2009 Ford F-450 sd problems

General information about Ford-F-450 sd
Overview of popular issues
Analysis of common problems
Сomplaints list
Recalls list

The Ford Super Duty (also known as the Ford F-Series Super Duty) is a series of heavy-duty pickup trucks produced by the Ford Motor Company since the 1999 model year. Slotted above the consumer-oriented Ford F-150, the Super Duty trucks are an expansion of the Ford F-Series range, from F-250 to the F-600. The F-250 through F-450 are offered as pickup trucks, while the F-350 through F-600 are offered as chassis cabs.

Rather than adapting the lighter-duty F-150 truck for heavier use, Super Duty trucks have been designed as a dedicated variant of the Ford F-Series. The heavier-duty chassis components allow for heavier payloads and towing capabilities. With a GVWR over 8,500 lb (3,900 kg), Super Duty pickups are Class 2 and 3 trucks, while chassis-cab trucks are offered in Classes 3, 4, 5, and 6. The model line also offers Ford Power Stroke V8 diesel engines as an option.

Ford also offers a medium-duty version of the F-Series (F-650 and F-750), which is sometimes branded as the Super Duty, but is another chassis variant. The Super Duty pickup truck also served as the basis for the Ford Excursion full-sized SUV.

The Super Duty trucks and chassis-cabs are assembled at the Kentucky Truck Plant in Louisville, Kentucky, and at Ohio Assembly in Avon Lake, Ohio. Prior to 2016, medium-duty trucks were assembled in Mexico under the Blue Diamond Truck joint venture with Navistar International.

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Common 2009 Ford F-450 sd problems

Based on complaints from owners of the Ford F-450 Super Duty 2009, several common problems have been reported. Here is a detailed list of these issues:

High Pressure Fuel Pump Wiring: Owners have reported issues with the high-pressure fuel pump wiring, leading to a no-start condition. The wires can get chafed, interrupting the signal and causing the fuel not to reach the engine, resulting in starting problems.
Intercooler Couplers: Another common problem is the failure of intercooler couplers, causing a significant loss of power due to the boost pressure leaking out. This can lead to the engine running without proper boost pressure, affecting performance.
Thermostat Bypass: Some owners have experienced problems related to the thermostat bypass, which can impact the engine's cooling system and overall performance.
EGR Cooler: Issues with the EGR cooler have been reported, affecting the vehicle's emissions control system and potentially leading to performance issues.
Death Wobble - Worn Steering Components: The "Death Wobble" is a serious issue related to the solid front axle, causing violent shaking of the steering wheel due to an imbalance. This can be caused by worn steering components and can be a safety concern for drivers.

These problems can impact the performance, reliability, and safety of the Ford F-450 Super Duty 2009. Owners experiencing these issues should consult with a qualified mechanic or dealership to address and resolve these concerns promptly.

Is the 2009 6.4 Powerstroke a good engine?

The 6.4L Powerstroke is perhaps the best you could achieve from the previous 6.0L version in terms of reliability. Unfortunately, the 6.4 still had a lot of similarities in the design with the problematic 6.0L predecessor.

What is the most common problem with the 6.4 Powerstroke?

6.4 Powerstroke Problems

Oil Dilution. This is a very common problem in 6.4 Powerstroke engines. ...
Leaky Radiator. If you see a puddle of coolant underneath your 6.4 truck, it's probably not a blown head gasket. ...
Bad Fuel Economy. ...
Other DPF Problems. ...
Cracked Up-Pipes. ...
Clogged EGR Coolers. ...
Piston Failure.

What year Ford f450 is best?

The Best Model Years to Buy a Ford F-450 Super Duty

With the 2022, you would only pay, on average, 100% of the price as new, with 100% of the vehicle's useful life remaining. The 2021 and 2019 model years are also attractive years for the F-450 Super Duty, and provide a relatively good value.

What is the life expectancy of a 6.4 Powerstroke engine?

Powerstroke Engine Average Life Expectancy:

7.3L400,000-500,000 miles. 6.0L200,000-300,000 miles. 6.7L200,000-300,000 miles. 6.4L150,000-200,000 miles.

Is the 2009 6.4 Powerstroke a good engine?

What is the biggest problem with the 6.4 power stroke?

ProSource Diesel takes a look at some of the most common problems with the 6.4 Powerstroke, what causes them, and what can fix them.

Oil Dilution. This is a very common problem in 6.4 Powerstroke engines. ...
Leaky Radiator. ...
Bad Fuel Economy. ...
Other DPF Problems. ...
Cracked Up-Pipes. ...
Clogged EGR Coolers. ...
Piston Failure.

What year Ford f450 is best?

The Best Model Years to Buy a Ford F-450 Super Duty

How long will a 6.4 Powerstroke last?

150,000-200,000 mile

The 6.4L Powerstroke Engine has become notorious for running into problems once it reaches the 150,000-200,000 mile range, but there are some things you can do to improve its longevity and drive down costs in replacements and labor.

2009 Ford F-450 sd car problems categorized by type of issue

After analyzing all complaints sent to the NHTSA and researching popular Ford F-450 sd problems, we found that the most common problems with these 2023 model year vehicles are:

Power train problems
Unknown or other problems
Engine problems
Tires problems
Engine and engine cooling problems

The graph below shows statistics for all 2009 Ford F-450 sd vehicle components and the number of complaints received.

2009 Ford F-450 sd complaints

The NHTSA has received 3 complaints about various vehicle components related to the 2009 Ford F-450 sd.

2015-01-06

POWER TRAIN,UNKNOWN OR OTHER,ENGINE PROBLEM

Date Of Incident: 2014-12-23
VIN: 1FDAF46R59E
Components: POWER TRAIN,UNKNOWN OR OTHER,ENGINE
Summary: MY 2009 FORD F-450 TRUCK CURRENTLY IS AT MY LOCAL DEALER WHICH IS KERRY FORD IN CINCINNATI WITH A BAD MOTOR AND BAD REAR DIFFERENTIAL. THE MOTOR HAS ONE FAILED LIFTER AND 2 FAILED ROCKER ARMS. THE REAR END HAS A BAD PINION BEARING WHICH SENT METAL THROUGH THE DIFFERENTIAL WHICH DESTROYED THE GEARS. THE MOTOR IS A 6.4 LITER POWERSTROKE DIESEL AND THE REAR END IS A DANA 110. THE MOTOR ISSUES ARE COMMON KNOWLEDGE TO BOTH FORD REPAIR FACILITIES AS WELL AS FORD CORPORATE OFFICES. THE REAR END IS ALSO A KNOWN ISSUE BOTH WHICH CAN BE CONFIRMED BY ANY POWERSTROKE CERTIFIED MECHANIC. THE MOTOR ISSUE WAS CONFIRMED BY 2 SEPERATE SHOPS TO WHICH I WAS SUGGESTED BY MY REPAIR FACILITY AND MECHANIC TO CONTACT FORD CORPORATE FOR A "GOODWILL POLICY" TO COVER THIS ISSUE EVEN THOUGH IT IS CURRENTLY PAST THE WRITTEN WARRANTY DUE TO THE FACT FORD HAS COVERED NUMEROUS ENGINE FAILURES BECAUSE OF THIS INHERENT ISSUE. THE REGIONAL FORD REP DENIED ANY ASSISTANCE TO THIS ISSUE WHEN EVEN THE DEALER HAS SAID ITS COMMON AND SHOULD BE ADDRESSED. UPON FINDING OUT THE DECISION WHICH TOOK 2 WEEKS OF MY TRUCK BEING IN THE SHOP I WAS ADVISED TO CONTACT THE CORPORATE CUSTOMER RELATIONS LINE WHICH I DID TO TRY TO TALK TO MY REGIONAL MANAGER BUT AS PER FORDS POLICY I CANNOT GET A DIRECT CONTACT TO ANY REGIONAL REP OR ANYONE ABOVE THIS PERSON. MY DEALERSHIP SERVICE MANAGER STATES HE CANT EVEN GET A DIRECT NUMBER TO THE REP HIMSELF SO BASICLY FORD INSULATES ITSELF FROM ANY DIRECT CONTACT FOR A CONSUMER TO RESOLVE ANY ISSUES. I HAVE NUMEROUS DOCUMENTED FAILURES OF THIS VEHICLE WHILE UNDER WARRANTY WHEN IT HAS BEEN MAINTAINED TO THE VERY BEST SCHEDULE. THIS ISSUE IS AN INHERENT DESIGN FLAW OF THIS MOTOR WHICH SHARES THE SAME VALVETRAIN PARTS WITH THE PREVIOUS 6.0 LITER POWERSTROKE WHICH IS ALSO DOOMED FLEETWIDE WITH THESE SAME ISSUES WHICH AS ALSO HIGHLY DOCUMENTED.

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2014-04-16

TIRES PROBLEM

Date Of Incident: 2009-06-01
VIN: 1FDXE45S97D
Components: TIRES
Summary: BOUGHT MY MOTOR HOME IN JUNE 2009 WITH MICHELIN TIRES SIZE LT 225/75R16 115/R/LRE LTX MS. SINCE NEW, MY TIRES HAVE BEEN CRACKING ON THE OUTSIDE OF THE TIRES MORE AND MORE. I ONLY HAVE LESS THAN 10,000 MILES ON THESE TIRES AND IT IS KEPT IN AN ENCLOSED GARAGE SINCE I BOUGHT IT. I AM VERY CONCERNED ABOUT THESE TIRES BLOWING OUT, BECAUSE OF THE WAY THEY LOOK, BUT AS I SAID, WE HAVE VERY LITTLE MILEAGE ON THESE TIRES AND THEY WERE SUPPOSED TO THE TOP OF THE LINE TIRES. PLEASE, REPLY. THANK YOU. ..UPDATED 04-16-14 *BF

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2011-11-14

ENGINE AND ENGINE COOLING PROBLEM

Date Of Incident: 2009-09-01
VIN: 1FTXW43R59E
Components: ENGINE AND ENGINE COOLING
Summary: TL* THE CONTACT OWNS A 2009 FORD F-450 SD DIESEL. THE CONTACT STATED THAT EXHAUST FUMES WERE BEING EMITTED INTO THE VEHICLE. THE CONTACT MENTIONED THAT THE VEHICLE WAS TAKEN FOR REPAIRS A TOTAL OF THIRTY-FIVE TIMES. THE VEHICLE WAS TAKEN TO THE DEALER WHO DIAGNOSED THAT TWO OF THE EXHAUST PIPES WERE LEAKING, THE EXHAUST MANIFOLD WAS FRACTURED AND SUDS WERE COMING THROUGH THE FIREWALL INTO THE CAB. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE WHO DID NOT OFFER ANY ASSISTANCE. THE VEHICLE WAS REPAIRED. THE FAILURE MILEAGE WAS 500 AND THE CURRENT MILEAGE WAS 90,000.

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2009 Ford F-450 sd recalls

The National Highway Traffic Safety Administration (NHTSA) has issued 5 recalls for different components of the 2009 Ford F-450 sd.

2014-06-23

Manufacturer: Palfleet Truck Equipment Company, LLC
Components: EQUIPMENT
Summary: Palfleet Truck Equipment Company, LLC (Palfleet) is recalling certain model year 2009-2013 Ford F-350, F-450, and F-550 super duty vehicles modified by Palfleet and equipped with certain Muncie Power Products PTO Assemblies. In the affected vehicles, oil may leak from the PTO pressure switch onto a thermal blanket covering the exhaust.
Consequence: The leaking oil may soak into the thermal blanket covering the exhaust, which when combined with heat from exhaust, may result in an increased risk of fire.
Remedy: Palfleet will notify owners, and dealers will install a new pressure switch kit that moves the switch away from the exhaust system, free of charge. The recall began on July 29, 2014. Owners may contact Palfleet customer service at 1- 502-376-2458.

2014-06-13

Manufacturer: Iowa Mold Tooling Co., Inc.
Components: EQUIPMENT
Summary: Iowa Mold Tooling Co., Inc. will notify owners and dealers to inspect the Muncie PTO pressure switch to determine if it is from the range of defective switches and if required, remove the pressure switch assembly and put a plug in the port where the PTO switch had been installed. This switch was never being utilized. This will be done free of charge. The recall is expected to begin in mid-July 2014. Owners may contact Iowa Mold Tooling Co., Inc. at 1-800-247-5958.
Consequence: The leaking oil may soak into the thermal blanket covering the exhaust, which when combined with heat from exhaust, may result in an increased risk of fire.
Remedy: Iowa Mold Tooling Co., Inc. will notify owners, and dealers will install a new pressure switch kit that moves the switch away from the exhaust system, free of charge. The recall began on July 28, 2014. Owners may contact Iowa Mold Tooling Co., Inc. at 1-800-247-5958.

2014-06-12

Manufacturer: Stahl
Components: EQUIPMENT
Summary: Stahl is recalling certain model year 2009-2014 Ford F-350 Super Duty, F-450 Super Duty, and F-550 Super Duty vehicles modified by Stahl and equipped with certain Muncie Power Products PTO Assemblies. In the affected vehicles, oil may leak from the PTO pressure switch onto a thermal blanket covering the exhaust.
Consequence: The leaking oil may soak into the thermal blanket covering the exhaust, which when combined with heat from exhaust, may result in an increased risk of fire.
Remedy: Stahl will notify owners, and dealers will install a new pressure switch kit that moves the switch away from the exhaust system, free of charge. Owners may contact Stahl customer service at 1-800-277-8245, or Muncie at 1-800-367-7867.

2014-06-10

Manufacturer: SOMERSET WELDING & STEEL, INC.
Components: EQUIPMENT
Summary: Somerset Welding & Steel, doing business as J&J Truck equipment (J&J), is recalling certain model year 2009-2013 Ford F-350, F-450, and F-550 Super Duty chassis with 6.8L gasoline engines modified by J&J to be equipped with certain Muncie Power Products PTO Assemblies. In the affected vehicles, oil may leak from the PTO pressure switch onto a thermal blanket covering the exhaust.
Consequence: The leaking oil may soak into the thermal blanket covering the exhaust, which when combined with heat from exhaust, may result in an increased risk of fire.
Remedy: Somerset will notify owners, and dealers will install a new pressure switch kit that moves the switch away from the exhaust system, free of charge. The recall began August 2014. Owner's may contact Somerset customer service at 1-800-777-2671.

2014-02-11

Manufacturer: Monroe Truck Equipment
Components: ELECTRICAL SYSTEM
Summary: Monroe Truck Equipment (Monroe) is recalling certain model year 2006, 2008 and 2009 Chevrolet C7500 vehicles, 2005-2006 Chevrolet Tahoe vehicles, and 2009 Ford F-350, and F-450 vehicles, equipped with Sure Power-brand battery equalizers or DC-DC converters containing a particular epoxy sealing, aka 'potting', compound. The specific potting compound used in the subject products for insulation was found to be capable of conducting electricity after being exposed to heat.
Consequence: Once electrically conductive, the material is capable of melting and burning, increasing the risk of a fire.
Remedy: Monroe will notify owners, and Sure Power will replace the equalizers or converters, free of charge. The recall began on March 24, 2014. Owners may contact Monroe at 1-608-328-8127.

Additional sources

More sources of information about 2009 Ford F-450 sd problems:

Top 5 Problems Ford F-250 6.4 Diesel Truck 2008-2010 2nd ...

Q&A: Troubleshooting 2008 Ford F-450 Super Duty - Starts Fine ...

https://www.justanswer.com/ford/8k2zt-f-450-2008-ford-f-450-6-4-starts-fine-runs-great.html

Jul 16, 2014 ... 2008 Ford f-450 With 6.4 Starts fine, runs great but has intermittent power loss. Loss happens suddenly and boost gauge - Answered by a ...

COMMON Ford POWERSTROKE 6.4 Issues and PROBLEMS ...

https://www.youtube.com/watch?v=oWurTz_9OSk

Sep 9, 2017 ... Today I talk about the shortcomings of the ford 6.4 liter motor manufactured between 2008 and 2010. The plant has it's up and downs but here ...

A/C not blowing cold air | Ford Powerstroke Diesel Forum

https://www.powerstroke.org/threads/a-c-not-blowing-cold-air.1142458/

Jun 26, 2016 ... Somewhat of a common problem ... yup core is common on these SD's. if they ... A forum community dedicated to Ford F-series owners and enthusiasts ...