2003 Ford F-250 Engine Problems

I HAVE PAID OVER $6.000 DOLLARS TO MY LOCAL FORD DEALER TO FIX MY TRUCK JUST TO HAVE THEM TELL ME THERE IS NO WAY TO FIX THE PROBLEM, ITS A DESIGN FLAW FROM FORD THAT CAN NOT BE FIXED. I HAVE BEEN BACK AND FORTH WITH FORD MOTOR COMPANY, I HAVE BEEN LIED TO, STRONG ALONG, CALLS NOT RETURNED AND SO ON. THE DESIGN FLAW HAS TO DO WITH THE EGR. AND TODAY ITS SEEMS THE 3RD NEW TURBO STOPPED WORKING AND THE MOTOR HAS STARTED TO HAVE A BAD VIBRATION. THIS HAS BEEN A NIGHTMARE AND EVEN THOUGH FORD KEPT TELLING ME THEY WILL TAKE CARE OF ME, NOTHING HAS HAPPENED. WHEN THE TURBO FAILED AS I WAS TRYING TO GET ONTO THE FREEWAY I HAD NO POWER AND NEARLY WAS REAR ENDED BY AN 18 WHEELER WHO WAS EXTREMELY ANGRY. I HAD TO STAY OFF THE FREEWAY ON OTHER ROADS TILL I COULD GET HOME. THE TRUCK DEVELOPED A BAD VIBRATION AND I WAS NOT SURE I WOULD GET IT HOME. IF I WOULD HAD BEEN TOLD BY FORD THE FIRST TIME I TOOK IT IN OF THE DESIGN FLAW AND THERE IS NO WAY TO FIX IT, I WOULD HAVE NEVER POURED SO MUCH MONEY INTO IT. IT IS A LEMON AND SHOULD HAVE BEEN RECALLED. I HAVE TALKED TO MANY PEOPLE AND RESEARCHED THIS TRUCK. I FOUND OUT FORD NEW OF THIS DESIGN FLAW AND THAT THEIR CUSTOMERS WOULD HAVE THESE PROBLEMS BUT RELEASED THE TRUCK TO US ANYWAY. I NOW CAN'T AFFORD TO PUT ANY MORE MONEY INTO THIS TRUCK, I CAN'T FIX IT, I CAN'T SELL IT, AND FORD WILL NOT DO ANYTHING TO HELP ME. WHEN I FOUND OUT I WAS LIED TO AND CAUGHT THEM AND SAID, I NOW YOU HAVE BEEN LYING TO ME AND I DO NOT TRUST YOU, I WAS LABELED A HOSTEL CUSTOMER. I ASK YOU, WHO LIKES TO BE LIED TO? THIS HAS BEEN GOING ON INTO 2 YEARS NOW. NOW I HAVE NO TRUCK. I AM INTERNING WHERE IT ASKS "WHEN THIS HAPPENED" TODAY'S DATE. PLEASE HELP. THANK YOU.

TL* THE CONTACT OWNS A 2003 FORD F-250. WHILE DRIVING 65 MPH, THE VEHICLE BEGAN TO STALL WITHOUT WARNING. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC WHO DIAGNOSED THAT THE TURBO NEEDED TO BE REPLACED. THE VEHICLE WAS TAKEN TO PENSKE FORD (LOCATED AT 8970 LA MESA BLVD, LA MESA, CA 91942, (619) 464-7777), BUT WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS NOT NOTIFIED. THE FAILURE MILEAGE WAS 72,000.

I have been trying to get the exhaust manifold bolts replaced by several machine shops and did my own checking on the Ford F-250 Web site and everyone tells me the same thing! Ford knows about the problem but is doing nothing to correct! I have finally found a shop that will fix the broken exhaust manifold blots ! But I would like to know what ford truly knows about this problem . To get it fixed they have to replace all the bolts do to the bolts being so rusted ! Now I only have 121, + miles on my2003 and with the bolts broken it starts admitting gas fumes into the cab . I did check your site and could only find but 1 complaint , so if this is an issue with the exhaust manifold bolts braking and all the ford forums are full of complaints where are they being filed at on your site ? And I do believe it is an issue because I have spoken to 5 different shoppes and 1 ford dealer , they all say the same thing SORRY but it is your problem ! ford knows but will not do anything about it ! I am having mine put in the shop for repairs on the week of 7 Feb 2022 , now that I found someone I could afford! I had quotes from I will not do the work because it is a V10 to $1000.00 per bolt please address this ! It won’t help me but maybe it will hold ford accountable for the product !

MY TRUCK SHUTS OFF WHILE DRIVING FOR NO REASON WHATSOEVER. THE LIGHTS COME AND IT THROWS NO CODES AT ALL. I HAVE EXPERIENCED THIS WHILE DRIVING DOWN THE ROAD AT SPEEDS OF 50 OR LESS. BUT IT DOESN'T MATTER IT STILL DIES JUST THE ENGINE. I HAVE NOT SEEN ONE INVESTIGATION BY THE GOVERNMENT AT ALL. AND AS I GO ONLINE MANY PEOPLE ARE SUFFERING THE SAME FATE TO WHERE PEOPLE HAVE GOTTEN INTO ACCIDENTS... I WANT ANSWERS!!! WE NEED ANSWERS AS THIS IS A SERIOUS PROBLEM. THE ENGINE JUST DIES BUT I DON'T LOSE ELECTRICAL POWER, BUT I DO LOSE STEERING AND IT'S VERY HARD TO CONTROL THE TRUCK AT THESE TIMES. FORD DENIES EVERYTHING AND WILL NOT HELP AT ALL WITHOUT MONEY IN HAND!!! THIS IS WRONG... WE NEED GOVERNMENT TO STEP IN AND HELP!!!

5.4 LITER MOTOR BLOWS SPARK PLUGS OUT OF THE ENGINE, BECAUSE SOME MORON AT FORD DESIGNED AN ENGINE WITH 2 OR 3 THREADS PER PLUG PORT ON ALUMINUM HEADS. FORD IS PAYING A CLASS-ACTION LAWSUIT FOR MODEL YEARS 2004 - 2008, BUT MINE IS A 2003. THANKS FOR THE SCREW-JOB, FORD.

THE TRUCK HAD WHAT SOUNDED LIKE VALVE TAP GOING ON WHEN IT WAS STARTED. I THOUGHT NOTHING OF THIS SINCE TRUCK IS A 2003 BUT THIS WAS A CHANGE FROM EARLIER TRIP. I PROCEEDED TO DRIVE THE TRUCK SINCE NO WARNING LIGHTS WERE ON AND POWER SEEMED FINE. GOING 35-40 MPH ABOUT 1 MILE FROM HOME I HEARD WHAT SOUNDED LIKE A SHOTGUN GOING OFF AND THE TRUCK BEGAN TO RUN BADLY AND I LIMPED IT HOME WITH WINDOWS DOWN BECAUSE OF GAS SMELL. THE NEXT DAY I OPENED THE HOOD TO SEE WHAT WAS GOING ON AND I FOUND CYLINDER #2 HAD BLOWN APART THE COIL PACK AND HAD ALSO EJECTED THE SPARK PLUG FROM THE CYLINDER HEAD. FOLLOWING THAT I TOOK REMOVED ALL OTHER COILS AND PLUGS TO FIND THAT 5 OF THE 8 WERE LOOSE AND WORKING THEIR WAY OUT OF THE THREADS. I BELIEVE THAT THE ONLY THING THAT PREVENTED AN ENGINE FIRE WAS THE FACT THAT THE SPARK PLUG HAD SHORTED ITSELF OUT. THIS IS A SERIOUS PROBLEM. I HAVE SINCE FOUND THAT THE PROBLEM SEEMS TO BE ON MANY YEARS AND MODELS AND IS DUE TO FAULTY CYLINDER HEADS THAT WERE MADE OF ALUMINUM THAT WAS TO SOFT. THE SPARK PLUGS HAD BEEN REPLACED ONCE AND I CHECKED THEM AFTER I BOUGHT THE TRUCK USED, I TIGHTENED TO CORRECT SPECS WITH A TORQUE WRENCH.

3RD SPARK PLUG ON PASSENGER SIDE BLEW OUT WITHOUT WARNING AND ALSO DESTROYED THE COIL. MY RESEARCH INDICATES THIS PROBLEM IS WELL KNOWN TO FORD, BUT NO RECALLS THAT I COULD FIND. *TR

TL* THE CONTACT OWNS A 2003 FORD F-250 SD. WHILE DRIVING APPROXIMATELY 60 MPH, THE CONTACT NOTICED SMOKE FROM THE REAR OF THE VEHICLE AND THERE WAS A LOUD POPPING NOISE. THE VEHICLE WAS COMPLETELY SURROUNDED BY SMOKE RESULTING IN A FIRE. THE VEHICLE STALLED. THE FIRE WAS EXTINGUISHED INDEPENDENTLY. THE VEHICLE WAS TOWED TO THE CONTACTS RESIDENCE AND WAS NOT DIAGNOSED OR REPAIRED. THE VEHICLE WAS NOT INCLUDED IN NHTSA CAMPAIGN NUMBER: 07V553000 (ENGINE AND ENGINE COOLING). THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 81,000. UPDATED 7/1/15*CN THE CONSUMER STATED THERE WAS NO FIRE, JUST EXCESSIVE PRESSURE IN THE CRANKCASE CAUSING THE ENGINE TO BLOW OIL OUT THE GLOW PLUG. UPDATED 03/31/16.*JB

TL* THE CONTACT OWNS A 2003 FORD F-250 SUPERDUTY. THE CONTACT WAS DRIVING 40 MPH WHEN THE VEHICLE STALLED AND FAILED TO RESTART. THE VEHICLE WAS TOWED TO THE DEALER BUT WAS NOT REPAIRED. THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURE. THE VEHICLE WAS NOT REPAIRED. THE FAILURE AND CURRENT MILEAGES WERE 108,000.

TL* THE CONTACT OWNS A 2003 FORD F-250. WHILE DRIVING 55 MPH, THE CONTACT HEARD A LOUD THUMP AND BEGAN TO SMELL GASOLINE FUMES ENTERING THE VEHICLE. THE VEHICLE WAS TAKEN TO A PRIVATE MECHANIC WHO DIAGNOSED THE VEHICLE WITH A BLOWN SPARK PLUG. THE DEALER WAS UNAWARE OF THE FAILURE AND ADVISED HIM TO BRING THE VEHICLE IN FOR DIAGNOSTIC TESTING. THE MANUFACTURER WAS AWARE OF THE FAILURE. NO REPAIRS WERE PERFORMED. THE CURRENT AND FAILURE MILEAGES WERE 75,000.

HAVE A 2003 FORD F-250 WITH THE 5.4L TRITON ENGINE I HAVE OWNED THE TRUCK APPROX. 6MONTHS AND IN A MATTER OF 1000 MILES I HAVE BLOWN 2 SPARK PLUGS AND INSERTS OUT, THIS REPAIR HAS COST ME $300 EACH TIME AND $150 IN TOWING FEES,I AM WAITING TO SEE WHEN THE OTHER ONES WILL BLOW, THIS PROBLEM IS WELL KNOWN BY ALL MECHANICS AND MAKE THE REPAIRS OFTEN, IF THIS PROBLEM IS SO WELL KNOWN MAYBE FORD SHOULD ADDRESS THIS ISSUE AND DEMAND A RECALL OF ALL VEHICLES WITH THIS WELL KNOWN ISSUE, THIS PROBLEM ALSO CAUSES OTHER ISSUES, LIKE ENGINE FIRES DUE TO THE FUEL FUMES ESCAPING FROM WHERE THE SPARK PLUG SHOULD BE, WHEN I TRY TO RESEARCH THIS PROBLEM I SEE THAT THERE IS A WEBSITE DEDICATED TO THIS TRUCK AND PROBLEM SO APPARENTLY FORD IS WAITING FOR AN ENGINE BLOWUP TO KILL SOMEONE BEFORE THEY TAKE THIS SERIOUSLY. *TR

TL* THE CONTACT OWNS A 2003 FORD F250 SUPER DUTY. THE CONTACT STATED WHILE DRIVING AT AN UNKNOWN SPEED, THE VEHICLE STALLED WITHOUT WARNING. THE CONTACT WAS ABLE TO RESTART THE VEHICLE AND THE VEHICLE WAS TAKEN TO THE DEALER FOR DIAGNOSIS. THE DEALER ADVISED THAT THE RIGHT REAR SPARK PLUG HAD BLOWN OUT OF THE ENGINE, CAUSING THE VEHICLE TO STALL. THE VEHICLE WAS NOT REPAIRED. THE VIN WAS UNAVAILABLE. THE FAILURE AND CURRENT MILEAGE WAS 77,000.

A HELICOIL BLEW THE SPARK PLUG ON MY F-250 6MONTHS AGO, FORD SERVICED IT, NOW 6 MONTHS LATER ANOTHER HELICOIL BLEW, OR IT MAY BE THE SAME ONE, IS THERE A RECALL ON THESES MOTORS. *TR

I WAS AT A STOP SIGN ON 12/3/2010 AND WHEN I STEPPED ON THE GAS TO GO, I HEARD A EXTREMELY LOUD POPPING NOISE. I PULLED OFF TO THE SIDE OF THE ROAD AND DISCOVERED THAT ONE OF MY SPARK PLUGS AND THE COIL WAS FLOPPING AROUND IN MY ENGINE. I CALL A FRIEND OF MINE WHO IS A MECHANIC AT A FORD DEALERSHIP AND EXPLAINED WHAT HAD HAPPENED. HE KNEW EXACTLY WHAT IT WAS AND WHICH PLUG HAD BLOWN OUT, WITHOUT EVEN LOOKING AT IT. AFTER GETTING MY TRUCK HOME AND TAKING A CLOSER LOOK, IT SEEMS THAT THESE WERE THE ORIGINAL SPARK PLUGS INSTALLED AT THE FACTORY. THIS WAS NOT A CASE OF OVER TORQUING OR NOT TIGHTENING. THIS IS A CASE OF FAULTY DESIGN AND POOR QUALITY BY A COMPANY THAT APPARENTLY DOES NOT CARE IF SOMEONE IS HURT OR KILLED BY THERE POOR DESIGN. WHAT IF THIS HAD CAUSED A ACCIDENT WITH MY KIDS IN THE CAR??? WHAT IF THIS STARTED MY VEHICLE ON FIRE????? AFTER RESEARCHING THIS PROBLEM IT SEEMS IT IS QUITE COMMON ON FORD VEHICLES. WHEN IS ENOUGH ENOUGH???? I AM CURRENTLY UNEMPLOYED AND AM BARELY ABLE TO KEEP UP WITH MY MONTHLY OBLIGATIONS. I HAVE NO IDEA HOW I AM GOING TO PAY FOR THIS REPAIR NOW. PLEASE, IT IS TIME TO HOLD FORD MOTOR COMPANY RESPONSIBLE FOR NOT FIXING A KNOWN PROBLEM AND POTENTIALLY GETTING SOME ONE KILLED.

THE TURBO ON THE LOW END STRUGGLES. EGR IS HAVING PROBLEMS. TRUCK HESITATES WHEN STARTING OFF, IT IS A POTENTIAL PROBLEM FOR WRECKS BECAUSE THE MOTOR HESITATES FROM TAKE OFF. TURNING OUT TO BE A SAFETY HAZARD. *TR

THE TURBO ON THE LOW END STRUGGLES. EGR IS HAVING PROBLEMS. TRUCK HESITATES WHEN STARTING OFF, IT IS A POTENTIAL PROBLEM FOR WRECKS BECAUSE THE MOTOR HESITATES FROM TAKE OFF. TURNING OUT TO BE A SAFETY HAZARD. *TR

I STARTED TO HEAR A TICKING NOISE IN MY TRUCK. SO I T HAD IT LOOKED AT BY MY MECHANIC. HE COULD NOT TELL WHERE THE NOISE WAS COMING FROM. SO ABOUT A WEEK LATER I WAS GETTING READY TO GO TO WORK, I STARTED UP MY TRUCK AND A LOUD POP!!! AND BLACK SMOKE FROM UNDERNEATH MY HOOD. I SHUT THE TRUCK DOWN AND POP THE HOOD AND THAT'S WHEN I SAW THE MANGLED COIL PACK. SO THERE I WAS [XXX] OUT OF A DAY OF WORK CAUSE I HAD TO FIX THIS PROBLEM, WHICH TOOK ME ALL DAY TO FIX. OFF TO PEPBOYS I WENT TO BUY ANOTHER COILPACK AS WELL AS ALL 8 SPARK PLUGS. MIGHT ASWELL RIGHT? SO $120.00 LATER THE PROBLEM WAS FIXED UNTIL NOW!!! HERE WE GO AGAIN..... SAME FREAKIN NOISE AND ITS GETTING LOUDER. SINCE I CAN'T TELL WHICH SPARKPLUG IT IS I REALLY DON'T KNOW HOW TO FIX THIS PROB BEFORE ANOTHER COILPAK BLOWS AGAIN. I REALLY HATE THIS ENGINE. IT HAS ONLY BEEN ^ MONTHS FROM THE FIRST TIME I FIXED THE OR AT LEAST THOUGHT I FIXED THE PROBLEM. I DIDN'T SAVE ANY OF THE OLD PARTS. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6). *TR

The contact owned a 2003 Ford F-250. The contact stated that while her husband was driving home, there was black smoke coming from the exhaust, with the check engine warning light illuminated. The vehicle was driven to the residence and turned off. The contact stated that while attempting to restart the vehicle, the vehicle failed to start. The vehicle was towed to an independent mechanic where the vehicle was diagnosed, and the contact was informed that the engine was faulty and needed to be replaced. The vehicle was not repaired. The manufacturer was notified of the failure. The approximate failure mileage was 171,000.

FORD 2003 F250 SPARK PLUG EJECTED CYLINDER #7 TRITON 5.4L OCCURRED TWICE. FIRST REPAIR (HELI-COIL INSERT) FAILED. *TR

#5 SPARKPLUG SHOT OUT OF THE HEAD WHEN STARTING VEHICLE. *TR