2006 Ford F-250 Super Duty

The 2006 Ford F-250 Super Duty is a heavy-duty pickup truck known for its robust capabilities and dependability. Available engine options included the 5.4L Triton V8 (300 hp, 365 lb-ft of torque), the 6.8L Triton V10 (355 hp, 455 lb-ft of torque), and the formidable 6.0L Power Stroke Turbo Diesel V8 (325 hp, 570 lb-ft of torque). Transmission options mainly consisted of either a 5-speed manual or a 5-speed automatic transmission, depending on the engine configuration. Owners often praise the truck’s towing capacity, ruggedness, and spacious cabin. Common complaints include issues with the 6.0L diesel engine, potential rust problems, and the vehicle’s overall fuel economy.

Engine

6.0L Power Stroke Turbo Diesel V8

• EGR Cooler Failure
  • Description/Symptoms: Overheating, coolant loss, white smoke from the exhaust, and potentially a sweet smell from the coolant. The EGR cooler cracks, allowing coolant to enter the exhaust system.
  • Solution: Replacement of the EGR cooler with an upgraded or aftermarket version designed to withstand higher temperatures and pressures. Some owners opt for EGR cooler delete kits (check local regulations).
  • Estimated Cost to Fix: $800 - $1,500+
  • Recalls: None Found
• Injector Failure
  • Description/Symptoms: Rough running, misfires, decreased fuel economy, excessive black smoke from exhaust. Often diagnosed with cylinder contribution tests.
  • Solution: Replacement of the failed injectors. Ensuring the fuel system is clean and functioning correctly to prevent future failures.
  • Estimated Cost to Fix: $300 - $600+ per injector (parts and labor)
  • Recalls: None Found
• Head Gasket Failure
  • Description/Symptoms: Overheating, coolant loss, white smoke from the exhaust, and pressure in the cooling system. Often accompanied by a bubbling sound in the coolant reservoir.
  • Solution: Replacement of the head gaskets. Often requires head studs to prevent future failure. Machining the cylinder heads may also be necessary.
  • Estimated Cost to Fix: $3,000 - $6,000+
  • Recalls: None Found
• High Pressure Oil Pump (HPOP) Failure
  • Description/Symptoms: Hard starting, no starting, rough running, stalling. Typically diagnosed by monitoring ICP (Injection Control Pressure).
  • Solution: Replacement of the HPOP.
  • Estimated Cost to Fix: $800 - $2,000+
  • Recalls: None Found

5.4L Triton V8

• Spark Plug Thread Failure
  • Description/Symptoms: Spark plugs ejecting from the cylinder head, causing misfires and loud popping noises. This is due to weak spark plug threads in the aluminum cylinder heads.
  • Solution: Repairing the spark plug threads using a thread repair kit (e.g., Time-Sert) or replacing the cylinder head.
  • Estimated Cost to Fix: $300 - $800 (thread repair) or $1,500 - $3,000+ (cylinder head replacement)
  • Recalls: None Found

6.8L Triton V10

• No Issues Found

Transmission

5R110W TorqShift 5-Speed Automatic (Typically paired with the 6.0L Diesel)

• Torque Converter Failure
  • Description/Symptoms: Shuddering during acceleration, slipping between gears, and potential stalling.
  • Solution: Replacement of the torque converter. Flushing the transmission fluid and inspecting for debris is also recommended.
  • Estimated Cost to Fix: $800 - $1,800+
  • Recalls: None Found
• Valve Body Issues
  • Description/Symptoms: Harsh or erratic shifting, delayed engagement, and slipping between gears.
  • Solution: Valve body replacement or rebuild.
  • Estimated Cost to Fix: $500 - $1,500+
  • Recalls: None Found

ZF5 5-Speed Manual (Typically paired with the 7.3L Diesel)

• No Issues Found

Suspension

• Ball Joint Failure
  • Description/Symptoms: Squeaking or popping noises from the front suspension, loose steering, uneven tire wear.
  • Solution: Replacement of the upper and/or lower ball joints.
  • Estimated Cost to Fix: $300 - $800+ per side
  • Recalls: None Found
• Leaf Spring Sag
  • Description/Symptoms: Vehicle sitting lower in the rear, reduced load-carrying capacity, rough ride.
  • Solution: Replacement of the leaf springs or adding helper springs/airbags.
  • Estimated Cost to Fix: $500 - $1,500+
  • Recalls: None Found

Electrical

• Glow Plug Control Module (GPCM) Failure (6.0L Diesel)
  • Description/Symptoms: Hard starting in cold weather, white smoke on startup.
  • Solution: Replacement of the GPCM.
  • Estimated Cost to Fix: $200 - $500
  • Recalls: None Found
• Alternator Failure
  • Description/Symptoms: Dimming lights, battery drain, starting issues.
  • Solution: Alternator Replacement.
  • Estimated Cost to Fix: $300 - $600
  • Recalls: None Found

Exterior

• Rust Issues
  • Description/Symptoms: Rust forming on the rocker panels, cab corners, and around the wheel wells, particularly in areas with high road salt usage.
  • Solution: Cutting out the rust and welding in new metal. Applying rust prevention coatings.
  • Estimated Cost to Fix: $500 - $2,000+ per area, depending on the severity.
  • Recalls: None Found

Interior

• Cracked Dash
  • Description/Symptoms: Cracks appearing on the dashboard, particularly in areas exposed to sunlight.
  • Solution: Installing a dash cover or replacing the entire dashboard.
  • Estimated Cost to Fix: $50 - $200 (dash cover) or $800 - $2,000+ (dashboard replacement)
  • Recalls: None Found

Summary

The 2006 Ford F-250 Super Duty is a capable truck, but it’s prone to certain issues, especially concerning the 6.0L Power Stroke diesel engine. EGR cooler, injector, and head gasket failures are common and costly repairs. Rust can also be a significant problem, depending on the region. The 5.4L spark plug thread issue is also relatively common and should be a point of inspection before purchase. While less severe, electrical and suspension components are also known to fail. Overall, potential buyers should thoroughly inspect the vehicle, especially the engine and undercarriage, and be prepared for potentially expensive repairs.