2006 Ford F650

The 2006 Ford F650 is a medium-duty truck often used for commercial applications. For the 2006 model year, it came equipped with a Caterpillar C7 inline-six diesel engine. Engine options included various horsepower ratings, generally ranging from 210 to 330 horsepower and torques ranging from 520-860 lb-ft. Transmission options are typically either a manual or automatic Allison transmission. Owners appreciate the F650 for its ruggedness, towing capacity, and overall capability, but dislike its size (making it difficult to maneuver and park), fuel consumption, and potential for expensive repairs due to its commercial-grade components.

Engine

Caterpillar C7

• Injector Failure
  • Description/Symptoms: Rough running engine, excessive smoke, poor fuel economy, and potential engine misfires. Can be caused by contaminated fuel or normal wear and tear.
  • Solution: Replace faulty injectors.
  • Estimated Cost to Fix: $500 - $1,000+ per injector (parts and labor), depending on location.
  • Recalls: None Found
• Head Gasket Failure
  • Description/Symptoms: Overheating, coolant leaks (internal or external), white smoke from the exhaust, and potential loss of power.
  • Solution: Replace the head gasket and inspect the cylinder head for warping or damage.
  • Estimated Cost to Fix: $3,000 - $5,000+ (parts and labor).
  • Recalls: None Found
• Turbocharger Failure
  • Description/Symptoms: Loss of power, black smoke from the exhaust, loud whistling or screeching noises, and potential engine damage.
  • Solution: Replace the turbocharger.
  • Estimated Cost to Fix: $2,000 - $4,000+ (parts and labor).
  • Recalls: None Found

Transmission

Allison Automatic Transmission

• Shifting Problems
  • Description/Symptoms: Harsh shifting, slipping between gears, failure to shift, and transmission overheating. Often caused by worn clutches, faulty solenoids, or low fluid level.
  • Solution: Diagnosis with a scan tool is necessary to pinpoint the cause. Repair options range from fluid and filter change to a complete transmission rebuild or replacement.
  • Estimated Cost to Fix: $300 (fluid/filter) to $5,000+ (rebuild/replace).
  • Recalls: None Found
• Torque Converter Failure
  • Description/Symptoms: Shuddering at low speeds, stalling, and poor acceleration.
  • Solution: Replace the torque converter.
  • Estimated Cost to Fix: $1,500 - $3,000+ (parts and labor).
  • Recalls: None Found

Suspension

• Leaf Spring Issues
  • Description/Symptoms: Sagging rear end, rough ride, squeaking noises, and reduced load capacity. Caused by worn or broken leaf springs.
  • Solution: Replace the leaf springs.
  • Estimated Cost to Fix: $1,000 - $3,000+ per axle (parts and labor).
  • Recalls: None Found
• Air Suspension Problems (If Equipped)
  • Description/Symptoms: Leaking air bags, failure to maintain ride height, and compressor malfunction.
  • Solution: Replace the air bags, compressor, or associated components.
  • Estimated Cost to Fix: $500 - $2,000+ per air bag or component (parts and labor).
  • Recalls: None Found

Electrical

• Wiring Harness Issues
  • Description/Symptoms: Intermittent electrical problems, such as lights flickering, gauges not working, and starting problems. Can be caused by corrosion, chafing, or loose connections.
  • Solution: Inspect and repair the wiring harness, replacing damaged sections as needed.
  • Estimated Cost to Fix: $200 - $1,000+ (depending on the severity and location of the damage).
  • Recalls: None Found
• Sensor Failures
  • Description/Symptoms: Engine performance issues, transmission shifting problems, and warning lights on the dashboard. Common culprits include the mass airflow sensor (MAF), oxygen sensors, and crankshaft position sensor.
  • Solution: Replace the faulty sensor.
  • Estimated Cost to Fix: $100 - $500+ per sensor (parts and labor).
  • Recalls: None Found

Exterior

• Rust
  • Description/Symptoms: Rust forming on the frame, body panels, and undercarriage. Especially prevalent in areas with road salt.
  • Solution: Remove the rust and apply rust protection.
  • Estimated Cost to Fix: $200 - $1,000+ depending on severity and location of rust
  • Recalls: None Found

Interior

• HVAC Issues
  • Description/Symptoms: Weak airflow, failure to heat or cool properly, and strange noises coming from the HVAC system. Can be caused by a faulty blower motor, clogged evaporator core, or leaking refrigerant.
  • Solution: Diagnose the problem and repair or replace the faulty components.
  • Estimated Cost to Fix: $200 - $1,000+ (depending on the cause).
  • Recalls: None Found

Summary:

The 2006 Ford F650, while a capable and durable truck, is prone to issues common in medium-duty vehicles. The Caterpillar C7 engine can experience injector and head gasket failures that can be expensive. Issues with the Allison transmission, particularly shifting problems, are also noted. Suspension and electrical problems can add to the overall cost of ownership. The severity and cost of repairs for the F650 can vary greatly, depending on the issue and the extent of the damage. Potential buyers should carefully inspect the truck’s maintenance history and consider a pre-purchase inspection by a qualified mechanic to assess its overall condition and identify any potential problems.