• Dec 16, 2005

The 6.0L Power Stroke diesel Ford debuted in 2002 has been riddled with problems since the get-go. In particular, Ford medium- and heavy-duty pickups from model year 2003 and 2004 have been affected by the troublesome engine, and the issue has cost Ford money in the form of abnormally high numbers of warranty repairs, as well as a serious blow to the "Built Ford Tough" image.
Autoweek reports that Ford has been sued 58 times over the engine and in the first nine months of 2005 warranty costs at the company have gone up by $500 million. The 6.0L Power Stroke, which is built by supplier International Truck and Engine Corp., has been partially redesigned, though still remains an extremely complex unit that technicians are struggling to deal with.

Read on for more on for more about Ford's Power Stroke woes…


Ford has issued 77 technical service bulletins for the Power Stroke diesel since 2002, while in comparison GM has issued only eight for its Duramax diesel and Dodge has issued none for its diesel powerplant.

The Power Stroke diesel sold in today?s super-duty pickups has a much better reliability record than those found in 2003 and 2004 models, however Autoweek estimates that Ford has sold more than 384,000 pickups with potentially defective engines.

Has any Autoblog readers had a first hand experience with a faulty Power Stroke diesel from Ford? We?d be interested to know how Ford has handled your case and if you?d buy another Ford pickup in the future.



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  • 43 Comments
      Gabor J Kadar
      • 2 Years Ago
      Well, another 6 litre friggin' nightmare. This is definetly the last Ford I will ever own. The Ford dealerships are "********" and all they can tell you is- BRING IT IN. With all the F_______g!!!! problems I've had with this 6.0litre Powerstroke its a wonder I haven't blown it up !!!! FORD can shove they're product and they're service "UP THEY'RE ASS!!!!" Especially the FORD dealership here in Quesnel, British Columbia- Canada.
      • 9 Years Ago
      #16 - I think Bogner was just trying to answer the question originally asked by John Neff. Beyond that, I think you're wrong about this blog and product reviews. I think that the majority of the discussions seem to turn into product reviews, and it doesn't seem to matter whether the people commenting have ever even seen the product they are reviewing. Many people here have opinions on any given topic, and whether it's an informed opinion or not, they're sure going to let you know what they think, even if it's based on 3rd party anecdotal evidence from 1978.
      • 9 Years Ago
      ford had to replace the 7.3 because it was too noisy for goverment regulations.
      Norman Dawes
      • 3 Years Ago
      What a piece or crap. This 2004 3/4 ton FORD stuffed with the bogus 2003 model year 6.0 has been a burden since almost accumulating 5000 miles. This is now 7 years later and it has been towed at least 4 times and laid up a total of a year. The last towing bill was $600.00+. Getting service in wonderful northern Ontario is also a major pain where it almost doesn't hurt anymore. Since 2007 and while still in warranty my issues fell on deaf ears with local dealers and FOMOCO. One of the hardest things to accept is you can't even buy an OEM service manual or the IDS scanner with software to work on it by yourself. I am a decent wrench but it is like wandering in the forest without a GPS. Canada needs a "LEMON LAW" like the United States to assist the unfortunate individuals that get stuck with known garbage. Anyone else with this common problem is invited to visit my site at www.chrysleroutboards.com and feel free to contact me. Norm
      Dawn
      • 1 Year Ago
      I have a 2005 F250, purchased it used in June of 2013, 39,900 on the miles. Ran great until it just didn't. The FICM was bad. I purchased a used one at a reliable auto salvage. It runs awesome. The problem is starting it for the first time. After that its great. Let it rest over night, won't start. Cranks. I purchased an extended warranty, now I am finding out that it is body only. Yes, I am very frustrated. I am a single mom with 3 daughters. I have a small landscape business, I have not been able to work in a little over three weeks. I am so very frustrated. No, I am not sure that I would buy another ford diesel. May be willing to try a Chevy diesel. Thank you, hope this helps ford pull their heads out! Right now, I have a $30,000., driveway ornament.
      • 9 Years Ago
      It's interesting and the reason I asked what the problems have been is because our Ambulance service in the town where I live uses the diesel, these are both 2004 vehicles and so far we've had no problems, with some pretty heavy use. There was discussion on this at our city council (I'm a councilman) when these were being purchased of "some problems" but noting concrete, so if anyone has had specific problems it would be nice to know. Thanks.
      • 9 Years Ago
      Our volunteer service had 3 identical E350 type 111 ambulances 1997 7.3 never a failure on 911 calls repl with 3 2004 E-350 111 6.0 diesels. recalls, 3each and lack of power on grade from HQ, at times driver had to call for another lance as the engine/trans did not perform at all. software prob??? can and has happened on any one of the 3. At a loss as what to do with the $135.000 units.2 trip/ea dealer, still problem
      • 9 Years Ago
      Looking for Mude Terrain Tires on 18" why did Ford go to a bigger rim with ou making sure they sold tires first please help!
      stinky_fuago_scooby
      • 2 Years Ago
      hi all if you are reading this don't buy it or sell it as fast as you can i got my f350 2004 truck feb. of 2010 got it for 15000.00 and i have had to put another 20000.00 in to it so far and i am still having trouble with it and it is looking like another 5 or more an i cant even sell it at a lost to get read of it and my local ford dealer is telling me all he will give me is 5000.00 because it has the 6.0 in it (i have had to put a motor in it head gaskets head bolts egr cooler a egr valve now i need 4" exhaust pipe and a programmer and i have had to send my ficm to be repaired and a turbo charger) so to any one that is looking at this trucks in less you all kinds of money to blow dont buy it
      • 9 Years Ago
      I have an early (before the fall boost in torque & horsepower) 2001 F250 7.3L Diesel. At 36308 miles, the throttle position sensor was replaced under Ford warranty, and leaky transfer case seals were replaced under my extended warranty. No other problems. I've been using a K & N filter -everything else standard. I guess I'm glad I have the, as the article says, "... relatively unrefined 7.3-liter Diesel" the 6.0 replaced! No chips or changes to exhaust; milage in town - 14.9 mpg (shift @ 1800 - 2000 rpm; light foot on throttle); on highway at high altitude (CO, NM), 18 mpg @ 70 mph; at low altitude (Amarillo to Austin) 16.5 mpg @ 70 mph. Towing 3000lb travel trailer - 12.0 mpg @ 66 mph (2000 rpm).
      raymondgoepher
      • 1 Year Ago
      I have a 2003 dually 6 litre.. Bought NEW , Only use it for towing offshore boat, 53000 miles so far and never a problem.. Run Ams Oil and have upgraded EGR and Exhaust and Cold Air Intake... Guess I,ve been Lucky..
      • 9 Years Ago
      Probably two years ago Motor Magazine addressed some reader questions from mechanics who were having problems with Ford's new "Cornbinder" Power Stroke diesel. If I remember correctly a new extra high pressure injection system was the basis of these problems. Seems to me these problems were also very hard to diagnose. I wish my memories of this article were clearer!
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