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2009 Ford F-250

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By Research the Car 5 min read

Here’s a comprehensive breakdown of common issues and complaints reported by owners of the 2009 Ford F-250 Super Duty. The 2009 Ford F-250 is a heavy-duty pickup truck known for its towing and hauling capabilities. Engine options include the 5.4L Triton V8 (300 hp, 365 lb-ft of torque), the 6.8L Triton V10 (362 hp, 457 lb-ft of torque), and the 6.4L Power Stroke Diesel V8 (350 hp, 650 lb-ft of torque). A significant selling point is its robust construction and ability to handle demanding tasks. Common complaints often revolve around fuel economy, particularly with the gasoline engines, and maintenance costs associated with diesel models.

Engine

5.4L Triton V8

  • Spark Plug Thread Failure
    • Description/Symptoms: Difficulty removing spark plugs, stripped threads in the cylinder head when removing or installing spark plugs, misfires, and engine performance issues. This is more prevalent in early production 3-valve 5.4L engines.
    • Solution: Spark plug thread repair kits or cylinder head replacement.
    • Estimated Cost to Fix: $200 - $1500+ depending on the repair method and number of affected cylinders.
    • Recalls: None Found
  • Roller Follower Failure
    • Description/Symptoms: Ticking noises from the engine bay; Reduced engine performance; Engine misfires
    • Solution: Remove cylinder head and replace faulty roller followers. Replace camshaft if necessary.
    • Estimated Cost to Fix: $1500 - $3000+
    • Recalls: None Found

6.4L Power Stroke Diesel V8

  • EGR Cooler Failure
    • Description/Symptoms: Coolant loss, white smoke from exhaust, potential engine overheating, rough running. The EGR cooler is prone to cracking and leaking coolant into the exhaust system.
    • Solution: Replacement of the EGR cooler. Upgraded aftermarket EGR coolers are often recommended.
    • Estimated Cost to Fix: $800 - $2000+
    • Recalls: None Found
  • High-Pressure Oil Pump (HPOP) Failure
    • Description/Symptoms: Hard starting, no start condition, rough idling, and decreased engine performance.
    • Solution: Replacement of the HPOP.
    • Estimated Cost to Fix: $1000 - $3000+
    • Recalls: None Found
  • Injector Failure
    • Description/Symptoms: Misfires, rough idle, white/black smoke from the exhaust, fuel in the oil, and potential engine damage.
    • Solution: Injector replacement. It’s often recommended to replace all injectors at once to ensure balanced performance.
    • Estimated Cost to Fix: $400 - $800 per injector.
    • Recalls: None Found
  • Radiator Failure
    • Description/Symptoms: Radiator leaks causing overheating.
    • Solution: Radiator replacement.
    • Estimated Cost to Fix: $400 - $1000+
    • Recalls: None Found

6.8L Triton V10

  • Exhaust Manifold Bolts Breaking
    • Description/Symptoms: Exhaust leak noise (ticking or hissing), reduced fuel economy. The exhaust manifold bolts are prone to corrosion and breakage.
    • Solution: Removal of broken bolts and replacement with new hardware. In some cases, the manifold may need to be replaced if warped or damaged.
    • Estimated Cost to Fix: $300 - $1000+ depending on the severity and number of broken bolts.
    • Recalls: None Found

Transmission

5R110W TorqShift (All Engines)

  • Torque Converter Failure
    • Description/Symptoms: Shuddering during acceleration, slipping between gears, unusual noises from the transmission, and potential stalling.
    • Solution: Torque converter replacement. Often requires transmission removal.
    • Estimated Cost to Fix: $1500 - $4000+ including transmission removal and installation.
    • Recalls: None Found
  • Valve Body Issues
    • Description/Symptoms: Harsh shifting, delayed engagement, slipping between gears, and erratic shifting behavior.
    • Solution: Valve body replacement or rebuild.
    • Estimated Cost to Fix: $800 - $2500+ depending on the extent of the damage and repair method.
    • Recalls: None Found

Suspension

  • Ball Joint Failure
    • Description/Symptoms: Clunking noises from the front suspension, uneven tire wear, and loose steering.
    • Solution: Ball joint replacement.
    • Estimated Cost to Fix: $300 - $800+ per side.
    • Recalls: None Found
  • Leaf Spring Issues
    • Description/Symptoms: Sagging rear suspension, reduced load-carrying capacity, and rough ride. Leaf springs can weaken and break over time, especially with heavy use.
    • Solution: Leaf spring replacement.
    • Estimated Cost to Fix: $500 - $1500+ per side.
    • Recalls: None Found

Electrical

  • Alternator Failure
    • Description/Symptoms: Dimming lights, battery not charging, and potential stalling.
    • Solution: Alternator replacement.
    • Estimated Cost to Fix: $300 - $800+
    • Recalls: None Found
  • Instrument Cluster Issues
    • Description/Symptoms: Erratic gauge readings, flickering lights, and complete failure of the instrument cluster.
    • Solution: Instrument cluster repair or replacement.
    • Estimated Cost to Fix: $300 - $1000+
    • Recalls: None Found
  • Trailer Light Issues
    • Description/Symptoms: Trailer lights not working or flickering, blown fuses, and wiring harness damage.
    • Solution: Diagnosis and repair of the trailer wiring harness, replacement of damaged connectors or fuses.
    • Estimated Cost to Fix: $100 - $500+
    • Recalls: None Found

Exterior

  • Rust on Undercarriage/Frame
    • Description/Symptoms: Visible rust on the frame, suspension components, and other undercarriage parts, potentially leading to structural weakness.
    • Solution: Rust removal and prevention treatment, frame repair or replacement (in severe cases).
    • Estimated Cost to Fix: $200 - $5000+ depending on the severity of the rust.
    • Recalls: None Found
  • Cab Corner Rust
    • Description/Symptoms: Rust bubbles or holes appearing on the lower rear corners of the cab.
    • Solution: Body panel repair or replacement.
    • Estimated Cost to Fix: $500 - $2000+ per side.
    • Recalls: None Found

Interior

  • Blend Door Actuator Failure
    • Description/Symptoms: Inconsistent or no airflow from vents, clicking noises from behind the dashboard. The blend door actuator controls the temperature of the air coming from the vents.
    • Solution: Blend door actuator replacement.
    • Estimated Cost to Fix: $200 - $600+
    • Recalls: None Found

Summary

The 2009 Ford F-250, while a capable truck, does have some common issues that potential buyers should be aware of. Engine issues, particularly with the 6.4L Power Stroke diesel (EGR cooler, HPOP, Injectors) and the 5.4L Triton V8 (Spark Plug Thread Failure, Roller Follower Failure), can lead to significant repair costs. Transmission problems with the 5R110W TorqShift (Torque Converter Failure, Valve Body Issues) are also a concern. Suspension (Ball Joint, Leaf Spring) and electrical (Alternator, Instrument Cluster, Trailer Light) issues can add to the overall cost of ownership. Rust on the undercarriage and cab corners is a prevalent issue, especially in regions with harsh winters. The severity and cost of these issues can vary widely depending on the truck’s maintenance history and usage.

Ford, F-250
Ford F-250 2009
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