2006 Ford F-350 SD Problems

What owners report

Owners of the 2006 F-350 Super Duty most often describe a violent front-end shake after hitting a bump or expansion joint at highway speed, usually resolved only by slowing well down, and many tie it to worn front-end and steering parts. A second large group reports loss of power or stalling traced to the fuel tank lining coming apart and contaminating the fuel system, plus turbo and EGR trouble on the 6.0L diesel.

1. 1
   Suspension

   Front-end shake / steering wheel shimmy over bumps

   • 52 complaints (41%)
   • median 37,000 mi at 3.4 yrs old (49 state mileage)
   • 3 mention a crash, fire or injury
   • owner-quoted repair $1,400 (median of 5 quotes)
   • filed 2007–2021

   Complaints describe the front end shaking or bouncing hard after the truck crosses a bump, pothole or bridge expansion joint, often at highway speed, and the shake usually continues until the truck is slowed to roughly 30-45 mph. Owners say the steering wheel can be hard to hold during the event and some report near loss of control. Several mention the dealer could not duplicate the problem, blamed tire pressure, or replaced front-end and steering parts with the shake returning later, and some refer to a letter from Ford about the condition. Reported from a few thousand miles up to well over 100,000 miles, most often at highway speed over uneven pavement or bridge joints.

   2 related service bulletins

   What to check: Drive the truck at highway speed over expansion joints and rough pavement and watch for any shake through the wheel. Ask for service records on ball joints, track bar, steering stabilizer and shocks, and whether the steering oscillation bulletin was performed.

   2 excerpts from owner complaints in NHTSA records

   “I have a 2006 f 350 with 28,000 miles on it .when I hit potholes or rough road the truck shakes {shimmies ] violently when speeds at 55 MPH I must slow down to 25/30 MPH on the freeway this is dangerous I went to the dealer they said it was tire pressure in side driverside door says 75 PSI that's what im running .the problem still happens.”

   NHTSA complaint #10246054, filed 2008-10, 18 miles

   “Was traveling on the highway at a rate of speed of 55mph on a 2006 f350 super duty 4x4 when I went over an uneven surface on the highway which caused the front end to shake violently almost causing me to hit a vehicle on my right hand side. Though I had experienced a flat but everything looked fine. Cannot drive this vehicle in this condition. Tire pressure on all wheels is fine.”

   NHTSA complaint #10507287, filed 2013-04, 85,034 miles
2. 2
   Tires

   Tire sidewall cracking and tread separation

   • 12 complaints (9%)
   • median 33,713 mi at 6.3 yrs old (12 state mileage)
   • 1 mention a crash, fire or injury
   • filed 2006–2015

   Owners report sidewall cracks, bubbles and belt or tread separation on tires fitted to the truck, sometimes on all tires including the spare. Several say a separation led to a blowout or vibration at highway speed, and a few mention partial cost assistance from the tire maker. Reported at low to moderate mileage, often a few years after the tires were installed.

   What to check: Inspect all tires, including the spare, for sidewall cracks, bubbles and uneven wear, check the DOT date codes, and confirm pressures against the door label.

   2 excerpts from owner complaints in NHTSA records

   “2 tires with in 7 months got bubbles in the side walls. I noticed the bubbles in the side walls and returned to goodyear with the problem. They told me that if the bubble would pop that the tire would not go flat , but the tire pop while I was there and the tire went flat. These tires are e ratrd and are on heavy duty trucks pulling heavy equipment and with a blowout at highway speeds some one could get killed. !st time date was 8/16/07. The tires were bought new on 7/17/07.tire size not listed on next page lt275/70r18 silent armor. …”

   NHTSA complaint #10221583, filed 2008-03, 49,200 miles

   “2006 f-350 Ford truck since truck was purchased when tires are about 60% used bad wobble in front end when on a curve right or left when hitting a bump in road or a change in pavement height. When this happens truck is hard to control until speed is reduced to approx 45 MPH. A rebalance of the tires help but still wobbles at speeds above 50mph in the above circumstances. …”

   NHTSA complaint #10246678, filed 2008-10, 1,000 miles
3. 3
   Fuel system

   Fuel tank lining fails, clogging fuel system

   • 18 complaints (14%)
   • median 37,150 mi at 5.4 yrs old (16 state mileage)
   • filed 2007–2015

   Owners describe sudden loss of power, stalling or an engine that will not restart, with the dealer diagnosing the inner lining of the fuel tank as delaminated or rusted and debris clogging the filter, lines or injectors. In several complaints the repair involved a new tank plus injectors or the fuel pump, and some owners say the work was not covered under warranty. One owner also notes repeated stalling after the filter was replaced. Mostly reported between roughly 10,000 and 60,000 miles, with some at higher mileage.

   2 related service bulletins

   What to check: Ask whether the fuel tank has been replaced and whether the fuel filters and injectors have been serviced, and look for a record of tank lining debris. A fuel pressure check and inspection of the filter for flakes is a reasonable pre-purchase step.

   2 excerpts from owner complaints in NHTSA records

   “We own a Ford f-350 diesel pickup. It is a 2006, purchased new. It has had repeated power failure in the last two and half years, with other similar problems before that. Most recently we had it towed to our dealership to the tune of $2500.00 repair for fuel injectors and fuel injector modules. The problem, is safety for our lives and possibly others in our path. The vehicle has recurring engine failure causing it to die while driving. This has happened not only at a stop light, but through intersections, and on straight roads. …”

   NHTSA complaint #10396672, filed 2011-04, 92,482 miles

   “- the contact has a 2006 Ford f-350 super duty, that continuously experiences severe loss of power. While driving on the highway, or going up a hill the vehicle stalls without any prior warning. The vehicle does not have enough power to pull the 5th wheel. The contact has taken the vehicle to the dealer and they stated that the injectors broke in half, dumping raw fuel into the hot oil of the motor. They also stated that there isn't any known repair for vehicle's failure. The contact can provide copies of invoice repair. …”

   NHTSA complaint #10179019, filed 2007-01, 50,000 miles
4. 4
   Engine cooling

   Turbo, EGR and power loss on the diesel

   • 14 complaints (11%)
   • median 96,000 mi at 5.1 yrs old (13 state mileage)
   • 1 mention a crash, fire or injury
   • filed 2007–2020

   Complaints describe sluggish performance, blue or black smoke, surging, rough running and sudden loss of power, with dealers pointing to the turbocharger, EGR valve or carbon buildup in the intake. Several owners report the turbo was replaced and the problem returned, and some mention head gasket or glow plug work. One complaint notes an early fuel fill nozzle shutoff. Spread from around 16,000 miles to over 100,000 miles, often while towing or under load.

   7 related service bulletins

   What to check: On a diesel, ask for turbo, EGR and injector service history and check for smoke or hesitation on a cold start and under acceleration. Confirm which engine is fitted and whether the relevant bulletins were applied.

   2 excerpts from owner complaints in NHTSA records

   “I had a 05 Ford super duty 6.0 liter diesel that had 3 new turbo's put on due to skoring. Ford replaced all 3. When turbo's go out you loose power. I have a 06 super duty that has 26828 miles. The warranty just went out 6/16/11. Ford had to put on another turbo because it was skored. Ford did pay $750 and I had to pay $1142. I was going down highway and lost power and had to limp home pulling a 5th wheel camper. I have read where Ford has had a lot of problems with the 6.0 liter diesel engine. …”

   NHTSA complaint #10419833, filed 2011-08, 26,828 miles

   “This year along with other years have a problem with the EGR valve and turbo. I understand that there was a deal where Ford had to repair emergency vehicles with this same problem but not a normal everyday consumer. There are many complaints regarding this engine blowing head gaskets and EGR valve issues which makes the truck suddenly have lose of power when driving along with other issues as smoking and engine lights going on. …”

   NHTSA complaint #10588902, filed 2014-05, 79,000 miles
5. 5
   Steering

   Cracked wheels and steering gear play

   • 22 complaints (17%)
   • median 81,900 mi at 4.4 yrs old (22 state mileage)
   • 2 mention a crash, fire or injury
   • filed 2007–2018

   Some owners describe a cracked rim that led to rapid air loss or a blowout, and others report loose or wandering steering with excessive play that needed the steering gear replaced more than once. Complaints also mention a power steering assist failure and, in one case, steering components found missing after a crash. Wheel cracks reported around 77,000-130,000 miles; steering play noted from about 10,000 miles upward.

   2 related service bulletins

   What to check: Check for cracks around the rim edge and spokes on all wheels and feel for steering play or wander on a test drive. Ask whether the steering gear or ball joints have been replaced.

   2 excerpts from owner complaints in NHTSA records

   “I am the original owner of this 2006 Ford f350 purchased dec. 2005. November 2010 I had a 20 oem Ford wheel crack. Crack was 5 long running parallel with the outside rim edge, 1 in, and between the spokes. Replaced with a used oem wheel. May 2012 I had another wheel crack which resulted in a blowout at 60mph. This crack ran 90 degrees from the rim edge to 1.25 under the bead resulting in air loss. Replaced with a used oem wheel and new oem 20 tire. …”

   NHTSA complaint #10468925, filed 2012-08, 130,000 miles

   “2006 Ford f-350 truck is road wild due to excessive play in steering box. Vehicle has had 3 new steering gears (and many other front end parts) in 34,000 miles. Each gear lasts about 8-10,000 miles. After roughly 10,000 miles, truck wanders requiring excessive steering wheel rotation to correct. Last service appointment Ford field engineer determined after a test drive that it drove like his truck and was normal.”

   NHTSA complaint #10221558, filed 2008-03, 10,000 miles

Buying note. Check the front end carefully on a highway test drive, look for fuel tank and injector service records, and inspect wheels and tires for cracks or sidewall damage. A pre-purchase inspection by a shop familiar with Super Duty trucks is worthwhile given how often the front-end and fuel-system complaints recur.

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.