1999–2004 Ford F-250 / F-350 Super Duty common problems and fixes

The first-generation Super Duty came with four engines: the 7.3L Power Stroke diesel (1999 to early 2003), the 6.0L Power Stroke diesel (2003–2004), the 5.4L V8 gas and the 6.8L V10 gas. Check the engine before reading on, because each has its own weak spots.

We counted 5,025 owner complaints filed with NHTSA for 1999–2004 F-250s and F-350s (retrieved October 5, 2026; each complaint counted once): 2,049 from 7.3L diesels, 723 from 6.0L diesels, 630 from 5.4L V8s and 483 from 6.8L V10s, identified by VIN; the rest (1,140) couldn't be matched to an engine. We left out 57 whose VIN belongs to another vehicle (e.g. an E-Series van, an Excursion or an F-150). These trucks are now over 20 years old, so the condition of the truck you're looking at matters far more than its reputation. Complaint counts show what owners report most often, not how many trucks have a problem.

At a glance

• 7.3L diesel: its best-known weak spot is the camshaft position sensor, which can stall the engine without warning.
• 6.0L diesel (2003–2004): the start of the troubled 6.0 era. Stalling is the top complaint, and the same engine problems as the 2005–2007 trucks apply.
• 5.4L and 6.8L gas: spark plugs blowing out of the cylinder head is the most frequently reported engine problem.
• Rust is the biggest issue at this age: cab corners, rocker panels, the radiator support and brake lines.

7.3L diesel: stalling from the cam sensor

Stalling or shutting off is the most common engine complaint on the 7.3L: about 280 of 2,049 complaints mention stalling, dying, cutting out or shutting off, and 167 mention the cam sensor. Owners frequently trace stalling to the camshaft position sensor, and Ford recalled certain 1999–2003 7.3L trucks to replace it with an improved sensor (recall 07V553000). These trucks use the power steering pump to power the brakes, so when the engine stalls, owners describe losing both power steering and power brakes at once.

Other commonly reported 7.3L problems:

• The wiring harness under the valve covers, which can cause misfires or rough cold starts
• Injector and injector driver module (IDM) failures
• Oil leaks at the turbo pedestal

When buying: start it cold and watch for long cranking, rough running or stalling. Ask whether the cam sensor has been replaced, and check under the turbo for oil buildup.

6.0L diesel (2003–2004)

On 6.0L trucks, stalling is about 4 in 10 of the complaints (about 320 of 723). Ford recalled certain 2004–2005 6.0L trucks for stalling, upgrading the injection control module (FICM) wiring or the ICP sensor connector (recall 05V270000). The 6.0L's bigger problems are covered in our 2005–2007 notes: oil cooler and EGR cooler failures leading to blown head gaskets, the fuel injection control module (FICM) and injectors. Ask for proof of "bulletproofing" work (head studs, upgraded oil and EGR coolers) and price the truck accordingly if it hasn't been done.

5.4L and 6.8L gas: spark plug blowout

About 1 in 4 gas-engine complaints mention spark plugs (278 of 1,113), most often a plug blowing out of the aluminum cylinder head. It's most often reported on the earlier years, and owners say the fix usually involves a thread repair insert.

When buying: listen for a ticking or puffing noise that gets louder with engine speed, which can be a loose plug. Ask whether any plugs have blown out and how they were repaired.

Fire risk: cruise control switch recall

About 330 complaints mention a fire or flames, and about 1 in 5 of those also mention the cruise control or a brake switch. Owners point to the cruise control deactivation switch, which Ford recalled on certain trucks because it could overheat and burn even with the engine off (recalls 06V286000 for gas trucks through 2002 and 09V399000 for 1999–2003 diesels). Check that the recall was done using the VIN.

Rust and brakes

• Look hard at the cab corners, rocker panels, wheel arches and radiator support. Owners and repair shops commonly name the radiator support as the first part to rot.
• 87 complaints mention rusted brake lines. Check the steel lines along the frame.
• Look along the whole frame for scaling or holes.

Tires (mostly history)

About 1,110 complaints mention tires or tread. About 660 of them are from 1999 and 2000 trucks, about half describe the tread separating, and about 300 name Firestone tires; most were filed in 2000–2004. Tires from that era are long gone, so this matters less today. Still check the age of the tires on the truck.

Before you buy

• Check open recalls at nhtsa.gov/recalls with the VIN, especially the cam sensor and cruise control switch recalls.
• Have a mechanic check the front end (ball joints, tie rods) and frame.
• For a diesel, use a shop that knows Power Strokes.
• Bring our used truck inspection checklist.