FORD: SOME FORD SUPER DUTY TRUCKS MAY EXHIBIT A LACK OF POWER WITH A DIAGNOSTIC TROUBLE CODE AT FULL OPERATING TEMPERATURE DURING ACCELERATION.
full bulletin at NHTSA ↗2008 Ford F-350 engine problems
severe 67 complaints filed with NHTSA · avg repair $3,100 · see engine across all vehicles →
Failure mileage
Complaints
67
Recalls
0
Avg fix
$3,100
1crash
5fires
2injuries
When does it fail?
Of the 67 engine complaints filed for the 2008 Ford F-350, here's the actual mileage breakdown — failures cluster heaviest at 25,000-50,000 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
Of the 18 model years of Ford F-350 we track for engine problems, this one carries the most owner complaints on file — 67.
Owners have filed 67 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.
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.
FORD: IF THERE IS AN INTERMITTENT LACK OF POWER, SURGE, OR HESITATION WHILE DRIVING THE BRAKES WILL OVERRIDE ACCELERATION.
full bulletin at NHTSA ↗FORD SERVICE CAMPAIGN: SEE DOCUMENT SEARCH BUTTON FOR OWNER LETTER. CATALYST Y PIPE WARRANTY EXTENSION.. IN SOME OF THE AFFECTED VEHICLES, CERTAIN VEHICLE OPERATING CONDITIONS CAN CAUSE THE CATALYST SUBSTRATE TO CRACK OR MELT. THIS CAN CAUSE SYMPTOMS INCLUDING BUT NOT LIMITED TO AUDIBLE NOISE FROM THE CATALYST Y PIPE AND/OR MALFUNCTION INDICATOR LAMP ILLUMINATION. CSC LETTER WAS RECEIVED.
full bulletin at NHTSA ↗FORD: SOME TRUCKS WITH 6.4L ENGINE WILL RUN ROUGH, SMOKES, OR NO START DUE TO GASOLINE OR ALCOHOL IN THE FUEL. GASOLINE/ALCOHOL LACK THE LUBRICITY OF DIESEL FUEL AND WILL CAUSE FUEL SYSTEM FAILURE.
full bulletin at NHTSA ↗FORD: SUPPLY/RETURN LINES INSTALLATION AT HIGH PRESSURE PUMP-REVISED WASHER FOR TRUCKS EQUIPPED WITH 6.4L ENGINES. WHEN INSTALLING SUPPLY OR RETURN LINES AT HIGH PRESSURE PUMP ON DIESEL ENGINES, DO NOT USE THE BONDED STYLE WASHER (W302870), USE ONLY THE HYBRID STYLE WASHER (W303659).
full bulletin at NHTSA ↗Source: NHTSA manufacturer communications. Bring the bulletin number to your dealer or shop.
The failure pattern owners describe
The 2008 F-350's 6.4L diesel engine draws sustained complaints across multiple failure categories. Engine stalls and complete shutdowns occur during normal highway driving, often with check engine lights followed by "STOP SAFELY NOW" messages that leave drivers only 10–20 seconds to pull off the road—a dangerous scenario when towing trailers or on bridges. Owners describe losing power steering immediately upon shutdown. Ford dealerships have identified exhaust gas temperature sensor failures and EGR valve issues as culprits; one owner's dealership technician acknowledged an "ongoing issue" with this engine that Ford knows about.
Fuel contamination emerges as a recurring theme. Owners report diesel fuel mixing with engine oil, causing overfill and catastrophic engine failure. High-pressure fuel pump disintegration sends metal debris through the fuel system, forcing $8,000 fuel system replacements. Corrosion in fuel tanks has damaged fuel injectors and regulators.
Cooling system failures dominate reports. Radiators leak from the driver's-side bottom on multiple vehicles, some owners replacing them three or more times under warranty. Thermostats fail prematurely. Overheating occurs during towing, even with low-speed operation under heavy load, sometimes without warning lights.
Oil leaks plague these engines. The front main seal leaks excessively; high-pressure fuel pump replacements sometimes worsen leaks. Owners also report oil overfill from fuel contamination and premature ring wear in the cylinder bore, causing crankcase pressure that forces oil past seals.
Exhaust system problems include manifold gasket leaks allowing carbon monoxide into the cab, manifold studs rusting off and separating, and flexible joints in exhaust pipes leaking fumes into the vehicle. White smoke from the tailpipe is chronic, sometimes continuous.
Engine fires have occurred during normal driving. One owner experienced flames in the wheel well; another reported white smoke and flames while hauling a log load.
Several owners report the vehicle would not restart for 30 minutes to an hour after stalling, requiring the engine to cool or time out before attempting restart.
Same Ford F-350 engine reports on nearby years: 2005 · 2006 · 2011
Failure modes owners describe
Exhaust gas temperature sensor failure
Sensor malfunction causes immediate engine shutdown with check engine light and 'STOP SAFELY NOW' message, sometimes 20 seconds after warning. Owners lose power steering instantly on active roadways. Multiple owners report this as a known issue Ford dealership technicians acknowledge, with at least one recall issued for 2011-2012 ambulance packages (campaign 13V535000).
When: Occurs during highway driving, reported at various mileages including 44,000 miles
Symptoms owners cite: Check engine light illuminates; STOP SAFELY NOW message appears; Complete engine shutdown within 10-30 seconds; Loss of power steering; Vehicle unable to restart for 30+ minutes
Codes mentioned: Exhaust gas temperature sensor code, CLEAN EXHAUST FILTER code
Repairs/costs cited: Dealerships replace exhaust gas temperature sensor; one owner's sensor was replaced previously, indicating recurring failure
Recalls/TSBs owners mention: Recall 13V535000 issued for 2011-2012 F-350/450/550 ambulance packages with 6.7L diesel, free sensor replacement; 2008 6.4L models reportedly not recalled despite identical symptoms reported by owners
Engine oil overfill from fuel contamination
Diesel fuel mixes with engine oil, causing oil level to rise 2-3 gallons above capacity per oil change. Owners report this occurs after Ford dealership oil changes. Oil overfill leads to catastrophic engine failure, melted pistons, and flooded CAC (charge air cooler) system.
When: Occurs shortly after oil changes performed at Ford dealerships; one failure at ~50,000 miles after scheduled service
Symptoms owners cite: Engine oil level excessively high after oil change; Catastrophic engine failure; Melted cylinder pistons (cylinder 8 reported); Check engine light appears intermittently then clears; Complete engine shutdown
Codes mentioned: Check engine light (intermittent, clears before diagnostic)
Repairs/costs cited: Complete engine replacement required, along with high-pressure fuel pump replacement; estimated repair cost in excess of what owners paid for the truck initially; one owner cited $8,000+ fuel system replacement for related fuel pump failure
Recalls/TSBs owners mention: Ford technician at dealership stated they are aware of the ongoing issue with the 6.4-liter diesel engine causing fuel/oil mixing; owners report Ford has not issued a recall or service bulletin to address root cause
High-pressure fuel pump disintegration
High-pressure fuel pump internally fractures and disintegrates, sending metal debris throughout the fuel system. Causes complete loss of engine power and stalling. Multiple owners report this as a known 'first year bug' for new design; one diesel mechanic stated entire fuel system must be replaced.
When: Reported at various mileages; one instance at relatively low miles; multiple occurrences on same vehicle
Symptoms owners cite: Engine power loss while driving; Complete engine stall, sometimes without warning; Stalling occurs unpredictably when accelerating; White smoke from exhaust prior to failure
Codes mentioned: High-pressure fuel pump failure code
Repairs/costs cited: Entire fuel system replacement required; independent diesel mechanic diagnosed cost at $8,000; dealers unable to warranty due to fuel quality blame
Recalls/TSBs owners mention: Ford refuses warranty; blames diesel fuel quality, though owners purchase from reputable stations and same fuel source used in other trucks without issue
Radiator leaks and failure
Radiators leak from driver-side bottom or develop cracks, often repeatedly on the same vehicle. Multiple owners report replacing radiators 2-4 times on single trucks. Failures occur at low mileage (16,000–60,000 miles). One owner documented 7 trucks out of 20 for-sale vehicles in a region had radiator replacements on their service records.
When: As early as 16,000 miles; repeated failures within 20,000–30,000 mile intervals
Symptoms owners cite: Antifreeze leaking from radiator bottom (driver side); Engine overheating during towing or heavy load at low speed; Loss of coolant without visible ground puddles; Coolant spraying from overflow cap only
Repairs/costs cited: Radiator replacement; Venturi Kit installed as part of 2008 cooling system recall, but does not prevent subsequent failures; some owners out of warranty or past the Ford Customer Satisfaction Program 08B06 window (expired June 30, 2009)
Recalls/TSBs owners mention: Recall cooling system updates (Venturi Kit) issued in 2008; Customer Satisfaction Program 08B06 issued December 2008, expired June 30, 2009; Ford denies warranty coverage on radiators beyond initial failure in many cases
Front main seal and engine oil leaks
Front main seal allows excessive oil leakage. Multiple replacement attempts fail to resolve the issue permanently. Oil leaks also observed after high-pressure fuel pump replacements.
When: Early in vehicle life; one documented at 20,000 miles with nine dealer visits by 53,000 miles
Symptoms owners cite: Large oil spillage under vehicle after oil changes; Persistent oil leaking from front of engine
Repairs/costs cited: Dealer replacement of high-pressure fuel pump attempted; rear main seal failed; nine separate dealer visits without permanent resolution by 53,000 miles
Recalls/TSBs owners mention: Dealers attempt repairs but warranty coverage unclear; no recall issued
Premature ring wear and crankcase overpressure
Cylind rings wear prematurely, building excessive crankcase pressure that forces oil past seals and gaskets. One diesel mechanic linked this to the self-cleaning exhaust system design. Oil spews from dipstick tube and other openings.
When: One reported failure at 165,000 miles; owner states diesel should last 2-3x that mileage
Symptoms owners cite: Oil spewing from dipstick tube; Excessive oil on ground; Crankcase overpressure (inferred from oil forced past seals)
Repairs/costs cited: Ford dealer diagnosed premature ring wear linked to self-cleaning exhaust system design
Exhaust manifold gasket and stud failures
Manifold gaskets fail allowing exhaust fumes and carbon monoxide to enter the vehicle cab through heater vents. Manifold studs rust off and separate from cylinder head. Flexible joints in exhaust up-pipes fail and leak exhaust gases into the cab.
When: As early as ~50,000–53,000 miles
Symptoms owners cite: Strange smell in cab when idling or running heater/AC; Exhaust fumes entering cab through vents; Carbon monoxide odor; Eyes burning, migraine headaches in occupants; Occupants feeling faint/passing out; Hissing sound after shutdown
Repairs/costs cited: Manifold gasket replacement; one owner required nine dealership visits over multiple years before repair (June 2012); manifold studs replaced when found rusted off
Recalls/TSBs owners mention: One owner reported health damage (two heart attacks from carbon monoxide exposure) and requested compensation; dealer eventually replaced manifold gasket after extended complaints
EGR valve failure
EGR valve failure triggers 'STOP SAFELY NOW' message and engine shutdown. Occurs in conjunction with exhaust system cleaning cycles.
When: Reported at ~45 MPH during normal driving; truck had 60,000-mile service and latest Ford recall reprogramming <100 miles before failure
Symptoms owners cite: 'EXHAUST DRIVE COMPLETE' message; 'STOP SAFELY NOW' message; Complete engine power down; Rapid deceleration despite throttle input; Engine will not crank after shutdown for 30–45 minutes
Repairs/costs cited: EGR valve replaced at dealer during scheduled maintenance; failure occurred despite recent recall reprogramming
Recalls/TSBs owners mention: Tech bulletin issued but not covered under engine warranty; owner paid out-of-pocket
Excessive white smoke from exhaust
White smoke continuously or intermittently emits from tailpipe, sometimes reported as a plume that completely obscures rear visibility and blinds following vehicles. Occurs shortly after engine reaches operating temperature. Often accompanied by fuel economy loss and rough idle.
When: Chronic throughout ownership; reported at 4,000 miles, 33,000–73,000 miles, and continuously at 36,000 km (22,400 miles)
Symptoms owners cite: Constant white smoke plume from exhaust at operating temperature; Smoke obstructs rear and following vehicle visibility; Fuel economy loss; Rough idle; Hesitation on acceleration; Excessive pressure applied to accelerator without power assistance; Engine dying during low-speed high-load operation
Codes mentioned: Check engine light (sometimes, but not always)
Repairs/costs cited: Dealers unable to diagnose; computerized system reprogrammed and motor replaced at 53,000 miles on one truck, but failure recurred on 12 subsequent visits; no permanent resolution achieved
Recalls/TSBs owners mention: Dealers unable to find cause; smoke issue documented as 'undetermined' in service paperwork; one owner claims dealer denied warranty because oil change receipts were disputed (paid cash)
Turbocharger compressor shaft fracture
Turbocharger compressor shaft completely fractures, causing significant power loss. Fractured shafts are brittle and prone to sudden failure during operation.
When: At approximately 94,442 miles
Symptoms owners cite: Significant engine power decrease while driving at 60 MPH; Vehicle continues operation at poor turbo performance
Repairs/costs cited: Turbocharger replacement required; both thermostats also found broken at same time
Engine fire
Engine fire occurs during normal operation. In one case, flames appear in the front right wheel well behind the tire; fire quickly spreads to engine compartment.
When: Occurred shortly after parking vehicle; another incident while hauling logs on highway
Symptoms owners cite: Flames visible in wheel well or under hood; Fire spreads rapidly to engine compartment; Heavy smoke from under hood
Repairs/costs cited: Fire department required to extinguish; one truck completely burned and lost
Engine stall during regeneration mode
Engine enters regeneration (exhaust filter cleaning) mode, then unexpectedly shuts down completely during or after the cycle. Engine temperature rises rapidly and may cause internal melting.
When: Reported at 50,000 miles during regeneration; regeneration cycles occur frequently (10 times per day reported by one owner)
Symptoms owners cite: Service warning indicating regeneration mode; Loss of power during regeneration; White smoke from under hood; Engine completely melted (one case); 'CLEANING EXHAUST FILTER' message followed by 'STOP SAFELY NOW' and immediate shutdown
Codes mentioned: Exhaust sensor code
Repairs/costs cited: Engine replacement required in one case; entire engine melted; another truck still at dealer after months with no resolution
Rocker arm wear and failure
Rocker arms wear prematurely and make loud noise from engine hood. If not replaced, they can puncture the motor and cause complete engine failure.
When: Very early in vehicle life (111 miles reported)
Symptoms owners cite: Loud noise coming from hood area
Repairs/costs cited: Rocker arms replaced
Radiator hose failure and secondary radiator damage
Upper radiator hose blows while vehicle is at idle, causing coolant loss. The loss triggers hot/cold cycles in the remaining coolant, which causes radiator cracks. Dealer will not cover radiator failure because hose failure is blamed on owner not retaining hose for Ford review.
When: Vehicle at idle; secondary radiator failure follows within months
Symptoms owners cite: Upper radiator hose rupture at idle; Excessive coolant loss; Radiator develops crack from thermal cycling
Repairs/costs cited: Hose replacement; radiator replacement when crack develops; owner paid out-of-pocket for radiator because Ford blamed lack of hose retention
Recalls/TSBs owners mention: Ford denied radiator warranty coverage claiming owner negligence in not retaining blown hose for inspection
Thermostat failure
Thermostats fail, contributing to overheating and engine temperature control issues. Multiple thermostats may fail simultaneously.
When: Reported at 40,000+ miles; one case at 94,442 miles alongside turbo failure
Symptoms owners cite: Engine overheating; Radiator coolant leaks or loss
Repairs/costs cited: Thermostat replacement; dealers sometimes blame owner maintenance or thermostats when radiator failure is actual cause
Air intake filter clogging in snow
Air filter becomes clogged with snow and ice during winter driving, causing engine to stall without warning.
When: In snowy conditions; one reported incident December 30, 2010 after 20-mile drive
Symptoms owners cite: Air filter accumulates 1/2-inch of snow inside and around filter; Engine stalls unexpectedly
Repairs/costs cited: Dealers state no fix available
Recalls/TSBs owners mention: Ford dealership states no fix available for this design issue
Fuel tank water contamination
Water accumulates in fuel tank vent area due to snow and ice buildup, contaminating diesel fuel and causing engine shutdown.
When: At 19,300 miles during winter conditions
Symptoms owners cite: Engine locked up
Repairs/costs cited: Owner found TSB (Technical Service Bulletin) documenting water in fuel tank vent area
Recalls/TSBs owners mention: Ford aware of issue per TSB regarding water entering fuel tank vent from snow and ice buildup
Transmission downshift and power loss
Transmission fails to downshift properly during acceleration, staying locked in high gear. Vehicle cannot downshift when needed to climb hills or accelerate from stops.
When: Reported at under 28,000 miles while attempting to accelerate from a stop
Symptoms owners cite: Vehicle stays in high gear; No downshift when accelerating or pulling; Inadequate acceleration
Repairs/costs cited: Dealer unable to duplicate failure; no repairs made
Intermittent engine miss
Engine develops intermittent miss/misfire that persists despite multiple dealer service attempts. Eventually causes complete engine stall.
When: Occurred over 25,000 miles of ownership; finally stalled on I-70 before holiday period
Symptoms owners cite: Intermittent engine miss/misfire; Complete engine stall
Repairs/costs cited: Dealers worked on issue multiple times without resolution
Coolant mixing with engine oil
Coolant contamination is found in engine oil, indicating a leak from the cooling system into the crankcase. This damages the engine and renders oil analysis unreliable.
When: Occurred during routine maintenance inspection; one case at unknown mileage but repair shop found contamination and blamed owner maintenance until oil sample proved otherwise
Symptoms owners cite: Engine oil contaminated with coolant; Rough running condition
Repairs/costs cited: Oil sample tested; confirmed coolant contamination despite shop initially blaming wrong oil type
Exterior light bulb failure
Headlights, tail lights, and turn signal bulbs fail repeatedly and continuously, with no identifiable root cause.
When: Reported at under 28,000 miles; ongoing throughout ownership
Symptoms owners cite: Headlight bulbs blow repeatedly; Tail light bulbs blow repeatedly; Turn signal bulbs blow repeatedly
Repairs/costs cited: Dealers unable to identify cause; no permanent fix achieved
Exhaust fumes entering cab during regeneration cycles
During exhaust filter self-cleaning (regeneration) cycles, exhaust fumes leak into the vehicle cab through heater vents or other openings. Fumes can cause illness and are a safety hazard during extended driving.
When: Ongoing since purchase; regeneration cycles occur 10+ times per day in towing use
Symptoms owners cite: Exhaust fumes detectable inside cab during regeneration; Occupants report fumes causing illness; Cannot keep windows up while exhaust system is cleaning
Repairs/costs cited: Dealer states exhaust filter is poorly designed; no repairs made
Recalls/TSBs owners mention: Ford dealership advised that issue exists only on this vehicle and states it is 'poorly designed' but offers no fix
Cooling fan not engaging during heavy towing
Cooling fan fails to engage when needed during heavy towing at low speeds, causing rapid engine overheating despite adequate coolant. Fan engages intermittently, allowing rapid coolant temperature drops when it does kick in.
When: Occurs during low-speed towing with 40-foot 5th wheel trailer; warranty expired before occurrence
Symptoms owners cite: Engine overheats quickly under towing load at low speed; No warning lights on dash; Coolant sprays from overflow cap only; Engine cools immediately when fan finally engages; Unidentified coolant loss (no leaks visible)
Repairs/costs cited: Cause unknown; coolant loss source not identified
Synthesized from 67 NHTSA owner complaints — unverified consumer allegations, summarized for patterns. The verbatim filings appear below.
What owners are reporting 7 most recent
While driving in snowy conditions, the air filter will get clogged with snow causing the engine to stall. On 12/30/2010 at 2pm I drove approximately 20 miles (zip code 57201) and the air filter had 1/2" of snow all around and inside the filter. Discussed with local Ford dealer and they say there is a no fix for this problem could cause vehicle to stall in adverse weather conditions…
Tl*the contact owns a 2008 Ford f350. The contact stated that the radiator failed and was leaking. The vehicle was inspected by a dealer who confirmed that the radiator needed to be replaced. The vehicle was repaired. The failure mileage was approximately 20,774. Updated 02/02/11 *cn
Tl*the contact owns a 2008 Ford f-350. The contact stated that the radiator on the vehicle was leaking. The leak was noticed by the driver after doing a daily inspection of the vehicle. The vehicle was not inspected by a dealer nor has it been repaired. The failure mileage was approximately 31,992. Updated 02/02/11 *cn
While in tow/haul mode towing 40' 5th wheel, engine overheated quickly which resulted in loss of power. No leaks seen and coolant was spraying out of overflow cap only. No lights came on in dash. Seems fan is not kicking on when needed? When fan does kick on, engine cools immediately. This is only at low speeds under heavy towing. Truck runs great otherwise with no overheating problems. This has…
2008 Ford f350 6.4 diesel. Job 1 truck production line. 33,000 miles, leaking radiator. Dealer replaced and determined defective. $1709.43 cost. Truck purchased 6/07. Truck is 6 months out of warranty. Most owners of this model reporting same problem. *tr
Engine did not kick out of regin causeing over heat
Tl* the contact owns a 2008 Ford f-350. The contact stated that the engine overheated while driving at various speeds. Upon inspection, it was found that there was a coolant leak. The vehicle was taken to a private mechanic where it was found that the radiator needed to be replaced. The vehicle was repaired but the failure recurred twice. The manufacturer was contacted about the failure. The…
Had engine trouble with your 2008 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 2008 Ford F-350?
It's a meaningful issue. 67 complaints have been filed and the failure mode causes operational problems for owners. Repairs average $3,100.
At what mileage does the engine typically fail?
Across the 58 complaints that reported odometer mileage, most engine failures cluster between 31,500 and 78,475 miles, with the median around 54,000. A quarter of owners report trouble before 31,500; a quarter make it past 78,475. 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/2008/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.