.
118200 mi US $1000	Alternator failed and was replaced.
150000 mi US $3000	Replaced tie rods, ball joints, adjusted parking brake.
151100 mi US $1000	Replace water pump after developed leak
158000 mi US $2100	Replaced defective diesel injector

135300 mi US $305	Alternator failed and needed replaced.
137000 mi US $3500	Failed fuel pump and exhaust up pipe.
143000 mi US $108	Failed glow plug controller. Replaced after check engine light came on. No apparent issues when light was on. After replacing, light remains off. Truck was missing heat shield that normally covers module.

132800 mi US $5500	Transmission rebuild
164200 mi US $3400	Replaced all wear items - Bearings, tie rods, sway bar links, drag links, springs
177000 mi US $100	Leaking fuel drain valve

74600 mi US $150	Lower Radiator Hose leaking. Dealer replaced hose.
116000 mi US $3500	EGR Cooler Failure, Oil Cooler Failure, engine coolant leaking into exhaust. Both coolers replaced. Along with degas bottle and some cooling system hoses. Full cooling system flush.