2003 Ford F-350
The 2003 Ford F-350 Super Duty is a heavy-duty pickup truck known for its robust capabilities and durability. Available engine options include the 5.4L Triton V8 (300 hp, 365 lb-ft of torque), the 6.8L Triton V10 (310 hp, 425 lb-ft of torque), and the 7.3L Power Stroke Turbo Diesel V8 (275 hp, 525 lb-ft of torque) in earlier models and the 6.0L Power Stroke Turbo Diesel V8 (325 hp, 570 lb-ft of torque) in later models. Transmission choices typically consist of a 5-speed manual and a 4-speed automatic for gas engines, and a 6-speed manual or 4-speed automatic for diesel engines. Owners often praise the F-350 for its towing capacity and ruggedness. Common complaints include issues related to the aging components, particularly in the diesel engines, as well as the ride quality that can be stiff due to its heavy-duty nature.
Engine
5.4L Triton V8
- Spark Plugs Breaking During Removal
- Description/Symptoms: Spark plugs becoming seized in the cylinder heads and breaking off during removal. This often requires specialized tools to extract the broken pieces. This issue is more prevalent with the 2-valve version of the engine.
- Solution: Use penetrating oil and carefully extract broken spark plugs. Sometimes, a spark plug extraction tool is necessary. Replacing the cylinder heads may be required in severe cases.
- Estimated Cost to Fix: $100 - $1000+ depending on the severity and whether cylinder head replacement is needed.
- Recalls: None Found
6.8L Triton V10
- Exhaust Manifold Leaks/Cracks
- Description/Symptoms: The exhaust manifolds are prone to cracking or developing leaks, resulting in a noticeable exhaust leak sound, reduced engine performance, and potential exhaust fumes entering the cabin.
- Solution: Replace the cracked or leaking exhaust manifold.
- Estimated Cost to Fix: $300 - $800+
- Recalls: None Found
7.3L Power Stroke Turbo Diesel V8
- Cam Position Sensor Failure
- Description/Symptoms: Stalling, rough running, no start.
- Solution: Replace the sensor.
- Estimated Cost to Fix: $50-$200
- Recalls: None Found
- Fuel Injector Issues
- Description/Symptoms: Rough idle, loss of power, excessive smoke, and poor fuel economy.
- Solution: Replacing faulty fuel injectors, may require specialized equipment.
- Estimated Cost to Fix: $200 - $500+ per injector
- Recalls: None Found
6.0L Power Stroke Turbo Diesel V8
- EGR Cooler Failure
- Description/Symptoms: Coolant loss, white smoke from the exhaust, and potential overheating. EGR cooler failure often leads to head gasket failure.
- Solution: Replace the EGR cooler, consider upgrading to a bulletproof EGR cooler design.
- Estimated Cost to Fix: $500 - $1500+
- Recalls: None Found
- Head Gasket Failure
- Description/Symptoms: Overheating, coolant loss, white smoke, and pressurized coolant reservoir.
- Solution: Replace the head gaskets and head bolts, upgrade to ARP head studs.
- Estimated Cost to Fix: $3000 - $6000+
- Recalls: None Found
- Injector Stiction
- Description/Symptoms: Rough running, hard starting when cold, excessive smoke. The injectors become sticky due to oil deposits.
- Solution: Use fuel additives to clean injectors, replace faulty injectors, or consider performing an oil change with an oil that addresses stiction issues.
- Estimated Cost to Fix: $100 (additives) - $500+ per injector
- Recalls: None Found
Transmission
4R100 4-Speed Automatic (Gas & Diesel)
- Torque Converter Failure
- Description/Symptoms: Shuddering during acceleration, especially when towing, slipping, and complete transmission failure.
- Solution: Replace the torque converter.
- Estimated Cost to Fix: $800 - $2000+
- Recalls: None Found
- Valve Body Issues
- Description/Symptoms: Hard shifting, erratic shifting, slipping, and failure to shift.
- Solution: Replace or rebuild the valve body.
- Estimated Cost to Fix: $500 - $1500+
- Recalls: None Found
ZF6 6-Speed Manual (Diesel)
- Clutch Failure
- Description/Symptoms: Slipping clutch, difficulty shifting, clutch pedal sticking.
- Solution: Replace the clutch, pressure plate, and throwout bearing.
- Estimated Cost to Fix: $800 - $2000+
- Recalls: None Found
Suspension
- Leaf Spring Sag/Wear
- Description/Symptoms: Rear end sag, poor ride quality, reduced load-carrying capacity.
- Solution: Replace or add-a-leaf to the leaf springs.
- Estimated Cost to Fix: $400 - $1200+
- Recalls: None Found
- Ball Joint Failure
- Description/Symptoms: Front end noise, loose steering, uneven tire wear.
- Solution: Replace the ball joints.
- Estimated Cost to Fix: $300 - $800+
- Recalls: None Found
Electrical
- Instrument Cluster Issues
- Description/Symptoms: Gauges not working correctly, flickering lights, complete instrument cluster failure.
- Solution: Repair or replace the instrument cluster.
- Estimated Cost to Fix: $200 - $600+
- Recalls: None Found
- Alternator Failure
- Description/Symptoms: Dimming lights, battery not charging, vehicle stalling.
- Solution: Replace the alternator.
- Estimated Cost to Fix: $200 - $500+
- Recalls: None Found
Exterior
- Rust (Cab Corners, Rocker Panels, Wheel Wells)
- Description/Symptoms: Rust forming on cab corners, rocker panels, and wheel wells.
- Solution: Repair or replace affected panels.
- Estimated Cost to Fix: $500 - $2000+ depending on severity.
- Recalls: None Found
Interior
- Cracked Dash
- Description/Symptoms: Cracking of the plastic dashboard, especially in hotter climates.
- Solution: Dash cover or replacement.
- Estimated Cost to Fix: $50 - $800+
- Recalls: None Found
Summary
The 2003 Ford F-350 is a capable truck but suffers from age-related issues. The 6.0L Power Stroke diesel is particularly problematic with EGR cooler and head gasket failures being common and expensive to repair. The 7.3L Power Stroke is generally considered more reliable, although issues like fuel injector problems can still occur. Gas engines can have issues with spark plugs breaking. Suspension components such as leaf springs and ball joints tend to wear out over time. Electrical issues such as instrument cluster and alternator failures can occur. Rust can be a significant concern, especially in areas with harsh winters. Repair costs can range from a few hundred dollars for minor fixes to several thousand dollars for major engine or transmission repairs.