2009 Ford F-450 Super Duty

The 2009 Ford F-450 Super Duty is a heavy-duty truck known for its towing and hauling capabilities. Engine options included the 6.4L Power Stroke diesel V8 and the 6.8L Triton V10. The 6.4L Power Stroke produces 350 horsepower and 650 lb-ft of torque. Both engines were paired with a 5-speed TorqShift automatic transmission. Owners generally appreciate the F-450’s power and towing capacity, but common complaints revolve around the 6.4L diesel’s reliability and fuel economy.

Engine

6.4L Power Stroke Diesel V8

• EGR Cooler Failure
  • Description/Symptoms: Coolant leaks, white smoke from exhaust, overheating, possible engine damage. Coolant may also leak into the engine oil.
  • Solution: Replace the EGR cooler. Upgraded, more robust aftermarket coolers are available.
  • Estimated Cost to Fix: $800 - $2000+
  • Recalls: None Found
• Injector Failure
  • Description/Symptoms: Rough running engine, misfires, poor fuel economy, black smoke from exhaust, possible engine damage if not addressed.
  • Solution: Replace faulty injectors. Ensure proper fuel filtration is in place to prevent recurrence.
  • Estimated Cost to Fix: $500 - $1500+ (depending on number of injectors needing replacement)
  • Recalls: None Found
• High-Pressure Oil Pump (HPOP) Failure
  • Description/Symptoms: Hard starting, no starting, stalling, poor engine performance.
  • Solution: Replace the HPOP.
  • Estimated Cost to Fix: $1000 - $2500+
  • Recalls: None Found
• Diesel Particulate Filter (DPF) Issues
  • Description/Symptoms: Reduced engine power, frequent regeneration cycles, “Check Engine” light, possible limp mode.
  • Solution: DPF cleaning or replacement. Deleting the DPF (though illegal in many areas) is a potential, but controversial, solution.
  • Estimated Cost to Fix: $500 - $3000+ (depending on the solution chosen)
  • Recalls: None Found

6.8L Triton V10

• Spark Plug Issues
  • Description/Symptoms: Misfires, rough idle, reduced power, “Check Engine” light. The 2-valve cylinder head design can cause spark plugs to eject from the cylinder head.
  • Solution: Replace spark plugs. Installation of thread repair inserts (such as Time-Serts) to the cylinder heads to prevent future ejection.
  • Estimated Cost to Fix: $200 - $1000+ (depending on severity and repairs needed)
  • Recalls: None Found

Transmission

5R110W TorqShift 5-Speed Automatic

• Valve Body Issues
  • Description/Symptoms: Harsh shifting, slipping between gears, delayed engagement.
  • Solution: Replace or rebuild the valve body. Upgraded valve bodies are available.
  • Estimated Cost to Fix: $500 - $1500+
  • Recalls: None Found

Suspension

• Leaf Spring Sagging
  • Description/Symptoms: Rear end sagging, reduced towing capacity, poor ride quality.
  • Solution: Replace leaf springs. Upgraded springs are available for increased capacity.
  • Estimated Cost to Fix: $500 - $1500+
  • Recalls: None Found
• Ball Joint Wear
  • Description/Symptoms: Loose steering, wandering, clunking noises from the front end.
  • Solution: Replace worn ball joints.
  • Estimated Cost to Fix: $300 - $1000+ (per axle)
  • Recalls: None Found

Electrical

• Instrument Cluster Problems
  • Description/Symptoms: Gauges not working, flickering, dim display.
  • Solution: Replace or repair the instrument cluster.
  • Estimated Cost to Fix: $300 - $800+
  • Recalls: None Found
• Alternator Failure
  • Description/Symptoms: Dimming lights, dead battery, vehicle stalling.
  • Solution: Replace the alternator.
  • Estimated Cost to Fix: $200 - $600+
  • Recalls: None Found

Exterior

• Rust (Cab Corners, Rocker Panels, Wheel Wells)
  • Description/Symptoms: Visible rust, especially in areas prone to moisture and road salt exposure.
  • Solution: Rust repair or panel replacement.
  • Estimated Cost to Fix: $500 - $3000+ (depending on severity)
  • Recalls: None Found

Interior

• No Issues Found

Summary

The 2009 Ford F-450 Super Duty, particularly with the 6.4L diesel, can suffer from several potentially expensive issues, primarily related to the engine and emissions systems. EGR cooler, injector, and HPOP failures can be costly to repair, as can transmission problems. While the V10 has fewer major issues, spark plug problems are common. Suspension and electrical issues are also possible. The overall cost of ownership can be high due to the potential for these significant repairs. Potential buyers should thoroughly inspect any used F-450, especially the 6.4L diesel, and consider a pre-purchase inspection by a qualified mechanic familiar with these trucks.