Which parts fail
Components named in complaints (fuel pump, injectors, fuel tank, hybrid and EV propulsion).
Mileage when the problem started
Owner reports
Selected complaints filed with NHTSA by 2006 Ford F-350 SD owners, lightly cleaned up (personal details are redacted by NHTSA).
This vehicles issues began with the galvanizing of the interior of the fuel tank flaking off and getting into the fuel system. It is a diesel. It has been to the shop to have the fuel tank replaced, injectors replaced, high pressure fuel pump replaced to name a few. All after the fuel tank problem. Since then the vehicle has shut down a number of times while on the highway. This is extremely hazardous to lose all power. Fortunately our drivers have been able to maneuver it off the highway before causing an accident. Ford has denied having a problem with their fuel tanks; however, when we checked around we found it to be quite common. In fact we had a difficult time securing a new tank because there were so many replacements being done. I believe Ford should step forward and admit there is an issue and deal with it. We discussed this with a zone manager and got nowhere.
There is a problem with the instrument cluster and the plugs. The dash goes dead, interior lights dont work. Power windows dont work radio shuts off. Vehicle runs improperly. The vehicle can be sitting or moving. I have done research and found Ford trucks from as early as 2002-2008 have this issue. Its unsafeand a know issuewith these year Ford truck f150-f450. A new dash is very expensive and used ones run the risk of the same issue happening again. The fix is simple, the cost is not. Theres videos on you tube dozens of forums. Excursion expeditions are also having the same issue. Im n the mid west its cold. I drove to pick up a coiple atvs an hour north. Halfway back issues happened while window was down. Drove home preg fiance 5yr old in the back -3 outside-15 windchill n we're drive 65mph to get home. That was misserable.
We own a Ford f-350 diesel pickup. It is a 2006, purchased new. It has had repeated power failure in the last two and half years, with other similar problems before that. Most recently we had it towed to our dealership to the tune of $2500.00 repair for fuel injectors and fuel injector modules. The problem, is safety for our lives and possibly others in our path. The vehicle has recurring engine failure causing it to die while driving. This has happened not only at a stop light, but through intersections, and on straight roads. We most recently had it die twice while pulling 2 horses in a trailer. Quickly shifting into neutral to restart to avoid an accident. It had to be towed to our home just last Thursday April 14th due to not restarting. Today, April 18th, we took this truck to our local Ford dealership as was recommended by Ford motor co. …
Purchased this vehicle less than a year ago and was originally very pleased. Suddenly we are now experiencing the death wobble as other have described. The violent shaking of the front end. This usually occurs when you are approaching the speed of 60mph. We do not have to hit a bump for it to happen. The other complaint, is that we bought this truck with very low mileage for the year, ran great, looked great, very pleased until this last month when the check engine light came on and it seems to sputter. Put some high quality fuel injector cleaner in the truck, thinking it May be a injector sticking. Nope, didn't fix the problem. Light never went off. Took it to a dealership, they tested it and came back with your fuel tank is deteriorating putting little metal shards in your engine. You are looking at a potential full engine rebuild costing a minimum of $6000. …
2006 Ford f-350 super duty diesel dump truck. This truck has been to crowley Ford in plainville ct. Over 50 times , yes that's right I said 50. The truck has been towed in no less than 6 times in 4 years. Many times leaving a crew of 5 stranded on the side of a highway. Ford technicians have not been able to determine what is wrong with the vehicle. Truck will suddenly loose power or just shut off. Ford has denied that there is anything wrong with this particular truck and motor but there are many contractors in our area that are having the same problem. Recently the truck sat at crowley Ford from March 1 through the end of March, their tech's nor fords tech's could figure out what was wrong with it. They are still denying that the gas tank delamination has any bearing on the situation. Completely disgusted with Ford and their lack of attention. …
The contact owns a 2006 Ford f-350 diesel. The vehicle at idle or driving down the road will without notice begin to buck, and suddenly increase RPM's and accelerate,or will stall. The vehicle was taken to the dealer and they replaced the erg valve. That corrected it for about 30 days and then it started it again. I took it back and they told me I would have to replace the manifold next, because the carbon that had built up in the manifold. After a lengthy discussion they admitted that this is a serious problem with this engine. The Ford engineers told them that this engine was designed by international for the european market and their diesel fuel is more refined than ours, stating that is what is causing the problem. Ford refuses to stand behind the problem. Just look at the internet about the 6.0 diesel engine and there is page after page stating the same problems. …
On 2006 Ford f350 vehicle with 6.0 diesel , the EGR coolers have defect that cause them to leak. After reading into this it is a common issue. I took the truck to Ford and they stated it is a very common problem and that I should look into an aftermarket cooler since the OEM unit fails quite often to the frequency of 2 to 3 within 100,000 miles. This repair is approx. 1000 to 2000 depending on if the head gaskets have been subsequently damaged as well. In my case I had to replace the oil cooler along with EGR cooler an EGR valve and head gasket. My total bill was $2095.63 Ford stated it is a very common problem and has TSB,s on this but has no plans for a voluntary recall. They did state that they will only compensate if instructed to due to a recall. These issues if researched online are more common then people needing any other parts on this vehicle. …
I have a 6.0 motor in my truck. Since last oct, 2010 I have had this truck in shop more times then what it is worth. I have had five fuel injectors replace, head gaskets, one head, rear end replace and now my turbo is going out on this motor. I also had the tow box replace. This truck has cost me more then what it is worth. I am very upset with this knowing that Ford was a good truck made in America., the total cost for all my problems ended up to be $18000.00 this is not right>>>>>>>>>>>>>>>>the truck not worth this my mileage is only 184xxx and hours are 4861.9 I feel like I got suck in a lemon from the factory. Never receive any information on this truck if their were problems.. Where I live there are about 200 or more people with the same problems.
Tl* - the contact has a 2006 Ford f-350 super duty, that continuously experiences severe loss of power. While driving on the highway, or going up a hill the vehicle stalls without any prior warning. The vehicle does not have enough power to pull the 5th wheel. The contact has taken the vehicle to the dealer and they stated that the injectors broke in half, dumping raw fuel into the hot oil of the motor. They also stated that there isn't any known repair for vehicle's failure. The contact can provide copies of invoice repair. Updated 2/27/2007 - the consumer has two identical vehicles and both failed in the same manner.
Tl* the contact owns a 2006 Ford f-350 super duty. The contact stated that the vehicle stalled while driving at various speeds on five separate occasions. The contact also stated that the failure was due to the delamination of the fuel tank, which created a flaky substance within the fuel tank. The vehicle was taken to an authorized dealer and the contact was informed that the fuel tank was delaminating. The contact replaced the fuel filter himself after the five separate failures. The manufacturer was made aware of the failure and offered no assistance. The failure mileage was 9,000. Updated 02/15/12 updated 04/26/12
Fuel System complaints in other F-350 SD years
Frequently asked questions
How common are fuel system problems on the 2006 Ford F-350 SD?
NHTSA has 21 complaints about the fuel & propulsion system of the 2006 Ford F-350 SD, 17% of the model year's 127 complaints. The component named most often is fuel injection system (2 mentions).
Is there a recall for 2006 Ford F-350 SD fuel system problems?
No. NHTSA lists no fuel & propulsion system recall for the 2006 Ford F-350 SD, though it has 1 recall for other components. If the problem is widespread, a repair may still be covered by an extended warranty or a manufacturer service bulletin — ask a dealer.
At what mileage do 2006 Ford F-350 SD fuel system problems start?
Half of the complaints with a recorded mileage happened before about 58,000 miles, and 21% before 25,000 miles.
Source: U.S. National Highway Traffic Safety Administration (NHTSA) — owner complaints through October 20, 2026, recalls and defect investigations; fuel economy from the EPA. Complaints are unverified reports and are not proof of a defect. How we rate model years.