1999 Ford F-250 SD Problems

What owners report

Owners of this model year most often report engine-related problems: spark plugs blowing out of the cylinder heads on the gas V8/V10 engines and diesel engines stalling or shutting off while driving. Brake lines rusting through and tires with tread separation are the other frequently described concerns. Many reports come in between roughly 60,000 and 160,000 miles, and many of these trucks are used for towing, which owners often mention as the setting for transmission and brake trouble.

1. 1
   Engine cooling

   Spark plug blows out of cylinder head

   • 61 complaints (25%)
   • median 108,555 mi at 9.4 yrs old (56 state mileage)
   • 3 mention a crash, fire or injury
   • owner-quoted repair $2,000 (median of 17 quotes)
   • filed 2003–2014

   Owners describe a loud bang or pop, sometimes followed by a misfire or loss of power, and on inspection a spark plug and its coil have come out of the cylinder head, often with the threads stripped. Several reports say the escaping fuel vapor or a ruptured fuel rail led to a fire in the engine bay, and others note the head had to be removed or replaced because the threads could not be repaired. According to the complaints, dealers often called it a known condition on these engines and quoted high repair costs, with no assistance offered outside warranty. Reported from roughly 40,000 to 180,000 miles, sometimes recurring on a different cylinder within weeks to months of a repair.

   What to check: Ask whether any spark plugs have blown out or been repaired with thread inserts, and have a mechanic check plug torque and thread condition before buying. A faint fuel or exhaust smell in the engine bay is worth investigating.

   2 excerpts from owner complaints in NHTSA records

   “I purchased a 1999 Ford f250 super duty in october of 1998 and after 130,000 miles the engine started pushing out the spark plugs right out of the engine heads. Ford said at the time that the truck was out of warranty so I purchase another engine from a dismantler and after 12,000.00 miles this engine did the same thing blowing out spark plugs.”

   NHTSA complaint #10373635, filed 2010-12, 130,000 miles

   “My truck has 78000 miles and on 3/22/04 a spark plug blew out of the cylinder damaging the ignition coil. Ford contacted and offered no assistance. Truck has never been tuned based on Ford's 100000 mile tune up recommendation. Dealer is stating I now need a very expensive new cylinder head.”

   NHTSA complaint #10063890, filed 2004-03, 78,000 miles
2. 2
   Electrical system

   Engine stalls or shuts off while driving

   • 34 complaints (14%)
   • median 125,000 mi at 8.0 yrs old (31 state mileage)
   • filed 2001–2014

   Complaints describe the engine cutting out without warning at idle, in traffic, or at highway speed, sometimes restarting after a few minutes and sometimes not. Owners report losing power steering and power brakes when it happens and say the camshaft position sensor was the part replaced. Some owners say the sensor was replaced and the stalling returned, and others report the dealer could not duplicate or identify the fault. Reported from about 45,000 miles up to well over 200,000 miles, with several noting it in cold weather or during deceleration.

   Recall 07V553000

   What to check: Ask whether the camshaft position sensor has been replaced and whether any stalling has been diagnosed since. A test drive that includes a stop-and-go stretch and a highway run can help surface an intermittent cutout.

   2 excerpts from owner complaints in NHTSA records

   “On the 7.3 powerstroke Ford truck I think it is a safety hazord if the camshaft position sensor were to fail approaching an intersection and you wouldnt have power brakes if the engin shuts off and you may not be able to stop fast enough to avoid an accident. I think there should be a recall on the cps because it seems that my life may be endangered every day on the way to work with the common problem.”

   NHTSA complaint #10192760, filed 2007-06, 155,000 miles

   “99 f-250 diesel stalls on freeway. Replaced the recalled cam shaft sensor but still stalls. I was told that the accelerator position sensor could be the problem and many other consumers are having the same problem. The cam shaft sensor was recalled due to stalling and causing possible injury accidents and this should be recalled for the same reason. My family is in danger while driving this truck. Ford knows about this problem and said there is nothing they can do about it. …”

   NHTSA complaint #10275023, filed 2009-06, 230,000 miles
3. 3
   Brakes

   Brake line corrosion and pedal going to the floor

   • 35 complaints (14%)
   • median 96,000 mi at 7.4 yrs old (31 state mileage)
   • 3 mention a crash, fire or injury
   • filed 2000–2013

   Owners describe the brake pedal sinking to the floor with little or no warning, and on inspection a steel brake line is found rusted through or leaking fluid, often along the frame rail or near a wheel. Several reports say the truck was stopped with the parking brake or that it rolled through an intersection before stopping, and a few mention a collision. Complaints also describe warped rotors and pedal pulsation or a grabbing pedal that dealers attributed to normal wear. Mostly reported between about 75,000 and 200,000 miles, with corrosion noted on older trucks in wet or road-salt conditions.

   1 related service bulletin

   What to check: Have the brake lines inspected along the frame and above the rear axle for rust and seepage, and ask whether any lines have been replaced. A service bulletin describes a pedal kickback or grabbing condition, so ask whether that procedure was performed.

   2 excerpts from owner complaints in NHTSA records

   “My wife was driving our vehicle, she was stopping at intersection (4 way) and when she applied the brake pedal to stop at this intersection, the brake pedal went to the floor causing to her to run the stop sign almost causing an accident. I found the defect, the brake line on driver's side was completely rusted through brake line.”

   NHTSA complaint #10199387, filed 2007-08, 106,000 miles

   “While backing out of my driveway, the brake pedal slowly sank to the floor. I put the truck in park and got out of the vehicle. I noticed an expanding pool of hydraulic fluid forming underneath the truck, just forward of the rear, driver's side tire. Upon investigation, the right rear brake line had chaffed a hole on the frame rail resulting in a loss of brakes. Had this brake line failed at any other time, rather just backing out of my driveway, it could have resulted in dire consequences.”

   NHTSA complaint #10523391, filed 2013-07, 93,000 miles
4. 4
   Tires

   Tire tread separation and blowouts

   • 27 complaints (11%)
   • median 89,900 mi at 9.5 yrs old (18 state mileage)
   • 4 mention a crash, fire or injury
   • filed 2000–2015

   Complaints describe tread separating from the tire at highway speed, sometimes with the tread wrapping around the axle or damaging the body and brake lines, and in a few cases the driver lost control. Owners note the tires were often replacements rather than the originals that came with the truck, and some mention a recall notice arriving after the tires had already been replaced or discarded. Several reports say the tire kept its pressure and did not go flat. Reported from about 70,000 to 165,000 miles, typically while driving at 50-70 mph.

   What to check: Check the DOT date codes and condition of all tires, including the spare, and look for uneven wear, bulges or cracking. Ask whether any tire recall notices applied to the tires currently fitted.

   2 excerpts from owner complaints in NHTSA records

   “While driving the vehicle at 70 MPH and no warning the left front tire tread separated and the consumer had to pull over. Firestone steeltex . Size #lt265/75r16 DOT #: vnw81xl149 the tire still had 70lbs of pressure. The front left tire separated without warning. The tread wrapped around the axle area and severed one of the brake line's. The tire had not blown out.”

   NHTSA complaint #10065534, filed 2004-06, 32,046 miles

   “While pulling a trailer at 65 MPH there was a noise in the front passenger side . Consumer lost control of vehicle, and it went in the direction of oncoming traffic. Consumer then turned the steering wheel hard to the right and vehicle went to the right , down an embankment, and crashed into a ditch. This collision occurred because the front passenger side tire tread separated.”

   NHTSA complaint #10097468, filed 2004-10, 164,000 miles

Buying note. These trucks are commonly used for towing, so check the brake lines for corrosion, the condition and age of the tires, and whether the spark plugs and exhaust manifold fasteners are sound before buying. Ask for service records covering these areas, since many of the reports involve repairs paid for by the owner.

Summary written with AI from a sample of 60 NHTSA complaints for this model year (picked at random, with complaints that state a mileage and recent ones taken first), then checked automatically against the source records. Where a problem shows a complaint count, every complaint for this model year was matched with fixed keyword rules (written with AI and tested against the sample), and the mileage, age and repair figures are calculated from those complaints; owners' figures are as stated, not verified. Other counts refer to the sample. The excerpts come from NHTSA's public complaint records and are unverified; capitalisation is normalised, NHTSA staff notes are removed, and shortened text ends with “…”. Something wrong? Request a correction.