4 Ford 3.0 Diesel Problems & How to Fix Them

Short answer: The most common problems with the Ford 3.0L Power Stroke diesel engine are EGR Cooler Problems, DPF Clogging, EGT Sensor Failure, and Crankshaft Bearing Failure. These issues happen due to the demands placed on modern diesel emissions control systems.

Diesel engine components like the EGR system, DPF, and EGT sensors are designed to reduce pollutants but often operate under high temperatures and pressures, which can lead to carbon buildup, sensor malfunctions, and wear over time.

Specific driving conditions—such as frequent short trips, idling, or low speeds—can exacerbate these issues by preventing optimal exhaust temperatures, which are necessary for the emissions systems to function properly and self-clean.

Continue reading to learn more about these issues and how to address them effectively

#1: EGR Cooler Problems

• What it is: The EGR (Exhaust Gas Recirculation) cooler helps reduce nitrogen oxide emissions by cooling and recirculating a portion of the exhaust gases back into the engine.
• Potential causes: Carbon buildup; Coolant leaks; Faulty EGR valve
• Symptoms: Engine overheating; Loss of power; Increased emissions; Check engine light
• Potential fixes: To address EGR cooler issues, you may need to start by cleaning or replacing the cooler itself, especially if carbon buildup is present. Next, inspect the system for any coolant leaks that could be disrupting the EGR’s function and repair these as necessary. If the EGR valve is defective, replacing it can help restore proper operation and reduce emissions.

#2: DPF Clogging

• What it is: The Diesel Particulate Filter (DPF) captures and stores exhaust soot to reduce emissions from diesel engines.
• Potential causes: Short driving cycles that prevent proper regeneration; Poor fuel quality; Defective sensors
• Symptoms: Loss of power; Increased fuel consumption; Warning lights on the dashboard; Regeneration issues
• Potential fixes: A forced regeneration can often clear out the accumulated soot from a clogged DPF, allowing it to function properly again. If clogging is severe, however, cleaning or replacing the DPF may be necessary. Switching to higher-quality fuel can help reduce soot accumulation and prevent future clogging, and it’s also essential to check and replace any faulty sensors that might be impacting the regeneration process.

#3: EGT Sensor Failure

• What it is: The Exhaust Gas Temperature (EGT) sensor measures the temperature of exhaust gases to help manage engine performance and emissions.
• Potential causes: Sensor wear and tear; Electrical issues; Contamination from exhaust gases
• Symptoms: Incorrect temperature readings; Engine performance issues; Increased emissions; Check engine light
• Potential fixes: Replacing the EGT sensor is the primary solution if it’s showing inaccurate readings or has failed. Additionally, checking the wiring for issues and repairing any damage can help ensure the sensor functions correctly. Proper installation of the sensor should also be confirmed, as an improperly installed sensor can lead to continued malfunctions or inaccurate readings.

#4: DPF Clogging

• What it is: Crankshaft bearings support the crankshaft and allow it to rotate smoothly within the engine block.
• Potential causes: Insufficient lubrication; Contaminated oil; Manufacturing defects
• Symptoms: Knocking noises from the engine; Low oil pressure; Metal shavings in the oil; Engine seizure
• Potential fixes: Replacing worn or damaged crankshaft bearings is typically necessary to resolve these issues. To prevent further problems, ensure the engine has proper lubrication by regularly checking oil levels and using the appropriate oil grade. High-quality oil and regular oil changes can help prevent contamination that might affect the bearings. If manufacturing defects are suspected, thorough inspection and addressing these issues may also be required to protect the engine.

Is There a Ford 3.0 Diesel Recall?

No, there are currently no Ford 3.0 Diesel Recalls. Ford engines have previously been the subject of recalls in recent years, however.

In September 2024, Ford and Lincoln issued a recall for over 90,000 vehicles equipped with 2.7L and 3.0L EcoBoost engines due to potential engine failures.

The affected models include the 2021-2022 Ford Bronco, F-150, Edge, Explorer, and the Lincoln Nautilus and Aviator.

The issue in this recall stems from defective engine intake valves made from a material called Silchrome Lite, which can become excessively hard and brittle if overheated during machining. This can lead to the valves breaking and potentially causing engine failure.

Ford has instructed dealers to perform an engine cycle test and replace the engines if necessary. Recall notices were sent to affected drivers by October 7, 2024.

For more information, you can contact Ford customer service at 1-866-436-7332, referencing internal Ford recall number 24S55.

Who Pays for My 3.0 Diesel Problems?

If your Ford 3.0L Power Stroke diesel engine is experiencing issues, who pays for the repairs depends on several factors:

• Warranty Coverage: If your vehicle is still under its original manufacturer warranty, Ford typically covers repair costs for problems included withinin the warranty terms. This often includes coverage under the powertrain warranty, which protects the engine and related components.
• Recalls: If your issue is tied to an official recall, Ford will cover the repair costs. For instance, the previously mentioned EGR cooler recall would be fully covered by Ford.
• Extended Warranty or Service Contracts: If you have an extended warranty or service contract, these may help cover repair costs even after the standard warranty period has ended.
• Out-of-Warranty Repairs: If your vehicle is no longer under warranty and the problem isn’t part of a recall, repair costs are usually your responsibility. However, Ford may sometimes offer goodwill repairs or partial coverage for certain known issues, even if your vehicle is out of warranty.

To confirm your specific coverage and options, it’s always a good idea to reach out to your local Ford dealership or the Ford customer service team.

Why a Lemon Law Attorney May Be Beneficial

If you’re dealing with persistent problems with your Ford 3.0 Power Stroke diesel engine—especially if repeated attempts to fix the issues under warranty have failed—consulting a Lemon Law attorney can be a smart move.

A skilled attorney specializing in Lemon Law understands the state-specific rules that can help you determine if your vehicle qualifies as a lemon.

Legal proceedings can be challenging, with detailed paperwork and strict deadlines that must be met to move your case forward.

An experienced Lemon Law attorney can ensure that everything is correctly filed, saving you from costly errors and making the entire process less overwhelming.

If you’re up against a manufacturer’s legal team, an attorney can negotiate on your behalf, leveraging their expertise to secure the best possible outcome, whether it’s a refund, a replacement vehicle, or a financial settlement.

For those facing unresolved issues with their Ford 3.0 Power Stroke diesel engine, Lemon Law attorneys can offer assistance.

A knowledgeable attorney can help Ford 3.0 diesel owners pursue compensation, a replacement vehicle, or even a refund if their engine qualifies as a lemon.

Since 2009, the Lemon Law Experts have successfully represented clients with various vehicle-related problems, including ongoing engine failures.

If you’re struggling with persistent issues affecting your Ford diesel engine, contact Lemon Law Experts today to explore your legal options and secure a fair resolution.