2003 Ford F-350 SD Problems

What owners report

Owners of the 2003 F-Super Duty most often describe engine and drivability trouble, particularly on 6.0L diesel trucks: loss of power, surging, rough running, stalling and repeated injector or turbo repairs. Separate clusters of complaints cover spark plug ejection on Triton gas engines, fuel tank corrosion and delamination clogging the fuel system, tire tread separation and sidewall bulging, and front-end vibration or steering wander.

1. 1
   Engine cooling

   Loss of power, surging, rough running and stalling (6.0L

   • 51 complaints (39%)
   • median 40,000 mi at 4.0 yrs old (45 state mileage)
   • 2 mention a crash, fire or injury
   • owner-quoted repair $1,924 (median of 10 quotes)
   • filed 2003–2012

   Owners describe the truck losing power or surging under load, running rough or idling poorly, and in some cases shutting off while driving, including while pulling trailers at highway speed. Complaints frequently mention repeated visits where the dealer replaced EGR valves, turbochargers, injectors or the injection control pressure sensor and wiring, and reprogrammed the computer, with the symptoms returning afterward. Several owners report being told the condition was normal or that no further repair was available. Reported across a wide mileage range, from a few thousand miles on nearly new trucks up to roughly 140,000 miles, often while towing or in cold conditions.

   Recall 07V553000Recall 09V3990005 related service bulletins

   What to check: Ask for service records covering injectors, EGR cooler, turbocharger and any computer reprogramming, and test drive at highway speed with a load if possible, watching for hesitation or smoke.

   2 excerpts from owner complaints in NHTSA records

   “Our company has purchased a 2003 Ford f350 in july 2003 it has 18,000 miles on it and has had 3 turbo's installed is runs rough lacks power and continues to have problems we do not drive the truck often but is run daily. I can't imagine the problems we would have if driven 500 miles a week . My concerns are what will happen when the warranty runs out and I need to pay 1500 for a turbo or new engine or injectors.”

   NHTSA complaint #10214738, filed 2008-01, 2,289 miles

   “I recently experienced severe surging at idle, making the vehicle jump forward, rough acceleration, and complete stalling at various speeds. Took vehicle to dealer for repair. They replaced the icp sensor, and the icp wiring harness (which was burnt and shorting out), and cleaned injectors = $1348.00 this is the same issue that Ford recall no. 05s34 addresses on the same truck, same engine (6.0), but one year newer. Ford did not return old parts to me and I failed to ask for them. …”

   NHTSA complaint #10228590, filed 2008-05, 58,000 miles
2. 2
   Tires

   Tire tread separation and sidewall bulging

   • 14 complaints (11%)
   • median 57,500 mi at 6.8 yrs old (9 state mileage, few)
   • 1 mention a crash, fire or injury
   • filed 2003–2017

   Owners describe vibration at speed, bulges or knots in the tread or sidewall, and tread separation that in some cases damaged fenders and body panels. Complaints involve several tire brands fitted to these trucks, with some owners noting replacements that also failed. Spread across the truck's life, from very low mileage up to over 200,000 miles, often at highway speeds.

   What to check: Check tire date codes, look for bulges or uneven wear on all tires including the spare, and confirm pressures and load rating suit the truck.

   2 excerpts from owner complaints in NHTSA records

   “I have a set of kuhmo tires - road venture at 285/75 -16 which experienced the same defects as the kuhmo road venture tires currently being recalled (which is sidewall delamination and then blowout) but my tires do not fall under the current recall. These tires are less than 2 years old and I no longer feel safe on them - I will replace them in 2 days. I think that all kuhmo tires of this line should be looked at.”

   NHTSA complaint #10276901, filed 2009-07, 127,400 miles

   “Purchased 4 lt continental conitrac 275/70r18 tires/Ford oem wheels from barney's tire and wheel in temecula, ca for my 2003 f350 Ford truck. These tire and wheels were in new condition. June 2, 2011 I had dinsaur tire located in calimesa ca replace the left front tire due to tire separation. Neither I or dinosaur tire were aware of the continental tire recall. March 22, I had the left rear tire separate and again contacted dinosaur tire to schedule a replacement. Again, they were unaware of the recall. …”

   NHTSA complaint #10452913, filed 2012-03, 209,475 miles
3. 3
   Engine cooling

   Spark plug ejection from cylinder head (Triton gas engines)

   • 5 complaints (4%)
   • median 107,000 mi at 7.6 yrs old (5 state mileage, few)
   • filed 2006–2012

   Owners of gas-powered trucks describe a loud bang followed by a persistent ticking, after which the engine misses or runs poorly; inspection shows a spark plug has come out of the cylinder head and the threads in the head are damaged. Complaints state the plug could not simply be re-installed and that repair involved cylinder head work at significant cost. Reported from roughly 11,000 to 165,000 miles, often during highway driving.

   What to check: Ask whether the spark plugs have been replaced and by whom, and have a mechanic check plug torque and listen for ticking from the cylinder heads before buying.

   2 excerpts from owner complaints in NHTSA records

   “I was traveling down rte 37w in toms river nj when a loud boom occurred in my engine followed by a continuous loud ticking sound. I had my vehicle towed (2003 Ford f-350) to the local Ford dealership for investigation. After speaking with lead technicians at Ford, I was informed that this is a very common issue with Ford motors and they are surprised this has not been recalled. My spark plug was ejected out of the cylinder head due to lack of threading within the cylinder head. This will cost approx $4000.00 to repair this. …”

   NHTSA complaint #10155567, filed 2006-04, 93,450 miles

   “Vehicle was accelerating onto on-ramp to interstate 90 west bound at pines road in spokane valley wa. Vehicle was driven by my wife. At approximately 30 MPH their was a loud bang and noise that sounded like an exhaust leak. Vehicle was driven to the shoulder and shut off. My wife called me and I came to investigate what had happened. I turned the engine over and determined it was not an exhaust leak but that a spark plug had been blown out of the right side of the engine. It was the number 4 spark plug from the front on my v-10 gas engine. …”

   NHTSA complaint #10488604, filed 2012-12, 107,000 miles

Buying note. These trucks are old enough that condition and service history matter more than mileage; ask for records of engine, fuel system and front-end work, and budget for a pre-purchase inspection covering the cylinder heads, fuel tank and steering components.

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.