In 2005, owners of Ford vehicles with 6.0L diesel engines were shocked to learn of a major design flaw and subsequent recall of their automobiles. The new engine design, which was implemented for model years 2004 and 2005 in order to help new vehicles meet increasingly tight emissions regulations, was initially considered a top contender for the title of "industry leader." Within a relatively short period of time, however, the vehicles were recalled and class action lawsuits were filed in direct response to the deeply flawed engine design. While many of the vehicles are still on the road today and have received the necessary updated parts, those which have not been repaired are notoriously unreliable and prone to failure. Recall and engine unreliability are a common complaint with these engines, with a variety of related issues.
Reasons for Ford 6.0 Recall and Engine Unreliability
There are several problems which can and often do result from the flawed design of this particular model if they haven't been repaired to meet recall standards.
- High Pressure Oil Pump Failure – The Power Stroke high-pressure oil pump pressurizes oil within the engine to upwards of 3,000 psi, which is then used to compress the fuel inside the injectors. One commonly recognized problem with the redesigned Ford engine is a tendency for the Power Stroke HPOP to malfunction. From complete failure to leak-prone seals, these pumps will often require replacement much sooner than those on comparable vehicles. While the pump is considered a wear item and, as such, is expected to require replacement at some point, the Power Stroke HPOP tends to fail much sooner.
- Sensor Failures – Both the injection control pressure and injection pressure regulator sensors have also shown a tendency for premature failure on this particular engine. The replacement components from Ford have shown no signs of being problematic, and can prevent failure of these sensors.
- EGR-Related Failure – One of the most common failures related to the design flaws in the 2004 and 2005 Power Stroke engines are exhaust gas recirculation valves and coolers. The EGR valve, which minimizes emissions by controlling the level of exhaust gases reintroduced to the engine, is prone to failure which can often be attributed to the buildup of soot. The EGR cooler, which acts as a heat exchanger to cool gases before they're reintroduced to the engine, is known to fail for the same reason. The coolers are also prone to failure which causes leakage of coolant into the exhaust system.
- Head Bolt Difficulties – Do the design of torque to yield head bolts and their one-use intention, they must be replaced completely if they're removed. If after-marketcomponents have been introduced to increase performance, pressure within the cylinder can rise to surpass the limits of the head bolts to cause failure of the head gasket.Because the exhaust gas recirculation system is known to cause higher-than-expected running temperatures, it can also lower the yield point or even warp cylinder heads.
Fortunately, Ford vehicles which feature these engines are as reliable as expected when they're properly repaired. Engine recalls and unreliability have plagued the reputation of the affected vehicles, but they're relatively simple fixes. If you've purchased a used vehicle within the affected model years or did not complete repairs related to the recall at the time of purchase, having your engine repaired can make it more reliable than it was when it left the showroom floor.
If you own a Ford and need repairs in the greater Tampa Bay area including Brandon, Riverview, Apollo Beach, Bloomingdale, Lithia and Fishhawk, call Absolute Auto Repair Inc today at (813) 409-3873
For more information about the Ford diesel engine problems visit http://www.bankspower.com/magazines/show/617-ford-power-stroke-6.0l-part-1-what-fails-and-why