We bought this 2004 Ford F-350 Dually Diesel from my late father-in-law in 2006 with only 3,000 miles on it. Had really no problems until the EGR valve went out in 10/2008 with only 54,968 miles on the truck - they replaced it. Second time with only 65,549 miles they cleaned it in 10/2009. 3rd time with only 74,020 miles it had to be replaced in 7/2010. Contacted FORD and they said they had no reports of problems on this year and type of truck for the EGR Valve and just follow the maintenance program in the book and we shouldn't have any problems. Today, 9/14/2010, it again had to go into the shop with 77,642 miles to have the EGR valve replaced. NO PROBLEM? I think this truck has major EGR valve problems. After this repair, I'm really curious what they are going to say.

I have had this truck now for about 1.5 years and for the most part it has been a good truck. I had some coolant issues last year, had to replace the water pump twice (at almost $800 each time!!!) Newest issue is that when I started my truck the other day the engine was idling very low (around 200-300 RPM) and when I stepped on the accelerator, no response at all. After 3 tries (had to shutdown and restart), finally got the accelerator to respond. Headed out on the highway and seemed to run ok, until after I trued to pass someone. Not much power after 100km/hr. Turbo seemed to still work ok however. Slowed down to come into town and noticed that the engine started jerking (sort of like it was missing or bad plugs or wires in a gas vehicle) Was able to make it to my house and now it sits. I have read about the EGR valve, etc...I really hope that is all it is. I am pretty well done with Ford as my wife's 2009 Escape has been in the shop as well more than it should be for a newer vehicle. I have heard nothing but complaints about the 6.0 PSD...should have done a bit more research before buying this POS.

If anyone has any ideas of what the issue may be (other than it being a POS Ford) I would love to hear about it. Thanx

My 04 F-350 6.0 has been great until I hit 70,000 mi. All the sudden I have been in the shop more than on the road. I am about to go back in for the 3rd time to have my EGR sensor and valve replaced in the past 1,000 mi. The turbo also went out in the past month! Now especially when I am towing everyone behind me turns on their lights to see through the smoke!! That, along with the loss of power is getting old fast! Ford cant seem to find out what the problem is, and just want to sell me another truck. (I guess so they can sell this one to someone else that won't complain about all the smoke!?!)

Built ford tough?? I'm not so sure!

My Ford F 350 Super duty Crew Cab Dually 6.0 Powerstroke has been in the Shop for a total of 24 days at different intervals, starting at 150 miles for several problems that I'll list later. The problem that I'm having now with the engine jerking/ stalling started at about 20,000 miles and has not been fixed as of 3/20/06 with 31,600 plus miles. For accuracy in describing the current problem, it would be similar to a gas engine that has faulty plug wires and is shorting out and missing. You will often times smell fuel in the cabin at startup and find no leak. When the truck jerks, a cloud of black smoke is seen coming from the exhaust. The mechanic has had the laptop record the problem with no solution other than seeing that it is missing on all cylinders. He's had the flight recorder hooked up twice, once with the wrong information encoded and they are still uncertain. The symptom is much more noticeable if I have a trailer and under a load but my fuel mileage has dropped an average of 6.5 MPG loaded or unloaded. The problem that is causing the jerking/stalling (that is a momentary stall for clarification) has caused me to smell fuel in the cab as well as a considerable amount of fuel. I've purchased four new vehicles in seven years and have had to take two of them in for warranty work once. This has been a major pain in the hinny to say the least. The dealer (the second I've tried) seems to be doing his best but Ford seems to want me and my truck to disappear. I've got other things to do and had I known about the lemon laws in my state (Va) and the time factor for filing, I'd have filed a long time ago! The fumes that come from this problem can be intoxicating at times.