NHTSA Complaint #10629052 — 2003 FORD F SUPER DUTY

THE PROBLEM: 6.0L HEAD BOLTS. PROBABLY THE MOST WELL-KNOWN AND PROBLEMATIC IS THE ISSUE WITH THE FACTORY HEAD BOLTS. ESSENTIALLY, THE BOLTS STRETCH, WHICH RESULTS IN A BLOWN HEAD GASKET. FORD IS AWARE OF THIS PROBLEM IS WHY THERE IS A LAWSUITE PENDING DUE TO THIS ISSUE AND OTHERS WITH THIS 6.0L ENGINE. THE PROBLEM: EGR COOLER THE 6.0L DIESEL HAS A BAD REPUTATION FOR BLOWN HEAD GASKETS AND STICKING EGR (EXHAUST GAS RECIRCULATION) VALVE. WHILE STRETCHING HEAD BOLTS ARE PARTLY TO BLAME FOR THE HEAD GASKET ISSUE, PROGRAMMERS THAT TURN UP THE POWER IN YOUR 6.0L TRUCK ARE GUILTY CULPRITS AS WELL. SIMPLY PUT, THE STOCK EGR COOLER CANNOT KEEP UP WITH FILTERING A MODIFIED 6.0L. A FAILING EGR COOLER CAN CAUSE YOUR TRUCK TO OVERHEAT, RUN POORLY, AND ADD TO THE POTENTIAL FOR HEAD GASKET FAILURE. THE PROBLEM: VACUUM LEAK ALTHOUGH THE SUPER DUTY USES UNIT BEARINGS UP FRONT FROM THE FACTORY, THE TRUCKS ARE STILL EQUIPPED WITH SELECTABLE HUBS. MANY OF THE EARLY TRUCKS WERE EQUIPPED WITH FORD-SPECIFIC HUBS WHICH HAD AN AUTO AND ON SETTING ONLY. THESE HUBS WERE VACUUM-ASSISTED AND KNOWN TO BE PROBLEMATIC. A LEAKING OR DRY-ROTTED VACUUM LINE IS NOT UNCOMMON TO FIND, NOR IS A DAMAGED HUB ACTUATOR. PICTURED HERE IS A QUICK TRAIL FIX THAT USES A STICK TO PLUG A VACUUM LINE THAT WAS LEAKING AND NO LONGER NEEDED BECAUSE THE TRUCK WAS OUTFITTED WITH AFTERMARKET HUBS. THE PROBLEM: FRONT UNIT BEARINGS BIG TIRES AND UNIT BEARINGS DON'T ALWAYS MIX WELL. EVEN IN THE FACTORY CONFIGURATION, THE NON-SERVICEABLE UNIT BEARINGS HAVE A LIMITED LIFE CYCLE. THE EASY WAY TO CHECK FOR A BAD UNIT BEARING IS BY JACKING UP THE FRONT AXLE, ONE SIDE AT A TIME. YOU'LL WANT TO RAISE THE TIRE OFF OF THE GROUND ENOUGH SO THAT A PRYBAR CAN BE PLACED UNDER THE BOTTOM OF THE TIRE. YOU CAN ALSO USE YOUR HANDS TO TEST THIS, BUT THE PRYBAR WILL GIVE YOU EXTRA LEVERAGE. ISSUE RECALL. *TR