2006 Ford F-350 Super Duty

The 2006 Ford F-350 Super Duty is a heavy-duty pickup truck known for its robust capabilities and workhorse nature. It was available with several engine options: a 5.4L Triton V8 (300 hp, 365 lb-ft of torque), a 6.8L Triton V10 (362 hp, 457 lb-ft of torque), and the popular 6.0L Power Stroke turbodiesel V8 (325 hp, 570 lb-ft of torque). Transmission options included a 5-speed manual and a 5-speed automatic. Owners often praise the F-350 for its towing capacity, durability, and overall performance. However, common complaints revolve around the reliability of certain components, particularly the 6.0L diesel engine, as well as its fuel economy and ride quality.

Engine

6.0L Power Stroke Turbodiesel V8

• EGR Cooler Failure
  • Description/Symptoms: Coolant loss, white smoke from exhaust, overheating, rough running. The EGR cooler cracks and leaks coolant into the exhaust system.
  • Solution: Replace the EGR cooler. Upgraded aftermarket EGR coolers are available that are more durable.
  • Estimated Cost to Fix: $500 - $1500+
  • Recalls: None Found
• Oil Cooler Failure
  • Description/Symptoms: Overheating, oil in coolant, reduced oil pressure. The oil cooler can become clogged or crack, leading to these issues.
  • Solution: Replace the oil cooler. Often, the EGR cooler is replaced simultaneously as it’s located in the same area.
  • Estimated Cost to Fix: $500 - $1500+ (may overlap with EGR cooler repair cost)
  • Recalls: None Found
• Fuel Injector Failure
  • Description/Symptoms: Rough running, misfires, black smoke from exhaust, poor fuel economy. The fuel injectors can become clogged or fail electronically.
  • Solution: Replace the faulty fuel injector(s). It is often recommended to replace all injectors at once.
  • Estimated Cost to Fix: $300 - $600+ per injector.
  • Recalls: None Found
• High Pressure Oil Pump (HPOP) Failure
  • Description/Symptoms: Hard starting, no-start condition, stalling. The HPOP provides the necessary oil pressure to operate the fuel injectors.
  • Solution: Replace the HPOP.
  • Estimated Cost to Fix: $800 - $2000+
  • Recalls: None Found
• Head Gasket Failure
  • Description/Symptoms: Overheating, coolant loss, white smoke from exhaust, bubbling in coolant reservoir, rough running. The 6.0L is prone to head gasket failure due to the use of torque-to-yield head bolts and the high cylinder pressures of the diesel engine.
  • Solution: Replace the head gaskets. Often, the heads are resurfaced or replaced as well. Upgraded head studs are highly recommended.
  • Estimated Cost to Fix: $3000 - $6000+
  • Recalls: None Found

5.4L Triton V8

• Spark Plug Issues
  • Description/Symptoms: Ticking noise. 2-piece spark plugs are known for breaking upon removal.
  • Solution: Special tools need to be used to remove the spark plugs and ensure the broken piece is also removed.
  • Estimated Cost to Fix: $200 - $500+
  • Recalls: None Found
• Cam Phaser Failure
  • Description/Symptoms: Ticking noise, rough idle, loss of power. The cam phasers are known for failing over time.
  • Solution: Replace the Cam Phasers, Chains, Tensioners, Guides, and Solenoids.
  • Estimated Cost to Fix: $1500 - $3000+
  • Recalls: None Found

6.8L Triton V10

No Issues Found

Transmission

5R110W 5-Speed Automatic Transmission

• Torque Converter Failure
  • Description/Symptoms: Shuddering during gear changes, slipping, stalling, or complete loss of drive.
  • Solution: Replace the torque converter and flush the transmission. Inspect the transmission for damage from debris from the failed converter.
  • Estimated Cost to Fix: $800 - $2500+ (depending on internal transmission damage).
  • Recalls: None Found
• Valve Body Issues
  • Description/Symptoms: Harsh or erratic shifting, slipping, delayed engagement.
  • Solution: Replace or rebuild the valve body.
  • Estimated Cost to Fix: $500 - $1500+
  • Recalls: None Found

Manual Transmission (ZF5)

No Issues Found

Suspension

• Worn Ball Joints
  • Description/Symptoms: Clunking or squeaking noise from front suspension, excessive tire wear, loose steering.
  • Solution: Replace the ball joints (upper and lower).
  • Estimated Cost to Fix: $300 - $1000+ per side
  • Recalls: None Found
• Worn Leaf Spring Bushings
  • Description/Symptoms: Squeaking or clunking noise from rear suspension, harsh ride.
  • Solution: Replace the leaf spring bushings.
  • Estimated Cost to Fix: $200 - $600+
  • Recalls: None Found

Electrical

• FICM (Fuel Injection Control Module) Failure (6.0L Diesel)
  • Description/Symptoms: Hard starting, no-start condition, poor performance, low voltage reading on the FICM.
  • Solution: Replace the FICM. Upgraded aftermarket FICMs are available.
  • Estimated Cost to Fix: $400 - $1000+
  • Recalls: None Found
• Alternator Failure
  • Description/Symptoms: Dimming lights, dead battery, charging system warning light.
  • Solution: Replace the alternator.
  • Estimated Cost to Fix: $200 - $600+
  • Recalls: None Found

Exterior

• Rust
  • Description/Symptoms: Rust forming around wheel wells, cab corners, rocker panels, and undercarriage. Common issue in areas with road salt.
  • Solution: Rust repair and repainting.
  • Estimated Cost to Fix: $500 - $5000+ (depending on severity)
  • Recalls: None Found

Interior

• Cracked Dashboard
  • Description/Symptoms: Cracks appearing on the dashboard, especially in sun-exposed areas.
  • Solution: Replace the dashboard or use a dashboard cover.
  • Estimated Cost to Fix: $300 - $1500+
  • Recalls: None Found

Summary

The 2006 Ford F-350 Super Duty is a capable truck, but potential buyers should be aware of the common issues, particularly those associated with the 6.0L Power Stroke diesel engine. Issues like EGR cooler, oil cooler, and head gasket failures can be costly to repair. While some issues are relatively minor, others can lead to significant downtime and expenses. The severity and cost of repairs vary widely depending on the specific issue and the extent of the damage. Thorough inspection and a pre-purchase inspection by a qualified mechanic are highly recommended before buying a used 2006 F-350 Super Duty.