1996 Ford F-250 Problems

What owners report

Complaints on this model year cluster around two older-truck themes: a cruise control switch on the brake master cylinder that has been reported to smoke, melt or ignite (including while parked with the key removed), and stalling on 7.3L diesel trucks traced by owners to the camshaft position sensor. Tires, steering and dual-tank fuel plumbing also come up repeatedly, and many reports arrive at high mileage, so condition and service history matter more than the model year alone.

1. 1
   Vehicle speed control

   Cruise control switch smokes, melts or catches fire

   Mentioned in 13 of 60 sampled complaints

   Owners describe smoke, a burning plastic smell or flames coming from the cruise control deactivation switch mounted at the end of the brake master cylinder, sometimes hours after the truck was parked and with the key out of the ignition. In several reports the switch body was found melted and had to be unplugged to stop the smoking, and a few describe engine-compartment or driveway fires that destroyed the truck. Complaints note that dealers checked the VIN and said the truck was outside the speed-control recall, even where the same switch design was involved; some owners paid for the switch or wiring repair themselves. Reported from roughly 30,000 to 200,000 miles, often on trucks parked for a period rather than while driving.

   Recall 06V286000Recall 05V388000

   What to check: Look at the switch on the end of the brake master cylinder for melted or discolored plastic, and ask whether the speed-control recall service was performed on this VIN. If the switch is unplugged or looks scorched, get it looked at before regular use.

   2 excerpts from owner complaints in NHTSA records

   “I had raised my hood to check the oil, and there was smoke from the cruise control shut off switch located at the end of the master cylinder. It continued to smoke and burn until I unplugged it. It was nearly on fire. The body of the switch is melted and burned. When I went to Ford dealer on 4/17/06 for a replacement part, the parts manager thought that this might be part of the recall that is in force for the f-150. The service manager checked, and it does not apply to the F-250. …”

   NHTSA complaint #10155625, filed 2006-04, 200,050 miles

   “I had raised my hood to check the oil, and there was smoke from the cruise control shut off switch located at the end of the master cylinder. It continued to smoke and burn until I unplugged it. It was nearly on fire. The body of the switch is melted and burned. When I went to Ford dealer on 4/17/06 for a replacement part, the parts manager thought that this might be part of the recall that is in force for the f-150. The service manager checked, and it does not apply to the F-250. …”

   NHTSA complaint #10155626, filed 2006-04, 200,050 miles
2. 2
   Tires

   Tire tread separation and blowouts

   • 34 complaints (19%)
   • median 130,373 mi at 13.4 yrs old (4 state mileage, few)
   • 3 mention a crash, fire or injury
   • filed 2000–2015

   Owners describe vibration or a bulge, then tread separating from the casing and the tire blowing out at highway speed, in some cases damaging the wheel well, exhaust or bodywork. Several complaints name specific tire brands and sizes fitted to these trucks, and a few note the tires were not covered by the tire recalls that applied to other sizes. Cracking and chunks coming off the tread were also reported when inspecting tires that had not yet failed. Reported across a wide mileage range, including tires with relatively few miles on them; several failures occurred at highway speeds.

   Recall 96V161000

   What to check: Check the DOT date codes and look for cracking or bulging on all tires, including the spare. Ask how old the tires are and whether the door-jamb label matches the tire size and pressure on the truck.

   2 excerpts from owner complaints in NHTSA records

   “Two out of four kumho tires have failed with a third one on advisement in poor condition. One tire separated in highway traffic at highway velocity. Extensive damage to vehicle, body and fuel system. Verbally and in writing I asked for an investigation into this matter with no action being taken. I have maintenance logs, receipts, pictures, estimates and all email correspondences for your review. On september 10, 2010, upon a visual inspection, the consumer noticed the right rear tire was getting ready to separate. …”

   NHTSA complaint #10481090, filed 2012-10, 126,881 miles

   “I have a Ford F-250 powerstroke year 1996. The tread on the tire separated, causing major damage to the truck. The tire was a trail cutter radial r/t. Lt 265/75/r16.”

   NHTSA complaint #10196412, filed 2007-07, 133,865 miles
3. 3
   Engine cooling

   Diesel engine stalls, traced to cam position sensor

   • 12 complaints (7%)
   • median 125,000 mi at 12.4 yrs old (7 state mileage, few)
   • filed 1998–2009

   Owners of 7.3L diesel trucks describe the engine quitting without warning at speed, at idle when shifting to reverse, or after months of rough running and hunting, then cranking but not restarting. Several say the truck had to be pushed or towed, and some report repeat failures of the camshaft position sensor; a few mention losing power steering assist when the engine died. Complaints note the same sensor issue on later model years was covered by a recall, but owners of this year say their VIN was excluded; repair was usually sensor replacement at the owner's expense. Mostly reported between about 100,000 and 240,000 miles, with some at higher mileage.

   What to check: Ask for service records showing whether the camshaft position sensor has been replaced and how recently, and whether a spare is kept in the truck. A test drive should include steady-speed and idle running to catch hunting or stalling.

   2 excerpts from owner complaints in NHTSA records

   “I have a 1996 Ford f250 7.3 liter diesel truck. It stalls on occasion at low speeds which I feel is a safety issue. I found out that Ford had a recall on 1997 and newer trucks because of the cam position sensor. Everything I could find out about my problem is the same. The cps unit causes this problem. I feel Ford should replace my cps unit as well.”

   NHTSA complaint #10246189, filed 2008-10, 100,000 miles

   “I have a 1996 f250 that I have had to replace the cam sensor for the same reason that the 97-03 have had to replace theirs this is a 7.3 liter powerstroke why am I not getting a recall notice for this year model its the same problem and have had several really close calls with it dying in traffic this has happened several times a day every time I drove it.”

   NHTSA complaint #10223081, filed 2008-04, 106,545 miles
4. 4
   Steering

   Steering looseness, column and pump hardware failures

   • 15 complaints (9%)
   • median 171,640 mi at 15.5 yrs old (4 state mileage, few)
   • filed 1996–2014

   Owners describe a loose or wandering steering wheel, steering that does not return after a turn, and in a few cases the steering wheel separating from the column or gearbox bolts snapping so the box hangs from the frame. Others report a power steering hose or pump bracket failing, with loss of assist and, in one case, the belt coming off. Repairs described include replacing the steering gearbox, column and hoses; one owner attributes the no-return feel to the upper column bearing. Spread from under 100,000 to over 260,000 miles, with several reports on high-mileage trucks.

   What to check: With the front wheels on the ground, have someone rock the wheel while you watch the steering box, column and frame mounts for movement, and check for play or a wheel that will not return to center after a turn.

   2 excerpts from owner complaints in NHTSA records

   “This is not a complaint but to let everyone know what I have found to be part of the problem on the steering not returning after a turn. The steering column bearing in the top of the column is bad. I have had to replace at least 20 of these for this complaint and fixed the problem. The locking of the steering when breaking is a hydroboost problem not a steering problem. Ford need to research this and correct it before there is a death because of it.”

   NHTSA complaint #10668218, filed 2014-12, 300,000 miles

   “1996 Ford, f250, 7.3 liter diesel: high pressure power steering hose failed at connection to the power steering pump. The failure occurred when backing out of a parking space. The cause of the failure is due to failure of an internal plastic component that connects the tubing to the connecting nut/fitting. Replaced with a fabricated hydraulic hose that did not have any internal plastic components.”

   NHTSA complaint #10366654, filed 2010-11, 80,280 miles
5. 5
   Fuel system

   Dual fuel tanks overflow or transfer fuel

   • 12 complaints (7%)
   • median 115,669 mi at 16.8 yrs old (8 state mileage, few)
   • 1 mention a crash, fire or injury
   • filed 2001–2022

   Owners of trucks with front and rear tanks describe fuel moving from one tank into the other, so the receiving tank overfills and fuel spills or sprays out when the cap is removed. Several trace it to a check valve in the fuel pump assembly and report the pump assembly was replaced to correct it, while others note the same symptom on earlier trucks that were recalled for it. A diesel owner also describes a fuel separator spraying fuel onto the hot engine. Reported mostly between about 78,000 and 230,000 miles.

   Recall 96V146000

   What to check: Fill each tank and watch for fuel crossing between them or pressure releasing when a cap is removed. Also check the crossmember and straps that hold the rear tank for corrosion and loose fasteners.

   2 excerpts from owner complaints in NHTSA records

   “Front fuel tank stopped working. Vehicle runs using rear fuel tank. If I take off the front tank fuel cap, gas pours out sometimes sprays ( about 8 ounces or so) . Front fuel tank seems to become pressurized. This can happen every time you drive it ( if you remove the front cap). In my opinion this is a definite safety hazard that needs to be addressed. I did some searches on the internet and this problem is quite common. Big fire hazard.”

   NHTSA complaint #10837715, filed 2016-02, 231,000 miles

   “The air/fuel separator (similar to a throttle body) on my 1996 Ford f250 diesel developed a hole away from any moving part. It sprayed fuel at about a gallon a minute onto the hot engine as my wife pulled into our driveway. It could have caused a fire going down the road with gallons of fuel all over the engine compartment and fuel all down the bottom of my truck and 30 foot trailer. The local Ford dealer said this is very common on my year pickup and they replace them regularly when they leak. I took digital photos and kept the part. …”

   NHTSA complaint #10151053, filed 2006-02, 104,692 miles

Buying note. On a truck this age, service records matter more than the badge: confirm whether the speed-control recall work was done, ask about camshaft sensor history on diesel examples, and check tire age and steering play before anything else.

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.