Ford F super duty 1996 problems

General information about Ford-F super duty
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 Ford F super duty 1996 problems

The 1996 Ford F-250 has been reported to have several common problems, primarily in the categories of accessories - interior, electrical, and engine issues.

Accessories - Interior Problems: The 1996 Ford F-250 has reported 2 interior accessories problems, with a total of 7 NHTSA complaints. While specific details about these issues are not provided in the search results, it is essential to pay attention to any interior accessories that may not be functioning correctly, such as the radio, climate control system, or power windows.

Electrical Problems: The 1996 Ford F-250 has 19 electrical problems reported, with a total of 19 NHTSA complaints. Electrical issues can range from minor inconveniences, such as malfunctioning interior lights, to significant safety concerns, such as faulty wiring or electrical components. It is crucial to address any electrical problems promptly to avoid potential safety hazards.

Engine Problems: The 1996 Ford F-250 has 43 engine problems reported, with a total of 43 NHTSA complaints. Engine problems can significantly impact the performance and reliability of a vehicle. Some common engine issues in the 1996 Ford F-250 include:
- Turbo Problems: Dirt build-up, sand-blasted or bent turbo fins, and an oily film inside the air tube connected to the back of the air filter are signs of potential turbo problems. These issues can lead to decreased performance and fuel efficiency.
- Coolant Issues: It is essential to check the coolant in a 1996 Ford F-250 and ensure that the previous owner has been adding FW16 or DCA4 to maintain a proper SCA level. This is crucial for preventing cavitation, which can cause engine damage.
- Injector O-Rings: The injector O-rings in the 1996 Ford F-250 have been known to be problematic. If the truck has an o-ring problem, one of the signs can be a discoloration of the fuel in the filter bowl. Checking the fuel in the filter bowl for discoloration can help identify potential injector o-ring issues.
- Glow Plugs and Relay: It is essential to ensure that the glow plugs and relay are in good working condition, as these components play a crucial role in starting and operating the engine, especially in cold weather conditions.

Transmission Problems: The 1996 Ford F-250 has 14 transmission problems reported, with a total of 14 NHTSA complaints. Transmission issues can significantly impact the drivability and reliability of a vehicle. It is crucial to address any transmission problems promptly to avoid potential safety hazards and costly repairs.

In summary, the 1996 Ford F-250 has several common problems, primarily in the categories of accessories - interior, electrical, and engine issues. It is essential to pay close attention to these areas and address any issues promptly to ensure the safe and reliable operation of the vehicle.

What are the worst years for f250 Super Duty?

The worst years for used Ford F-250 include:

2002 Ford F-250.
2006 Ford F-250.
2008 Ford F-250.
2011 Ford F-250.
2017 Ford F-250.

How many miles can a 1996 F-250 last?

300,000 miles as long as they are properly taken care of. Meaning regular maintenance is done, oil, oil filter, air filter, transmission service ( fluids and filter changed ), Brakes are checked, rear end fluid changed, tune up done at MFG mileage ( always use OEM parts ) recommendation.

Is Ford Super Duty a reliable car?

Ford Super Duty Honored as America's Most Dependable Large Heavy-Duty Pickup by J.D. Power. DEARBORN, Mich., Feb. 8, 2024 – The 2021 Ford Super Duty is the most dependable large heavy-duty pickup in the J.D. Power 2024 U.S. Vehicle Dependability Study, based on feedback from drivers after three years of ownership.

What is the most reliable Ford Super Duty year?

Reliability refers to how well the vehicle can handle heavy loads and rough terrains. The model years 2005, 2009, 2011, and 2020 were some of the stand-out models from the four generations of Ford F-250.

Is Ford Super Duty a reliable car?

What are the worst years for F-250 Super Duty?

The worst years for used Ford F-250 include:

2002 Ford F-250.
2006 Ford F-250.
2008 Ford F-250.
2011 Ford F-250.
2017 Ford F-250.

Is the 1996 Ford 5.8 a good engine?

The 5.8L (351 cubic inch V8) is a solid engine, and has been for many years. It is one of the last years Ford used a push rod engine in their truck line (in 1998, Ford went to their overhead cam engines for the Super Duty trucks). The manual transmission, however, is not the strongest part of your prospective truck.

What is the most reliable Ford Super Duty year?

Ford F super duty 1996 car problems categorized by type of issue

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

Vehicle speed control problems
Fuel system problems
Other problems
Engine and engine cooling problems
Power train problems

The graph below shows statistics for all Ford F super duty 1996 vehicle components and the number of complaints received.

Ford F super duty 1996 complaints

The NHTSA has received 10 complaints about various vehicle components related to the Ford F super duty 1996.

2008-02-13

VEHICLE SPEED CONTROL PROBLEM

Date Of Incident: 2005-06-23
Number Of Injuries: 1
Fire: 1
VIN: 1FTHW26F4TE
Components: VEHICLE SPEED CONTROL
Summary: SPEED CONTROL DEACTIVATION SWITCH FAILURE THAT RESULTED IN AN ENGINE COMPARTMENT FIRE WHILE THE VEHICLE WAS BEING DRIVEN. THIS VEHICLE IS EQUIPPED WITH A DIESEL ENGINE AND HAS NOT BEEN INCLUDED IN THE RECALL TO DATE. *TR

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2008-02-01

VEHICLE SPEED CONTROL PROBLEM

Date Of Incident: 2007-08-28
VIN: 3FCMF53G7TJ
Components: VEHICLE SPEED CONTROL
Summary: TL*THE CONTACT OWNS A 1996 FORD F SUPER DUTY. THE CONTACT RECEIVED A RECALL NOTICE FOR NHTSA CAMPAIGN ID NUMBER 07V336000 (VEHICLE SPEED CONTROL) AND FORD RECALL NUMBER 05S28 IN AUGUST OF 2007. HE CALLED FORD SEVERAL TIMES AND THEY STATED THAT THE PARTS WOULD BE AVAILABLE IN MID'DECEMBER OF 2007 AND THEN IN JANUARY OF 2008. THE DEACTIVATION SWITCH WAS DISCONNECTED. THERE HAD BEEN NO FAILURE TO DATE. THE CURRENT MILEAGE WAS 25,000.

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2003-07-24

POWER TRAIN PROBLEM

Date Of Incident: 2024-11-24
VIN: 1FDLF47F1TE
Components: POWER TRAIN
Summary: WHILE DRIVING TRANSMISSION QUIT RUNNING, UNABLE TO ACCELERATE. DEALERSHIP REPLACED THE TRANSMISSION, BUT THE PROBLEM RECURRED.*AK

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2002-03-19

FUEL SYSTEM, OTHER PROBLEM

Date Of Incident: 2002-03-11
VIN: 1FDLE40G6TH
Components: FUEL SYSTEM, OTHER
Summary: WE WERE TRAVELING FROM LIVINGSTON TEXAS BEFORE LEAVING LIVINGSTON WE GASED OUR MOTOR HOME UP AND WE BEGIN TO SMELL GAS WE TRAVELED TO SAN ANTONIO TEXAS AND NOTICED WHEN WE FILLED THE TANK THAT WE COULD SMELL GAS LOOKING AROUND THE MOTOR HOME WE SAW NOTHING SO WE TRAVELED ON TO EL PASO TEXAS. UPON ARRIVING IN EL PASO WE DECIDED TO FILL UP AND THEN PARK FOR THE EVENING. WHEN I BEGIN TO FILL THE TANK GAS STARTED SPILLING OUT. WE WERE INFORMED TO TAKE THE VEHICLE TO SHAMALAY FORD ON LE TREVINO DRIVE IN EL PASO WHEN WE TOOK IT TO A FORD DEALER THEY LOOKED AND DISCOVERED THAT THE PUMP WAS BROKEN AND THAT THREE SCREWS WERE MISSING FROM THE TANK IN FACT THE TANK WAS BARELEY HOLDING ON. IT SHOWED THAT THE SCREWS WERE SEVERED AND THE GAS TANK HAD COME LOOSE. WHEN WE WERE DRIVING WE HAD HEARD A NOISE THAT SOUNDED AS IF SOMETHING WAS FALLING INSIDE OF THE MOTOR HOME. THE FORD SUPER DUTY E SERIES HAS A WINNEBEGO MOTOR HOME BUILT ON IT. WE HAD JUST FILLED OUR PROPANE TANKS AND IF WE WOULD HAVE DRIVEN ANY FURTHER THER MAY HAVE BEEN A TERRIBLE ACCIDENT. THE DEALER TOLD US THAT FORD WOULD NOT PAY FOR THIS BECAUSE IT IS NOT LISTED AS A COMPLAINT ON RECALL.*AK

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2000-03-30

ENGINE AND ENGINE COOLING PROBLEM

Date Of Incident: 2000-03-25
VIN: 3FCMF53G7VJ
Components: ENGINE AND ENGINE COOLING
Summary: THE PASSENGER'S SIDE EXHAUST MANIFOLD ON MY 1997 MOTORHOME HAS WARPED, WHICH SUBSEQUENTLY CAUSED A BOLT HOLDING THE MANIFOLD IN PLACE TO BREAK OFF. THE FORD DEALER NOW REPAIRING THE VEHICLE SAID THAT FORD HAS HAD MANY PROBLEMS WITH EXHASUT MANIFOLDS ON THE 460 CID ENGINE IN MOTORHOMES...WHY NO RECALL, WHY NO ACTION ON THIS? THE RESULTING EXHAUST LEAK CLEARLY POSED A DANGER TO MY FAMILY AS WE TRAVELED IN OUR MOTORHOME. *AK

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1999-10-15

FUEL SYSTEM, GASOLINE,FUEL SYSTEM, OTHER PROBLEM

Date Of Incident: 2024-11-24
VIN: 3FCMF53GXTJ
Components: FUEL SYSTEM, GASOLINE,FUEL SYSTEM, OTHER
Summary: FAILURE OF THE FUEL PUMP, FUEL FILTER AND SENDING UNIT CAUSED THE MOTOR HOME TO STALL OVER AND OVER AGAIN. YH

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1999-10-15

ELECTRICAL SYSTEM PROBLEM

Date Of Incident: 2024-11-24
VIN: 3FCMF53GXTJ
Components: ELECTRICAL SYSTEM
Summary: WIRING ASSEMBLY FAILED. YH

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1999-10-15

VEHICLE SPEED CONTROL PROBLEM

Date Of Incident: 2024-11-24
VIN: 3FCMF53GXTJ
Components: VEHICLE SPEED CONTROL
Summary: IDLE AIR VALVE ASSEMBLY REPLACED DUE TO STALLING. YH

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1998-07-01

SUSPENSION PROBLEM

Date Of Incident: 1996-06-21
VIN: 1FDLE40G0TH
Components: SUSPENSION
Summary: REAR LEAF SPRINGS FAILED. QCAW

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1998-04-29

ENGINE AND ENGINE COOLING PROBLEM

Date Of Incident: 1998-04-29
VIN: 3FCLF53G3TJ
Components: ENGINE AND ENGINE COOLING
Summary: RECALL # 97V20900/FORD/EXHAUST GAS LEAK, OWNER NOT ABLE TO MAKE CONTACT WITH MANUFACTURER TO CORRECT RECALL. THE 800 NUMBER LISTED ON THE NOTICE IS CONSTANTLY BUSY. OWNER HAS BEEN TRYING TO REACH MANUFACTURER FOR A TOTAL OF 3 DAYS. *AK

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Ford F super duty 1996 recalls

The National Highway Traffic Safety Administration (NHTSA) has issued 2 recalls for different components of the Ford F super duty 1996.

1997-11-13

Manufacturer: FORD MOTOR COMPANY
Components: ENGINE AND ENGINE COOLING:EXHAUST SYSTEM:EMISSION CONTROL:GAS RECIRCULATION VALVE (EGR VALVE)
Summary: VEHICLE DESCRIPTION: MOTOR HOME CHASSIS. HOT EXHAUST GASSES CAN LEAK FROM THE EXHAUST GAS RETURN (EGR) TUBE ON THE ENGINE. A HOLE CAN DEVELOP IN THE FLEXIBLE SECTION OF THE TUBE. HEAT DAMAGE TO THE PASSENGER COMPARTMENT FLOOR AND FLOOR COVERING CAN OCCUR.
Consequence: DEPENDING ON THE MATERIALS USED IN THE CONSTRUCTION OF THE COMPLETED VEHICLE, IGNITION OF THESE MATERIALS COULD OCCUR RESULTING IN A VEHICLE FIRE.
Remedy: DEALERS WILL REPLACE THE EGR TUBE.

1996-08-01

Manufacturer: FORD MOTOR COMPANY
Components: STRUCTURE:FRAME AND MEMBERS
Summary: THE CROSSMEMBER FRAME GUSSETS WERE INSTALLED WITH UNDERSIZED THREADED FASTENERS FOLLOWING A BREAKDOWN OF THE PRODUCTION RIVET GUN THAT IS GENERALLY USED. THIS GUSSET IS THE ATTACHMENT POINT FOR THE REAR STRAP OF THE MID-SHIP FUEL TANK.
Consequence: THE SUBJECT FASTENERS CAN SEPARATE CAUSING IN THE REAR STRAP OF THE AFFECTED FUEL TANK TO BECOME DISCONNECTED. A LOOSE OR DISCONNECTED REAR STRAP ALLOWS THE FUEL TANK TO POSSIBLY CONTACT THE ROAD SURFACE INCREASING THE RISK OF A VEHICLE FIRE.
Remedy: DEALERS WILL REPLACE THE CROSSMEMBER GUSSET FASTENERS WITH THE SPECIFIED ALTERNATIVE FASTENERS (BOLTS).

Additional sources

More sources of information about Ford F super duty 1996 problems:

1996 Ford F-250 - common problems?

https://repairpal.com/common-problems-321

Feb 11, 2011 ... It is one of the last years Ford used a push rod engine in their truck line (in 1998, Ford went to their overhead cam engines for the Super Duty ...

1996 F-250 7.3 Common Problems - Ford Truck Enthusiasts Forums

https://www.ford-trucks.com/forums/1482842-1996-f-250-7-3-common-problems.html

Mar 27, 2017 ... 1994.5 - 1997 7.3L Power Stroke Diesel - 1996 F-250 7.3 Common Problems - Any advice on common problems these trucks have before I buy one?

Fuse 22 blows on 1996 Ford F-250 7.3 PS | Ford Powerstroke ...

https://www.powerstroke.org/threads/fuse-22-blows-on-1996-ford-f-250-7-3-ps.1400222/

Feb 16, 2023 ... Fuse 22 blows on 1996 Ford F ... I know as owners we're all aware of this common problem ... Sold 2001 2wd Ford F-250 XLT Super Duty Power Stroke ...