FORD TRUCK: SOME TRUCKS EQUIPPED WITH A 6.0L DIESEL ENGINE MAY EXHIBIT A HARD START/LONG CRANK OR NO START CONDITION DUE TO LOW INJECTION CONTROL PRESSURE (ICP).
full bulletin at NHTSA ↗2006 Ford F-350 engine problems
moderate 29 complaints filed with NHTSA · avg repair $3,100 · see engine across all vehicles →
Failure mileage
Complaints
29
Recalls
0
Avg fix
$3,100
When does it fail?
Of the 29 engine complaints filed for the 2006 Ford F-350, here's the actual mileage breakdown — failures cluster heaviest at 100,000-125,000 mi.
0-25k
25-50k
50-75k
75-100k
100-125k
125-150k
150k+
Each bar shows the share of total complaints filed at that mileage range. Peak failure window highlighted. Some owners report problems earlier; some make it well past 150,000 miles symptom-free. Maintenance habits and driving conditions shift the curve as much as mileage alone.
What stands out
Owners have filed 29 engine complaints with NHTSA against this vehicle, but no formal recall covers the issue — the federal record reflects what manufacturers have admitted, not everything owners are reporting.
Among the 18 model years of Ford F-350 in our records for engine problems, this one ranks #3 by owner-complaint volume.
Is there a fix? Manufacturer service bulletins
The manufacturer has issued service bulletins covering engine on this vehicle — documented repair instructions, service campaigns, or warranty extensions sent to dealers. A TSB isn't a recall (it's not a free safety remedy), but it's the manufacturer acknowledging the issue and how to fix it.
MISFIRE AND DTC P0300.
full bulletin at NHTSA ↗MISFIRE LACK OF POWER BUCK JERK EXCESSIVE SMOKE CRANK NO START 6.0L ENGINE DIAGNOSTICS FOR FUEL SYSTEM . SERVICE TIPS.
full bulletin at NHTSA ↗COOLANT DEGAS BOTTLE OVERFLOW.
full bulletin at NHTSA ↗VEHICLES EQUIPPED WITH A 5.4L 3V OR 6.8L 3V ENGINE BUILT ON OR BEFORE 09/08/06 MAY EXHIBIT AN EXHAUST SYSTEM NOISE OFTEN DESCRIBED AS A SNAP/POP/TICK/PING NOISE.
full bulletin at NHTSA ↗Source: NHTSA manufacturer communications. Bring the bulletin number to your dealer or shop.
The failure pattern owners describe
The 2006 F-350 diesel engine is plagued by serial failures in critical systems that persist despite repairs. Turbochargers fail repeatedly—one owner replaced five by 11,750 miles. EGR valves clog and require replacement multiple times, sometimes three times with no permanent fix; when they fail, the engine loses power, overheats, and stalls. Oil pumps fail suddenly at low mileage (8,200 miles), causing complete loss of power while driving, with some trucks experiencing three or more failures through 41,000 miles. Head gaskets blow routinely, forcing full engine replacements in high-mileage cases; one owner needed two rebuilt engines in 50,000 miles on a truck with a replacement engine that also failed. Fuel injectors fail in groups—one owner replaced 16, then 8 more—accompanied by clogged fuel filters and corroding fuel tanks. Owners report engine stalling at highway speeds, exhaust leaks into the cabin, and oil cooler/EGR cooler overheating that disables the computer. Ford issued multiple technical service bulletins acknowledging turbo problems but replaces failed components with identical units rather than fixing root cause. Dealers have stated these failures are common with no recalls available. Most owners receive no warranty coverage beyond a few years despite the chronic nature of these defects.
Same Ford F-350 engine reports on nearby years: 2005 · 2008
Failure modes owners describe
Turbocharger failure and repeated replacements
Turbochargers fail repeatedly at short intervals despite proper maintenance. Multiple owners report the turbo being replaced several times; one owner had five replacements by 11,750 miles. Ford issued multiple TSBs acknowledging turbo problems but replacements use the same design, failing to address root cause.
When: As early as 2,000-mile intervals; by 65,000–112,000 miles in other cases
Symptoms owners cite: Engine runs poorly; Loud roar or noise from engine; White or blue smoke from exhaust; Loss of engine power, especially under load or uphill; Tachometer does not respond properly
Repairs/costs cited: Turbo replacement; one owner paid no cost initially under extended warranty, then faced repeated failures. Independent shops also replaced turbos.
Recalls/TSBs owners mention: Ford issued six or more Technical Service Bulletins (TSBs) acknowledging turbo problems. Ford extended one owner's warranty to 2011 via OASIS Service Contract but refused further assistance after multiple replacements. Other owners received no manufacturer support post-warranty.
EGR system failure (valve and cooler)
EGR valves clog and fail, often requiring replacement multiple times. EGR cooler leaks coolant into the engine or oil system. Carbon buildup from the EGR clogs exhaust filters and turbo filters. One owner had the EGR bypassed with a kit; another had it fail three times after repair. Repairs cost up to $2,500.
When: 75,000–113,000 miles; some as early as 69,000 miles
Symptoms owners cite: Check engine light illuminated; Wrench indicator symbol on dashboard; Loss of engine power; Engine overheating; Antifreeze smell in cabin; Exhaust smoke (white or blue); Engine stalling while accelerating or reversing; Truck won't restart after hot shutdown for ~1 hour
Repairs/costs cited: EGR valve replacement (single or multiple times); EGR cooler replacement often paired with oil cooler replacement. One owner reports EGR bypass kit installed. Costs noted: $2,500 for EGR system repair. One owner had EGR replaced three times with no permanent fix.
Recalls/TSBs owners mention: Dealers advised owners that Ford knew about the problem and should have recalled it. Ford manufacturer denied assistance outside of warranty on most cases.
Oil pump failure and low oil pressure
Oil pump fails, causing abnormally low oil pressure. One owner experienced sudden power loss and stalling at 8,200 miles; the failure recurred at least three times through 41,000 miles. A dealer stated the problem was very common but no recalls were available.
When: As early as 8,200 miles; recurring through 41,000 miles
Symptoms owners cite: Sudden loss of engine power while driving; Engine stalling; Power steering assist failure when stalling; Vehicle losing power at highway speeds (50–60 mph)
Repairs/costs cited: Dealer kept vehicle for 7 days for diagnosis; root cause of repeat failures never determined. Vehicle in and out of shop repeatedly, including one 60-day stint.
Recalls/TSBs owners mention: Dealer stated the failure was very common and that no recalls were available.
Head gasket failure
Head gaskets blow, causing coolant leaks and overheating. One owner reported two complete engine replacements within 50,000 miles due to head gasket and related failures. Replacement engines also experience gasket issues, suggesting ongoing design problems.
When: By 69,000 miles; severe cases by 50,000 miles in rebuilt engines
Symptoms owners cite: White smoke from exhaust; Engine overheating; Antifreeze smell in cabin; Liquid under vehicle; Loss of power
Repairs/costs cited: Head gasket replacement; one owner needed the entire engine replaced twice in 50,000 miles. Replacement engines supplied by Ford also experienced gasket failures.
Recalls/TSBs owners mention: Manufacturer refused assistance outside warranty on several cases. One owner notes Ford no longer manufactures this engine and owners are left without support once warranty expires.
Fuel injector failure and fuel control issues
Fuel injectors fail or malfunction, causing loss of power and poor performance. Low fuel injection pressure is a recurring diagnostic. One owner had 16 fuel injectors replaced, then 8 more replacements needed. Fuel control module and injector contact module also fail.
When: Multiple occurrences reported between 40,000–170,000 miles
Symptoms owners cite: Loss of engine power, sometimes severe (limping at 10 mph); Check engine light on repeatedly; Sluggish takeoff; Poor fuel economy indicator; Intermittent loss of power
Codes mentioned: Low fuel injector pressure codes
Repairs/costs cited: Fuel control module replaced; fuel injectors replaced (multiple sets noted: 16, then 8 more in one case). Fuel filters replaced repeatedly ($60 each reported). Oil pressure line replaced in attempt to cure low pressure codes.
Recalls/TSBs owners mention: Limited manufacturer assistance reported.
Exhaust manifold gasket failure
Exhaust manifold gasket fails, allowing exhaust fumes to leak into the engine bay and cabin. One case involved incorrect installation of manifold and stud during manufacturing, causing premature gasket failure at 3,000 miles.
When: As early as 3,000 miles
Symptoms owners cite: Exhaust fumes in vehicle cabin; Odor from exhaust leak (caused nausea in one owner); Noise from exhaust leak; Exhaust fumes visible in front of vehicle
Repairs/costs cited: Exhaust manifold and studs require replacement; one case noted incorrect factory installation.
Recalls/TSBs owners mention: Manufacturer stated warranty was no longer valid and refused to assist.
Engine stalling and no-start conditions
Engines stall unexpectedly while driving at various speeds or fail to start when ignition is turned on. One owner experienced multiple no-start events requiring several ignition attempts; another heard a loud explosion before stalling.
When: By 49,600–170,000 miles
Symptoms owners cite: Engine stalls while driving (40–70 mph); Engine fails to start on first attempt; Loud explosion or noise before stalling; Recurring stalling pattern after repair
Repairs/costs cited: No root cause identified in several cases. One case had oil pump, fuel injectors, and fuel injection module replaced but stalling recurred.
Oil cooler and EGR cooler integration failure
Oil cooler and EGR cooler work in tandem; failure of one or overheating between the two causes computer shutdown. High temperature between coolers disables the truck, leaving it inoperable. Repair cost noted at $6,793 for one owner.
When: By 84,000 miles
Symptoms owners cite: Loss of power under load or pulling trailer uphill; White smoke from exhaust; Engine instability; Computer shutdown (truck becomes inoperable); Engine overheating; Check temperature light illuminated
Repairs/costs cited: Oil cooler and EGR cooler replacement required. Repair cost: $6,793 noted in one case.
Recalls/TSBs owners mention: No recalls issued; owners report no manufacturer assistance.
Fuel tank delamination and corrosion
Fuel tanks delaminate and corrode internally, causing rust particles and contamination in the fuel system. Multiple dealers reported corroding fuel tanks; one owner had tank replacement needed alongside fuel system overhauls.
When: By 80,000 miles
Symptoms owners cite: Fuel sensor error codes; Check engine light; Rough engine running; Visible fuel tank delamination
Repairs/costs cited: Fuel tank replacement required. One owner had fuel pump, new fuel tank, and multiple fuel filter changes ($60 each).
Recalls/TSBs owners mention: Dealers identified as manufacturing defect but no recall issued.
Transmission and driveline issues (secondary engine-related)
Transmission shift sensor failure and erratic shifting occur in association with engine-related diagnostics. One case involved transmission rebuilding and shift sensor replacement.
When: By 80,000 miles
Symptoms owners cite: Erratic transmission shifting; Check engine light; Vehicle shaking when decelerating; Front-end vibration over rough road surface
Repairs/costs cited: Transmission shift sensor replaced; transmission rebuilt by independent mechanic.
Synthesized from 29 NHTSA owner complaints — unverified consumer allegations, summarized for patterns. The verbatim filings appear below.
What owners are reporting 9 most recent
My 2006 Ford crew cab powerstroke turbo diesel has an engine oil cooler and EGR/EGR cooler problems that keeps the truck from full power up hills and with loads. Extremely dangerous pulling trailer up grade's, it loses power, blows white smoke and becomes unstable. The temp. Between the oil cooler and the EGR cooler shuts down the trucks computer, leaving the truck inoperable. Costs to repair…
Tl* the contact owns a 2006 Ford f-350. While driving approximately 50 MPH, the contact drove over an uneven road surface and the front end of the vehicle began to shake vigorously. The vehicle would also shake abnormally when decelerating. The contact stated that in addition, the check engine warning light was illuminated, the vehicle would erratically shift, and the fuel tank was delaminating.…
Tl* the contact owns a 2006 Ford f-350. The contact stated that when the ignition was turned to the on position, the engine did not start. After several attempts, the engine started. The failure recurred numerous times. The vehicle was not taken to a dealer or diagnosed. The manufacturer was made aware of the failure. The failure mileage was approximately 170,000. Updated 08/02/16*lj updated…
Tl* the contact owns a 2006 Ford f-350. The contact stated that the vehicle failed to start. The contact had the vehicle towed to the dealer for a diagnostic test. The dealer advised the contact that the park block and the injector contact module needed to be replaced. The vehicle was not repaired. The failure mileage was 123,823.
Truck runs rough, check engine light come on, fuel sensor error. There seems to be quite a few similar complaints. Dealers stated fuel tanks are corroding. Why has there not been a recall? This is a manufacturing problem. Ford should deal with it or made to. *kb
Engine dies while driving. Does not do it all the time. Mainly when accelerating and if let off gas and apply brakes.
2006F-350 super duty 5.4engine,,had to be replaced two and a half years ago the Ford dealer at cirroca of York,,told me that the new motor was improved that the new motors valve train was improved,,why wasn't it a recall,, if it would affect emissions and overall performance and reliability
Tl* the contact owns a 2006 Ford f-350. The contact stated that while driving 40 MPH, the vehicle started to emit white smoke. The vehicle taken to the dealer where the technician diagnosed that the turbo booster and fuel injectors was defective and needed to be replaced. The manufacturer was made aware of the failure. The vehicle was repaired. The failure mileage was 112,000 and the current…
Tl*the contact owns a 2006 Ford f350. The contact stated while attempting to reverse, the vehicle lost power and released smoke. The vehicle was towed to dealer who performed a diagnostic that located the failure at the engine exhaust EGR valve. The manufacturer denied assistance with the repair. The EGR valve was replaced. The failure mileage was 113,048 and the current mileage was 114,232.…
Had engine trouble with your 2006 Ford F-350?
File a complaint with NHTSA → It's free, official, and how every report above got here — owner filings are the federal safety record this page is built on.
Common questions
How serious is the engine problem on the 2006 Ford F-350?
It's a documented issue but not catastrophic. 29 complaints have been filed. Repairs average $3,100 and most owners catch it before it causes a breakdown.
At what mileage does the engine typically fail?
Across the 27 complaints that reported odometer mileage, most engine failures cluster between 42,000 and 112,000 miles, with the median around 69,338. A quarter of owners report trouble before 42,000; a quarter make it past 112,000. Maintenance history matters more than the odometer alone — this is the reported failure window, not a guarantee.
What does it cost to fix?
Independent shops typically charge around $3,100 for engine repairs on this vehicle. Dealer pricing tends to run 20-40% higher. The exact figure depends on the specific failure mode, parts availability, and your local labor rates. If you're outside factory warranty, an extended service contract often covers this category.
Are there any recalls related to engine?
No active recalls currently cover engine issues on this vehicle. The complaints filed represent owner-reported failures that haven't risen to the level of a manufacturer-issued recall — but they're still worth knowing about before you buy or budget for repairs.
Related
Complaint and recall data sourced from the National Highway Traffic Safety Administration (NHTSA)
public records database. Verify the raw federal record at
nhtsa.gov/vehicle/2006/Ford/F-350.
Severity ratings are derived from reported crashes, fires, injuries, and fatalities. Repair cost estimates are
independent-shop national averages and may differ in your area. Some links on this page are affiliate links.