2003 Ford F-250 Engine Problems

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.

NHTSA ID

11658268

Incident

Jul 31, 2010

Mileage

171,000 mi

Truck had no check engine light then caught on fire going down the road and burned to ground within seconds Incident report 46-24-05039 08_30-74 US-30 - PA 74 30 W

NHTSA ID

11618329

Incident

Sep 24, 2024

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 !

NHTSA ID

11450126

Incident

Feb 3, 2018

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.

NHTSA ID

11271727

Incident

Oct 28, 2019

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.

NHTSA ID

11265693

Incident

Sep 25, 2019

Mileage

72,000 mi

FAILED SMOG AND EVERY TIME SENSORS ARE REPLACED FAILURE HAPPENS AGAIN.

NHTSA ID

11092790

Incident

Apr 30, 2018

Mileage

189,168 mi

THE CHECK ENGINE LIGHT CAME ON AND WE PULLED OVER THEN WHEN I PUT THE TRUCK INTO DRIVE TO PULL OUT IT BARELY MOVED. WE WERE ALMOST HIT BC THE TRUCK WOULDN'T MOVE SO I PUT IN IN REVERSE TO GET OUT OF THE ROAD AND IT DID FINE. SO I TRIED TO PULL OUT AGAIN N DRIVE AND AGAIN IT WOULDN'T GO NO MATTER HOW MUCH GAS I GAVE IT. IT SOUNDS LIKE SOMETHING IS DROWNDING OUT OR IT ISN'T GETTING GAS. BUT LIKE I SAID. IT WON'T GO FORWARD IN DRIVE OR 1ST OR 2ND. ONLY IN REVERSE WILL IT MOVE NORMALLY. THIS IS MAJOR!!! I CAN'T HAVE MY KIDS AT RISK BC THERE'S SOMETHING WRONG WITH THE TRUCK. I HAVE ONLY HAD THE TRUCK ABOUT 3 WEEKS SO IT'S VERY FRUSTRATING.

NHTSA ID

11092593

Incident

May 8, 2018

Mileage

300,000 mi

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!!!

NHTSA ID

10958840

Incident

Feb 6, 2017

Mileage

110,375 mi

TL* THE CONTACT OWNS A 2003 FORD F-250. THE CONTACT STATED THAT IN ORDER TO KEEP THE VEHICLE'S ENGINE ON, THE HAZARD LIGHTS AND HEADLIGHTS HAD TO BE ACTIVATED; HOWEVER, THE LIGHTS DID NOT ILLUMINATE. THE VEHICLE WAS NOT DIAGNOSED NOR REPAIRED. THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 200,000.

NHTSA ID

10897881

Incident

Aug 8, 2016

Mileage

200,000 mi

TL* THE CONTACT OWNS A 2003 FORD F-250. THE CONTACT STATED THAT THE VEHICLE MADE AN ABNORMAL NOISE AND STALLED WITHOUT WARNING. THE VEHICLE WAS TOWED TO A DEALER WHO REPLACED THE OIL PUMP. THE CONTACT ALSO INDICATED THAT THERE WERE MULTIPLE FAILURES WITH THE VEHICLE. AT LEAST TWELVE FUEL INJECTORS WERE REPLACED BY THE DEALER AT LEAST TWELVE TIMES; HOWEVER, THE MAIN FAILURE WAS THE TURBO BRACKET BEING UNSTABLE. THE DEALER DIAGNOSED THAT THE FOUR BOLTS WERE RUSTED WITH CORROSION AND THE BOLTS, WHICH WERE NOT IN PLACE AND THE J-TUBE INTERNALLY FRACTURED. THE DEALER REPLACED THE FOUR BOLTS AND THE J-TUBE. THE VEHICLE WAS REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE WAS 100,000.

NHTSA ID

10896379

Incident

Mar 10, 2015

Mileage

100,000 mi

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.

NHTSA ID

10778674

Incident

Sep 21, 2015

Mileage

91,000 mi

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

NHTSA ID

10715070

Incident

May 6, 2015

Mileage

115,000 mi

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

NHTSA ID

10502810

Incident

Jun 28, 2010

Mileage

69,462 mi

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.

NHTSA ID

10424752

Incident

Sep 9, 2011

Mileage

75,000 mi

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

NHTSA ID

10389975

Incident

Mar 12, 2011

Mileage

152,000 mi

I JUST ENTERED A SAFETY COMPLAINT REGARDING BRAKE ROTORS RUSTING (( 10328142 ) ON MY 2003 FORD F250 7.3 L DIESEL. THIS COMPLAINT REGARDS RUSTING OUT RADIATOR HOSE BRACKETS. ON JULY 6 TH 2007 A RADIATOR HOSE CLAMP RUSTED OUT , AND I RAPIDLY LOST COOLING, WHILE ON INTERSTATE 68 IN MD TRAVELING AT 65 MPH TOWING A TRAVEL TRAILER. I MANAGED TO STOP THE VEHICLE AND TRAILER SAFELY BUT HAD TO BE TOWED TO A DEALER FOR REPAIRS. THIS WAS ON A 4 YEAR OLD TRUCK.( JUST RECENTLY IN CONJUNCTION WITH THE ROTOR PROBLEM A WIRING CLAMP RUSTED OUT UNDER THE BODY LEAVING LOOSE DANGLING WIRES. AT THE TIME I THOUGHT IT WAS A SINGLE RUSTING ISSUE. NOW THAT I AM EXPERIENCING MULTIPLE FAILURES I KNOW THE PROBLEMS ARE MORE EXTENSIVE. *TR

NHTSA ID

10328147

Incident

Jul 6, 2004

Mileage

24,289 mi

TL*THE CONTACT OWNS A 2003 FORD F250. WHENEVER THE VEHICLE IS AT A STOP LIGHT, STOP SIGN, OR IDLING, IT SURGES FORWARD. THE CONTACT HAS TAKEN THE VEHICLE TO A DEALER OVER 25 TIMES, BUT THE FAILURE HAS NOT BEEN DIAGNOSED. THE CURRENT MILEAGE WAS 55,000 AND FAILURE MILEAGE WAS 11,000.

NHTSA ID

10223821

Incident

Jun 26, 2003

Mileage

11,000 mi

MY 2003 FORD F250 TRITON V10 BLEW A SPARK PLUG OUT OF THE HEAD WHILE I WAS TRAVELING IN TRAFFIC. *TR

NHTSA ID

10222210

Incident

Mar 20, 2008

Mileage

120,000 mi

WHEN IN A SLOW ACCELERATION THE MOTOR RPM WILL RACE AND YOU HAVE TO QUICKLY APPLY THE BRAKE IN ORDER TO AVOID A MISHAP. THE NEXT THING THAT IS A SAFETY HAZARD IS THE CAB FILLS WITH DIESELS FUMES. MAKING EVERYONE NAUSEAS. ACCELERATION FROM STOP VEHICLE BILLOWS WHITE SMOKE AND IS SLUGGISH. *TR

NHTSA ID

10220409

Incident

Mar 1, 2008

Mileage

35,000 mi

CAM SHAFT POSITION SENSOR ( CPS ) FAILURE, TRUCK ENGINE STOPS RUNNING. FORD DEALERSHIP REPLACED IT AT COST OF $388.*AK

NHTSA ID

10190570

Incident

May 11, 2007

TL*- THE CONTACT STATED THAT ON 11/01/06 HE COULD HEAR THE EXHAUST SYSTEM AND HE COULD SMELL FUMES COMING FROM THE VEHICLE. THE CONTACT STATED THE 2003 FORD F250 WAS TAKEN TO SEVERAL DEALERSHIPS, AND HE WAS INFORMED THAT THE MANIFOLD BOLTS BROKE. THE CONTACT STATED THAT THEY WOULD HAVE TO REPLACE THE MANIFOLD BOLTS, AND THIS WAS ONLY A TEMPORARY REPAIR. HE HAS BEEN INFORMED BY THE DEALERSHIP THAT THIS WAS AN ONGOING PROBLEM. THE CONTACT STATED THAT THE ONLY WAY TO RESOLVE THIS PROBLEM WAS TO TAKE THE HEADS OFF THE ENGINE AND DRILL THE EXHAUST MANIFOLD HOLDS AND REASSEMBLE WITH LARGER BOLTS. THE FAILURE MILEAGE WAS 13500, AND THE CURRENT MILEAGE WAS 15800.*AK UPDATED 03/30/07. *JB

NHTSA ID

10183133

Incident

Nov 1, 2006

Mileage

13,500 mi

[XXX] 5/3/03 RECALL 03B06 6/4/03 AIR CONDITIONER FAILURE 6/17/04 AIR CONDITIONER FAILURE , AC BLEND DOOR BINDING ,PLENUM DEFECTIVE,HAD TO REMOVE DASHBOARD TO REPAIR 6/18/03 4X4 FAILED TO ENGAGE, FAULTY GEM MODULE 6/18/03 OIL LEAKING AT REAR OF MOTOR, REAR MAIN SEAL FAILURE, STILL LEAKING TO DATE 11/6/03 WATER SEPERATOR FAILURE, PERFORM RECALL 03E04, PERFORM RECALL 03L12 1/14/04 REAR HEATER LEAKING , REAR HEATER CORE FAILURE, REPLACE FUEL MANIFOLD,BECAUSE FUEL SEPERATOR LIGHT STILL WARNING 2/27/04 REAR MAIN SEAL LEAKING/ NO REPAIR OFFERED 3/11/04 REAR MAIN LEAKING / NO REPAIR OFFERED 5/17/04 AIR CONDITIONER FAILURE,FAULTY LINE CONECTION/REAR MAIN STILL LEAKING 6/10/04 REAR MAIN STILL LEAKING /NO REPAIR OFFERED 8/5/04 RECALL 04S15 PEFORMED/ TURBO FAILURE, UNRELATED TO RECALL 8/13/04 REAR MAIN STILL LEAKING/ NO REPAIR OFFERED 9/15/04 REAR MAIN STILL LEAKING / NO REPAIR OFFERED/POWER LOSS SINCE TURBO REPLACEMENT *JS INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ID

10111911

Incident

May 2, 2003

Mileage

5,810 mi

WHEN TAKING OFF FROM EITHER A STOP SIGN OR LIGHT VEHICLE FAILED TO ACCELERATE FORWARD PROPERLY. THIS CAUSED THE VEHICLE TO STALL AT AN INOPPORTUNE TIME. ITS WAS AN ONGOING PROBLEM. CONSUMER TOOK VEHICLE TO DEALERSHIP 6 TIMES IN 1 1/2 YEARS, AND WAS INFORMED BY DEALER THAT PROBLEM WAS LOW RPM POWER, WHICH WAS POOR TORQUE, AND AN IMPROPER GEAR RATIO IN TRANSMISSION.*AK THE CONSUMERS FOOT CONTACTS THE ACCELERATOR PEDAL HANGER WHEN ATTEMPTINGTO DEPRESS THE PEDAL TO THE FLOOR. THE ENGINE RUNS ROUGH AT IDLE 750 RPM CAUSING THE VEHICLE TO VIVRATE. AT SPEEDS BETWEEN 750 AND 1000 RPM THE ENGINE WILL NOT MAINTAIN A CONSTANT SPEED. SPEED FLUCTUATES UP AND DOWN RAPIDLY. THE ENGINE PRODUCES VERY LITTLE POWER AT LOW RPM'S BELOW 1500. OTHER PROBLEMS WITH THE VEHICLE ARE AS FOLLOWS: DEFECTIVE FUEL INJECTORS, LEAKING REAR MAIN SEAL, LEAKING BRAKE LINE JUNCTION BLOCK, LEAKING GASKETS ON REAR TRANSMISSION HOUSING, AND BROKEN FASTERNER ON THE METAL LINE. *TC

NHTSA ID

10094069

Incident

Aug 17, 2004

Mileage

289 mi

WHILE DRIVING AT 60 MPH VEHICLE SHUT DOWN. VEHICLE WILL NOT START RIGHT UP AGAIN. ONE HOUR INTO DRIVING THE PROBLEM STARTED. ENGINE MADE A WHISTLING SOUND. OTHER THEN THAT THERE WERE NO WARNINGS. CONSUMER HAS TAKEN THE VEHICLE IN FOR THE SAME PROBLEM A TOTAL OF FOUR TIMES. *AK POWER STEERING AND BRAKES SHUT DOWN AS A RESULT OF LOSS OF ENGINE POWER. *TC

NHTSA ID

10092726

Incident

Jun 1, 2004

VEHICLE WAS RUNNING ROUGH. THERE WAS A PROBLEM WITH THE CRUISE CONTROL. WHEN THE CRUISE WAS SET, IT WOULD KICK OFF WITH THE BRAKE OR COME TO A COMPLETE STOP AND THE CRUISE WOULD RE-ENGAGE. THE RE-ENGAGING WOULD OCCUR INTERMITTENTLY. *SC THE ENGINE LOST POWER. *JB

NHTSA ID

10094374

Incident

Sep 1, 2004