Ford F150 Diesel Problems: Common Issue

Some common Ford F150 diesel problems are crankshaft bearing failing, EGR Cooler problems or the DPF getting clogged up. You can also expect problems in the fuel system with malfunctioning fuel injectors and fuel pumps. Although most of these problems are highly unlikely to occur, you should still need to watch out for the symptoms. 

The solution for most of the problems especially in the 2018 Ford F150 is replacing the damaged parts. To get a clear idea of most of these problems, their symptoms, and methods to solve them, let’s get started. 

Common Ford F150 Diesel Problems

Now the table below shows some of the common issues you will find with the Ford F150 diesel.

Problems	Symptoms	Solutions
Crankshaft Bearing Failure	1. Engine Knocking Noise 2. Increased vibration 3. Rumbling or thumping type noise	Replace Crankshaft Bearing
Exhaust gas recirculation EGR and EGR Cooler Problem	1. Fault code P0401 2. White exhaust smoke	Replace EGR Cooler
Diesel Particulate Filter or DPF Clogging	1. Reduced engine power 2. Abnormal throttle response	Unclog DPF Filter
Exhaust Gas Temperature or EGT Sensor Failure	1. Decreased fuel efficiency 2. Check engine light coming on	Replace EGT Sensor
Faulty Fuel Injector	1. Engine Misfiring Rough Idling 2. Engine Stalling	Replace Fuel Injector
Faulty Fuel Pump	1. Engine Starting Problem 2. Decreased engine power	Replace Fuel Pump

With this, let us dive into the details of each of the problems, and steps to solve them. 

Problem 1: Crankshaft Bearing Failure

The main reason for this is the drop in the static pressure of the oil. When this pressure drops below the vapor pressure at the working temperature then vapor bubbles form in the oil. As the pressure increases, the bubble collapses leading to the eventual wear of the crankshaft bearing.

However, some other reasons for the crankshaft bearing to fail are the lack of lubrication, formation of dirt in the bearing surface, and increases in the surface contact between the bearing and the bore. 

Symptoms: 

Following are some of the symptoms of failing crankshaft bearing on a Ford F15O diesel. 

1. Knocking noises from the engine
2. Increased vibration from the bearing
3. Metal shaving and copper sheen in the oil
4. Rumbling or thumping type noise from the engine 

Solution: Replace Crankshaft Bearing 

If you find out that the crankshaft bearing is worn out then you need to replace it. This can be a slightly complicated process but you can replace the bearing while the crankshaft still remains in the installed position. 

This Change Main bearings with crankshaft still installed is a good guide to help you out with the process. 

However, it is understandable if you want it diagnosed and replaced by a professional. In that case, it is going to cost you around $165 to $190 with labor costs ranging from $80 to $100 and parts ranging from $85 to $90. 

Problem 2: EGR and EGR Cooler Problems

EGR and EGR cooler helps to reduce the pollutants inside the engine combustion chamber by lowering the temperature. To lower the temperature it dilutes the mixture using a small amount of inert exhaust gas. 

The main reason for the EGR cooler to fail is the stress from extreme temperatures. Through continued exposure to the repeated cycling of thermal stress, the EGR cooler fails.

Symptoms:

Following are some of the symptoms of EGR and EGR cooler problems on the Ford F150. 

1. Fault Code P0401
2. White exhaust smoke
3. Reduced coolant in the overflow bottle
4. External coolant leaking
5. Check engine light

Solution: Replace EGR Cooler

The solution here is to replace the EGR Cooler. Although technically the process can be discouraging due to its complexity, there are some easy guides out there to help replace the EGR cooler. 

Problem 3: DPF Clogging

Although not part of the engine, Diesel Particulate Filter or DPF helps to reduce the particulate from the emission. As a result of long-term exposure to pollutants, it becomes clogged. But the problem increases more rapidly if you regularly keep driving short distances. 

This is because when you drive only a short distance, your engine does not get enough time to go to its optimum temperature, the soot remains unburnt and keeps clogging up the DPF. 

Symptoms: 

Look for the following symptoms if you think that the DPF is clogged. 

1. Bad throttle response
2. Reduced engine power
3. Black smoke coming from the exhaust
4. Increased exhaust fumes
5. Decreased fuel economy
6. Bad smell from the engine

Solution: Unclog DPF Filter

To fix this issue, you need to unclog the DPF filter. It means you have to manually clean the DPF filter. This Manually cleaning the DPF on a Ford 6.7L Super Duty is a good source to give you an idea of the process. 

Problem 4: EGT Sensor Failure

Exhaust Gas Temperature sensor or EGT sensor helps to provide the thermal data of the exhaust and in the long term protect the engine from getting damaged. When you use the truck for heavy load activity such as towing or just over-rev the engine, then the EGT sensor becomes prone to getting cracked or damaged. 

Symptoms: 

Following are the symptoms of EGT sensor failure. 

1. Decrease in fuel efficiency
2. Check Engine light coming on

Failed emission tests are another symptom that you need to watch out for. It means that your car has failed to meet the emission standard set by the state’s legal limits. If your car fails this test, then you need to take it to a servicing center as soon as possible and get the EGT sensor replaced. 

Solution: Replace EGT Sensor

Following are some of the steps for replacing the EGT sensor for a 6.7 L Engine. 

Step 1: Pop the hood of the 2015 Ford F-350 with a 6.7-liter Power Stroke diesel engine.

Step 2: Loosen and remove the stock EGT probe using a 14mm wrench.

Step 3: Take off the plate holding the stock EGT probe, using a 5mm Allen wrench to remove the bolts.

Step 4: Retain the metal exhaust gasket from the plate for reuse.

Step 5: Obtain a GlowShift EGT plate adapter.

Step 6: Place the adapter plate on the exhaust manifold, aligning it correctly and using the metal gasket for a proper seal.

Step 7: Secure the adapter plate with the provided bolts.

Step 8:Apply anti-seize compound to the adapter threads and screw in the SCT probe using a 17mm wrench.

Step 9: Apply anti-seize compound to the factory EGT probe threads and insert it into the adapter, tightening with a 14mm wrench.

Step 10: Route the cable, ensuring it is secure and away from moving or hot engine parts.

Watch this Ford 6.7 SCT EGT Probe Install to get an idea of replacing the EGT sensor in your f150. 

Problem 5: Faulty Fuel Injector 

Fuel injectors pressurize and spray fuel into the air that has been compressed into the combustion chamber. Similar to most components in the fuel system, the fuel injector starts to underperform due to carbon buildup. This happens from repeated exposure to the fuel. However, the problem exacerbates when the fuel is low in quality. 

Symptoms: 

Following are some of the symptoms of a faulty fuel injector 

1. Engine Misfiring
2. Rough Idling
3. Engine Stalling
4. Reduced Fuel Economy
5. Check Engine Light Coming on

Solution: Replace the Fuel Injector

Once you identify that the fuel injector is clogged or malfunctioning before you go on to replace the fuel injector, check the quality of the fuel. You can watch out for the signs of dirty fuel like a decrease in fuel efficiency. But you can also get the sample fuel tested. Here’s a good guide Testing Diesel Fuel Cleanliness with Fleetguard FK36000 Portable Fuel Testing Kit.

It is crucial to address this because if the fuel quality remains bad then changing the fuel injector should not be the first priority rather cleaner fuel should be used.  

Assuming that the fuel quality is good, the following are the steps of replacing the fuel injector on the Ford F150 Diesel.

Tools Required:

1. Wrench
2. 8mm socket
3. 10mm socket
4. Screwdriver

Step 1: You need to start by releasing the fuel pressure line by removing the cap and Schrader valve on the fuel rail. 

Step 2: Next you need to disconnect the fuel rail. Start by removing the 10mm screws from the rear side of the engine. Lift the fuel rail off by prying between the injector and the fuel rail.

Step 3: Now remove the injectors from the fuel rail by disconnecting the clip. 

Step 4: Now install the new injectors by wiping the top of the seal with motor oil and sliding it into place.

Step 5: After the injectors are installed, put back the fuel rail over the injectors by starting from the rearmost one to the front.

Step 6: Finally, re-install the two 10mm screws and connect the Schrader valve back on. 

Now, if you want to learn the visually then go for this How To Replace Fuel Injectors 97-04 Ford F150 video. 

Problem 6: Faulty Fuel Pump

The fuel pump helps to transfer the fuel from the fuel tank to the combustion chamber where it is mixed with the already compressed air. Through repeated use, there is sludge buildup and other contaminants in the fuel pump. 

This makes the fuel pump underperform. When it underperforms then the truck will fail to maintain good fuel pressure. This lack of pressure causes a multitude of problems for the truck. 

Symptoms: 

Following are some of the symptoms of a faulty fuel pump.

1. Starting Problem
2. Loss in Engine Power
3. Decreased Fuel Efficiency
4. Engine Stalling

Solution: Replace the Fuel Pump

The solution here is to replace the fuel pump of the Ford F150 Diesel. Following are the steps for replacing the fuel pump.

Tools Required: 

1. Jack 
2. Jack stand
3. Hose clamp pliers or Screwdrivers
4. Ratchet wrench set

Step 1: Begin by unplugging the fuel pump driver module’s electrical connector. It is mounted on the rear cross member.

Step 2: Start the engine and let it run until it stops. Disconnect the negative battery cable and secure it to prevent accidental reconnection.

Step 3: Apply the handbrake and chalk the rear wheels to prevent the vehicle from rolling.

Step 4: Place a floor jack under the frame rail, raise the front of the truck, and support it with a jack stand.

Step 5: Disconnect the fuel supply line and evap vapor line quick connect fittings at the front of the fuel tank. Soak up any fuel spillage with shop rags.

Step 6: On top of the fuel tank, disconnect the sensor electrical connectors and unclip the wiring harness from the vapor tubes.

Step 7: Remove the safety clip and disconnect the fuel tank filler hose vent tube quick connect fitting from the top of the fuel pump module.

Step 8: Slide out the safety tab and disconnect the pump module electrical connector. Disconnect any remaining evap sensor connectors.

Step 9: Support the fuel tank with a suitable lifting device and remove the fuel tank strap bolts. Carefully lower the fuel tank while checking for any remaining connections.

Step 10: Use compressed air to blow off debris from the area on top of the pump module. Disconnect the fuel line connections and remove the fuel pump assembly from the tank by turning the locking ring counterclockwise. Replace the o-ring and clean the o-ring surface.

If you want a visual demonstration of the overall changing of the Ford F150 fuel pump then check this How to Replace the fuel pump on a Ford F-150 2015 to 2017 out.

Is F150 Diesel Worth It?

Yes, the Ford F150 diesel is worth it when it comes to good performance in towing and fuel efficiency. The truck shows an impressive maximum torque of about 1750 rpm whereas if you combine this with the 10-speed automatic transmission, then the truck can tow up to 11,400 pounds. 

Now, in a general sense, it may not be the best performance but it shines when it comes to fuel consumption rate. Ford F150 Diesel comes with a fuel consumption rating that is quite impressive. In fact, it can go about 30 miles per gallon while cruising. 

This combination of good towing ability along with an efficient fuel consumption rate make the Ford F150 diesel a good choice to consider. However, now that it has been canceled, if you are still looking for a truck primarily for good towing ability then you can go for the PowerBoost hybrid engine as it comes with even better towing ability and fuel economy. 

Is Ford F150 Diesel Canceled? 

Yes, unfortunately, Ford F150 Diesel has been canceled. It has not been canceled for any technical shortcoming; rather it was the overwhelming demand for Ecoboost V6 engine that led to the F150 diesel getting canceled. Ford F150 released its diesel version in 2018  where they incorporated the 3.0 L V6 Turbo diesel engine. It was continued up to F150 2021, until in July 2022, the manufacturers announced that they would no longer continue with this version despite its impressive fuel consumption rating.

This is exactly what the manufacturers stated when asked for the reason for ceasing the operations for Ford F150 Diesel. F150 Diesel was widely accepted because of its towing and heavy-duty capability so the announcement definitely made a lot of people disappointed.  

FAQs

What Kind of Cooling System Does the Ford F150 Diesel Have?

Ford F150 Diesel uses a combination of a viscous controlled mechanical fan and the radiator shutter to cool the 3.0 L power stroke diesel engine. This helps the cooling system to move more air through the radiator and intercooler. Therefore, when using it in extreme conditions or heavy duty activities, the Ford F150 diesel will have an advantage. 

Are There Any Recalls Related to Ford F150 Diesel Problems?

No, there has not been any recall related to Ford F150 Diesel engine. Although there have been recalls related to the suspension, braking, tire or the electric system, none of them were related to the diesel engine itself. 

What is the Warranty on Ford F150 Diesel Engine?

The warranty on the Ford F150 Power Stroke diesel engine is for 05 years or 1,00,000 miles. Of course whichever comes first. This has been the warranty that is covered by the Ford manufacturer. 

Conclusion

Hopefully, now you must be clear on the Ford F150 Diesel problems. Although discontinued, make sure to watch out for the problems discussed here. Some of the solutions are relatively simple and you can solve them. However, if you want to buy the Ford F150 diesel specifically for the specs of the Power Stroke engine then we say go for it.