To make a long and expensive story short the protective coating on the inside of the fuel tank was peeling off and clogging fuel delivery. Ten days later, the exhaust valve dropped and was completely destroyed. There were no warnings that this was going to happen and occurred suddenly without warning. The failure occurs at speeds between 30 and 60 mph. This was very costly and could have caused the vehicle to stall and created a dangerous situation. This is clearly poor and defective craftsmanship and dangerous. Engine restarted and continue to operate normally and contacted and delivered vehicle to the servicing Ford dealership.
The vehicle was taken to the dealer numerous times for the failure. Thank you for moving the post Powerstroke72. Consequence: The fuel line may separate at the connection to the main fuel bundle. I wonder how many injuries or deaths have been related to these failures. Consequence: Should the engine stall, a vehicle crash could occur. I had the truck in for some warranty work just before it reached over 100. Marty The paste you are describing is the carbon from the exhaust coming back into the intake.
The truck now has 109,000 miles and I no longer have a warranty on the injector. Silver particle and rust is getting into the injecters and clogging filters. This did not correct the problem. The consumer stated on a second trip, one of the turbo hoses blew off. Insurance company hired a fire origin and cause analyst and it was determined that fire was caused when fuel leaked from the banjo fitting on the fuel filter onto the hot surface of the engine. Ford knows there is a problem but refuses to do anything. If the truck is just for pleasure, not work ie.
The vehicle was not repaired. My first major complaint with the truck is the awlful smell exhaust that enters that cabin when the truck is running. My issue is - beside the sticker shock, reading forums and on-line discussions on the Ford 6. At highway speed, and with no warning this could spell disaster. This has happened to me three times since August 2010 in interstate traffic. The dealer told me he has replaced 200 or more tanks already.
The contact stated that while driving 40 mph, the vehicle stalled without warning. The coolant flush can wait until you sort out the performance issues if money is tight, but you can find a great write up on how to do it in the tech folder as well. I was driving into town about 17 miles. I began to limp my truck to the nearest exit ramp. The contact stated that while driving at 30 mph, the engine stalled without warning. Sorry for the long post, but this one is keeping me up at night. The failure mileage was approximately 27,900.
Ford needs to be forced into designing a fix for these oil systems and recall them them. The contact took the vehicle to the dealer the following day. Was also told that Ford has a lot of problems with this. The vehicle was towed to an independent mechanic where she was informed the fuel injection control module burned out. With a little knowledge and skill, you can cut that bill in half. Also, if anyone knows of a good Ford mechanic in the Little Rock Arkansas area I would appreciate a contact number.
After pulling off to the side of the road and restarted the truck it ran rough. On another occasion the vehicle was taken to the dealer, where it was diagnosed that the pressure unit for the diesel pump needed to be replaced. No telling when it will come in. The vehicle has 72,000 miles. If one injector fails, the vehicle could have erratic power surges and partial or full loss of power with failed or reduced braking and steering. Advised there is no recall for this issue even though this is a common problem with many of these trucks. The vehicle was repaired but the failure recurred.
The manufacturer was notified of the failure. Not to mention a costly fix and Ford cant even fill the tank orders its been on back order for 6 weeks. I know that many others have experienced this problem in the 2003 to the 2006 powerstroke 6. In the case of two injectors failing at once, the vehicle would be inoperable with failed braking, steering and power loss. Vehicle towed to the dealership for repair. The dealer replaced the fuel tank, fuel filters and several fuel injectors December 2007.
This shouldn't happen on a truck that is only 5 years old. The truck never goes out of state. Although intermittent this occurred numerous times. The contact called the manufacturer who offered no assistance. I'm baffled as to why nothing has been done about this. It was towed to a location where the fuel filters were changed.