The 2007 F-250 Super Duty is a split-personality truck: the 5.4L gas V8 is generally reliable but underpowered for heavy towing, while the 6.0L Power Stroke diesel is notoriously problematic and expensive to maintain, with catastrophic failures common at modest mileage.
6.0L Power Stroke EGR Cooler Failure
Common · high severityTypical onset: 60,000-120,000 mi
Symptoms: white smoke from exhaust, coolant loss with no visible leak, overheating under load, milky oil on dipstick
Fix: EGR cooler cracks internally, dumping coolant into exhaust and intake. Requires removing cab or pulling engine to replace cooler, often combined with EGR valve and oil cooler while you're in there. 12-16 hours labor with cab removal, 20+ hours pulling engine. Many shops now delete EGR systems where legal.
Estimated cost: $2,800-4,500
6.0L Power Stroke Head Gasket and Head Bolt Failure
Common · high severityTypical onset: 80,000-150,000 mi
Symptoms: loss of coolant, white exhaust smoke, rough idle when cold, bubbles in coolant reservoir, hard starting when warm
Fix: Factory TTY head bolts stretch and lose clamping force, allowing head gaskets to fail. Requires cab removal or engine pull, surface heads, install ARP studs (never reuse OEM bolts), new gaskets. While apart, replace EGR cooler and oil cooler. 24-30 hours labor total.
Estimated cost: $4,500-7,000
6.0L Power Stroke Oil Cooler Failure
Common · high severityTypical onset: 70,000-130,000 mi
Symptoms: oil in coolant or coolant in oil, rapid overheating, poor heat from cab heater, oil pressure fluctuations, chocolate milk on dipstick
Fix: Oil cooler located in valley under intake manifold fails, mixing oil and coolant. Requires intake removal, flush entire cooling system after repair. Often done preventively during EGR cooler or head gasket jobs. 8-10 hours labor standalone.
Estimated cost: $1,800-2,800
6.0L Power Stroke Fuel Injection Control Module (FICM) Failure
Common · medium severityTypical onset: 90,000-180,000 mi
Symptoms: extended cranking before start, especially cold, rough idle, loss of power, multiple injector codes, stalling at idle
Fix: FICM provides 48V to injectors; internal board cracks cause weak or no signal. Located on driver side valve cover. Can be repaired (solder work) or replaced. 1.5-2 hours labor for replacement.
Estimated cost: $600-1,200
6.0L Power Stroke Turbocharger Failure
Occasional · high severityTypical onset: 120,000-200,000 mi
Symptoms: loss of boost/power, excessive black smoke, oil leaking from turbo, loud whistle or grinding noise, Check Engine light with boost codes
Fix: Variable-vane turbo experiences vane sticking or bearing failure, often accelerated by EGR system dumping soot into intake. Requires turbo replacement or rebuild. 6-8 hours labor.
Estimated cost: $1,800-3,200
Transmission Oil Cooler Line Failure (All Engines)
Occasional · medium severityTypical onset: 100,000-180,000 mi
Symptoms: transmission fluid leak at radiator, pink fluid visible under truck, transmission slipping or delayed engagement, overheating transmission
Fix: Steel lines rust through at radiator connections or along frame rail. If cooler ruptures internally, coolant mixes with trans fluid requiring full flush. Line replacement 2-3 hours; if internal cooler fails add radiator replacement and trans flush, 5-6 hours total.
Estimated cost: $400-1,200
5.4L Triton Spark Plug Blowout
Occasional · medium severitySymptoms: sudden misfire, loud popping from engine, Check Engine light, loss of compression on one cylinder, visible damage to spark plug
Fix: Aluminum heads have insufficient thread engagement; spark plugs can blow out stripping threads. Requires timesert or helicoil repair, sometimes head removal if damage is severe. 2-4 hours per plug depending on damage.
Estimated cost: $400-1,000
Ball Joint Failure (All Engines)
Common · high severityTypical onset: 80,000-120,000 mi
Symptoms: clunking over bumps, wandering steering, uneven tire wear, steering wheel vibration, visible play when jacked up
Fix: Both upper and lower ball joints wear, especially on 4WD models with heavy use. Failure can cause wheel separation. Press-in style requires C-frame press or replacement knuckles. 4-6 hours for both sides, all four joints.
Estimated cost: $800-1,400
Buy the 5.4L gas for reliability and accept the power limitations; avoid the 6.0L diesel unless it's already bulletproofed and you have a $5K repair fund—these engines destroy wallets as reliably as they haul loads.
AI-assisted summary drawn from NHTSA recall data, our labor-times database, and platform knowledge. Not a substitute for a pre-purchase inspection on a specific vehicle.