NHTSA Complaint #10287147 — 2004 FORD F-250 SD ENGINE AND ENGINE COOLING:ENGINE

Complaint Details

ODI Number	10287147
Vehicle	2004 FORD F-250 SD
Component	ENGINE AND ENGINE COOLING:ENGINE
Date of Incident	May 30, 2009
Date Filed	October 12, 2009
Mileage	53,163 miles
Crash	No
Fire	No
Injuries	0
Deaths	0
Vehicle Towed	No
State	LA

Consumer Description

2004 FORD 6.0 LITER DIESEL MOTOR- EGR COOLER CRACKING AND THUS CAUSING COOLANT LEAKS INTO THE EXHAUST SYSTEM AND ENGINE CYLINDERS. EGR COOLER FAILURE CAUSES COOLANT TO ENTER ENGINE CYLINDERS THUS INCREASING CYLINDER PRESSURES ON HEADS. HEAD BOLTS STRETCH AND HEAD GASKETS FAIL. WATER IN CYLINDER LEADS TO MAJOR ENGINE FAILURE. 1000'S OF FORD 6.0 LITER DIESEL OWNERS HAVE THE SAME PROBLEM. DEALERS REPAIR THEM CONSTANTLY. FORD DEALER PARTS DEPT STATES THAT THEY HAVE PARTS IN STOCK BECAUSE THEY CHANGE THEM OUT ON A DAILY BASIS. MY VEHICLE WAS 2 MONTHS OUT OF WARRANTY WHEN PART FAILED AT 53,163 MILES. EGR COOLER CRACKED, LEAKED OUT COOLANT IN THE EXHAUST AND INTO THE MOTOR, THUS MOTOR FAILED. DEALER SAYS NEED NEW MOTOR AT $10,000. FORD NEEDS TO RECALL THE OLDER EGR COOLER COMPONENT. CURRENTLY WHEN THEY CHANGE THEM OUT UNDER WARRANTY, THEY REPLACE IT WITH A NEW AND IMPROVED EGR COOLER. IF IT IS NEW AND IMPROVED, WHY ISN'T THE OLD ONE RECALLED IF THEY KNOW IT IS A BAD DESIGN? *TR

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