2008 Ford F-450 SD Problems

What owners report

Complaints about this model year center on the 6.4L diesel's cooling system and fuel system, with owners describing coolant leaks, repeated radiator replacements and fuel-side breakdowns that can bring the truck to a stop. Many of these reports come in at low mileage, often while towing or under load, and owners frequently mention repeat repairs rather than one-time fixes.

1. 1
   Engine cooling

   Coolant leaks and repeated radiator replacement

   • 14 complaints (21%)
   • median 37,063 mi at 3.3 yrs old (13 state mileage)
   • filed 2008–2016

   Owners describe coolant leaking from the radiator, hoses and EGR cooler, sometimes with the temperature gauge jumping from normal to hot within moments and the engine losing power. Several report the radiator being replaced more than once, in some cases repeatedly within months, and dealers or shops replacing the radiator, hoses and EGR cooler according to complaints. Some reports note the loss of heat or air conditioning along with the coolant loss. Reported from a few thousand miles up to around 125,000 miles, often while towing or driving on the highway in warm weather.

   4 related service bulletins

   What to check: Inspect the radiator, hose connections and degas bottle for seepage or staining, and ask whether the cooling system venturi tee update and any radiator replacements were done. Check that the heater and air conditioning work at full temperature.

   2 excerpts from owner complaints in NHTSA records

   “I have 2008 Ford f450 with 60 k miles and radiator start leaking at the bottom and it was building preassure on the top of atifreaze box and heat air stoped working and Ford dealer that I bought from disnt cover the warranty I paid 1400$ to get problem fixed and it second radiator that I changed from my pocket !!!! I think Ford needs to do something with that it should be a recall for all 2008-2014 power stroke diesel engines”

   NHTSA complaint #10821300, filed 2016-01, 61,000 miles

   “First time it was my radiator, I replaced it. Second time it was and injector, I had that fixed. Now it is my turbo and engine. Ford refuses to cover it under wanrrenty, many people have had issues with these models.”

   NHTSA complaint #10467138, filed 2012-07, 30,000 miles
2. 2
   Engine

   Stalling and loss of power while driving

   • 18 complaints (26%)
   • median 37,063 mi at 3.3 yrs old (15 state mileage)
   • filed 2008–2016

   Owners report the truck shutting down or dropping into a reduced-power mode without much warning, sometimes on the highway and while pulling a trailer, which also takes away power assist for steering and brakes. Complaints describe the check engine or throttle warning light coming on, fluctuating RPM, smoke from the exhaust system, and dealers replacing or reprogramming components such as the fuel pump, EGR valve, turbo, manifold bolts and computer. Several owners say the repair did not resolve the problem or that the condition returned. Spread widely, from roughly 15,000 miles to over 120,000 miles, with many reports during highway driving or towing.

   Recall 07V1390007 related service bulletins

   What to check: Ask for service records on the fuel system, EGR and turbo, and whether any calibration updates were applied. A scan for stored trouble codes and a road test under load can show pending issues.

   2 excerpts from owner complaints in NHTSA records

   “I was making a left hand turn afyer stoping at a traffic light and loss power. The engine light came on and the turbo pressure gauge dropped. I took the truck into the dealer and the dealer told me that a manafold bolt had broken which caused a bad exhuast leak. Repair cost was $3500. I drove the truck less than 50 miles over the next two days and the problem happened again with loss of power and engine light on. …”

   NHTSA complaint #10730584, filed 2015-06, 124,000 miles

   “Probably around 30,000 miles my Ford f450 started having the water in fuel light come on constantly. I would attempt to drain and there would be no water. Right around the same mileage that my f250's water in fuel sensor went bad (at 35,000 miles), the computer in my f450 had been re-calibrated at the dealership while in for service. The re-calibration caused the truck to go into limp home mode everytime the water in fuel sensor came on. …”

   NHTSA complaint #10434351, filed 2011-11, 37,000 miles
3. 3
   Fuel system

   Fuel system and injection failures

   Mentioned in 9 of 60 sampled complaints

   Complaints describe fuel pump, injector and entire fuel system replacements, sometimes with the truck jerking, smoking, or refusing to accelerate past a low speed. Some owners report material from a deteriorating fuel tank interior or debris from a failed high-pressure pump reaching the rest of the fuel system, and one describes fuel injector seals allowing diesel into the crankcase so the oil level rose. Dealers reportedly replaced sensors, filters and pumps first, with the full fuel system replacement coming later in some cases. Mostly reported between about 8,000 and 70,000 miles, with a few at higher mileage.

   Recall 07V1390003 related service bulletins

   What to check: Check the oil level and smell the dipstick for diesel, and ask whether injectors, the high-pressure pump or the fuel tank have been replaced. Look for records of fuel system work and any repeated filter or sensor replacements.

   2 excerpts from owner complaints in NHTSA records

   “Right front tire threw its tread while driving on the highway. No warning vibrations or noises prior to the incident. Tire failure caused the truck to veer hard right across three lanes of highway traffic but managed to avoid any collisions. Tire was oem. We have noticed that the front tire sidewalls get too hot to touch after highway trips (the rear ones do not). The failed tire still had 3/4 of unused tread. We verify pressures before each trip (110 PSI frt) and have never taken the truck off-road. …”

   NHTSA complaint #10292775, filed 2009-11, 11,600 miles

   “This truck started having issue at 24,593 miles from the radiator, cooler, and gasket issues, replaced parts. Then 6 months later issue again on radiator and replace again. 4 days later back again for same issues. 1 month later again in shop for coolant leaking. Feb 2010 we replaced fuel pump assembly. July 2010 had to replace fuel system on vehicle and all 8 injectors. Had work done at another shop because 2 Ford dealerships where behind 2 weeks. Vehicle only had 39,849 mileage and Ford would not reimburse me since Ford dealer did not fix. …”

   NHTSA complaint #10401591, filed 2011-05, 24,593 miles
4. 4
   Steering

   Steering loss or binding

   • 8 complaints (12%)
   • median 43,520 mi at 2.1 yrs old (7 state mileage, few)
   • filed 2008–2016

   Owners report the steering wheel becoming very hard to turn or locking altogether, in some cases along with the engine shutting off, and in one report a steering column bolt broke so the wheel no longer worked. Complaints describe dealers replacing the power steering box or diagnosing the column, and several mention the problem recurring after repair. Reported from very low mileage up to around 170,000 miles, at both highway and low speeds.

   What to check: Turn the wheel full lock both ways at idle and listen for whine or binding, check the power steering fluid and look for leaks at the box and pump, and ask about any steering column or pump repairs.

   2 excerpts from owner complaints in NHTSA records

   “The contact owns a 2008 Ford F-450 SD. While driving 68 MPH, the contact drove over a bump in the road and the vehicle shut off and the steering wheel locked. The same failures occurred the previous day. The vehicle was diagnosed by the dealer, but the failures still persists. The current and failure mileages were 43,520.”

   NHTSA complaint #10231366, filed 2008-06, 43,520 miles

   “The contact owns a 2008 Ford f450 sd. The contact stated while driving 55 MPH he felt as if the vehicle was losing power of the steering wheel and brakes. The vehicle was taken to the dealer for diagnosis. The dealer stated that the power steering box needed to be replaced. The vehicle was not repaired. The manufacturer was not contacted. The failure and the current mileage was 55,000. Updated 9/25/12 updated 10/04/12”

   NHTSA complaint #10472668, filed 2012-08, 55,000 miles
5. 5
   Transmission and drivetrain

   Transfer case failure

   • 6 complaints (9%)
   • median 85,600 mi at 5.2 yrs old (5 state mileage, few)
   • 2 mention a crash, fire or injury
   • filed 2010–2024

   Several owners describe the transfer case breaking apart while driving, with a loud noise, fluid loss and in some cases damage to the driveshaft, brake lines, fuel lines or wiring. Complaints say the truck was towed and the transfer case and driveshaft needed replacement, and that the dealer could not explain the cause. Some reports note this happened while towing a trailer at highway speed. Reported from around 50,000 to over 160,000 miles, typically at highway speed and often while towing.

   2 related service bulletins

   What to check: Listen for whine, clunk or vibration from the transfer case on a test drive, check for fluid seepage around the case and driveshaft, and ask whether transfer case fluid changes are documented.

   2 excerpts from owner complaints in NHTSA records

   “Driving down the road at 65 MPH pulling a horse trailer, transfer case blew up, breaking the front drive shaft, which wiped out the brake lines, trailer brake line and the fuel lift pump and lines. Had no power or brakes. Had Ford fix the truck, but they would not take any responsibility for the failure. The reason for the failure was not found.”

   NHTSA complaint #10497616, filed 2013-02, 50,000 miles

   “Driving on interstate when suddenly felt truck vibration. As I pulled off to exit - heard and felt what sounded like an explosion from underneath. When got out to look underneath, noted that half of the transfer case was gone; there was oil spilled all over the ground and gears laying on top of the cross member. Had truck towed to the dealership where purchased. Technician said the drive shaft and transfer case needed replacing. Unable to say why it occurred. Charges over $3,000.00. …”

   NHTSA complaint #10661141, filed 2014-11, 85,600 miles

Buying note. These trucks are often worked hard, so service records matter more than mileage: ask specifically about radiator and cooling system repairs, fuel system and injector work, and transfer case condition. A pre-purchase inspection by a diesel-capable shop, including a code scan and a road test while towing, is worth the cost on this model year.

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.