Ford F-250 Super Duty (2003–2007): What Actually Breaks
The 6.0L Power Stroke era — built from 1,055 owner complaints and 10 recalls in the public NHTSA record, cross-linked to the codes and guides that cover each system.
How to read this. These are the systems 2003–2007 F-250 owners reported problems with to NHTSA — not a scientific failure rate, and not split by engine (this generation was sold with 5.4L/6.8L gas V8/V10 and the 6.0L Power Stroke diesel). The 6.0L is the engine that defined this truck’s reputation, and “Engine & Cooling” topping the list lines up with its well-documented weak points.
Complaints by system
Where the 1,055 complaints landed, by NHTSA component category:
Steering and suspension rank high largely because of the solid-front-axle “death wobble” these trucks are known for — a mechanical alignment/worn-component issue, not something a scan tool codes for. The engine, fuel, and powertrain lines are where diagnostic codes actually help, so those are the ones we’ve linked out.
The 6.0L Power Stroke, specifically
If you’re looking at one of these with the diesel, the 6.0L is famous for a short list of well-documented failure points. None of these are a reason to walk away on their own — many trucks have already had them addressed — but they’re what to check for and budget around:
- EGR cooler — cracks and dumps coolant into the intake; classic white smoke and coolant loss. EGR cooler guide →
- Oil cooler — clogs and starves the EGR cooler and oil system; often replaced together.
- Head gaskets / head studs — the factory torque-to-yield bolts stretch under boost; ARP studs are the common permanent fix.
- FICM (fuel injection control module) — degrades and causes hard starts and misfires, especially cold.
- Injectors & fuel delivery — a low-rail-pressure or injector fault shows up in the codes. P0087 fuel rail pressure guide →
Start any 6.0L diagnosis at the Power Stroke code hub or browse all diesel fault codes.
Safety flags in the complaints
Of the 1,055 complaints, owners reported 32 crashes, 33 fires, and 40 injuries (no deaths). The fire reports cluster around the electrical/speed-control issues that also drove recalls — worth taking seriously on an unrepaired truck.
Recalls for this generation
10 NHTSA recall campaigns cover the Ford F-250 Super Duty (2003–2007). Check any specific truck by VIN on NHTSA’s lookup — a recall may or may not have been completed:
- Engine & Engine Cooling: Diesel #07V553000
- Vehicle Speed Control #07V078000
- Vehicle Speed Control #09V399000
- Electrical System: Wiring #05V270000
- Fuel System: Delivery (hoses, lines, fittings) #05V266000
- Exterior Lighting: Tail Lights #11V352000
- Exterior Lighting #06E026000
- Wheels: Hub #07E106000
- Equipment #08E026000
- Steering #20E090000
Buying or diagnosing one? A code reader that speaks Ford diesel saves you guessing. See our heavy-duty scanner recommendations, and if you already have a code, look it up in the diesel section.
Data source: U.S. National Highway Traffic Safety Administration (NHTSA) Office of Defects Investigation — public-domain complaint and recall databases, retrieved June 2026. Complaint counts reflect what owners chose to report and are not adjusted for sales volume, so they aren’t a failure rate. This is a reference, not a substitute for a pre-purchase inspection by a diesel-experienced mechanic.