I've been really happy with the performance and mileage from my 2011 F-250 XLT 4WD super cab until it hit 70k miles.

In the last 3,000 miles the batteries dropped cranking amps and fried the Nox sensor, EGR valve overheated (warranty) and now she will only start about 4 out of 10 times. Dealer says it was a loose connection at the battery junction box and tried to glue it to save me money ($350 + 9 days of troubleshooting/lost use). The repair lasted exactly two days, now they say I need to replace the entire electrical harness at $2,300.

Sales manager says ford is not aware of this as a common problem but the initial service writer told me that Ford had 19 active "no start" cases and warned me that the resolved cases required harness, PCM or gauge cluster replacement which were high cost. Anyone have any info. or experience on this?

 

Cant say Ive seen much in the way of posts about this.

 

SavageNFS had electrical issues pretty similar. He did a post about it and can probably describe some things for you and maybe help with the experience he went through.

Try searching and sending him a message.

 

Here is the thread you can read about it.
https://www.ford-trucks.com/forums/1...-man-down.html

The cause of my issue was the voltage regulator failed and sent the alternator charging to max capacity. This over charged the batteries, and overloaded everything. Total catastrophic failure. BCM, PCM, main wiring harness, nav, batteries, cables, alternator, it was crazy. Total freak occurrence that hasn't happened since or the truck would be gone.

 

Send me your info in a PM, swhhfrc; I want to look into this to see how I can help. Be sure to include your full name, best daytime phone number, VIN, mileage, and servicing dealership; I'll check out some ways to assist.

Crystal

 

Update - Shortly after my last post Ford contacted me and stepped in. They paid 80% of the cost of replacing the entire wiring harness.

I picked up the truck (3 days at shop, while awaiting parts), immediately hooked up my trailer and proceeded to drive all over gods creation in upstate PA for a weekend (not a single problem). Drove to work that Monday and backed into my normal parking spot with no problems. Went to leave for the airport and no start again. Fiddled with key, kept playing with every switch I could, shook the truck and cursed out the truck/dealer/Ford (actions not necessarily in that order) and it finally started.

Dropped it back off at the dealer after returning home last Thursday and as of this morning they can't replicate problem (I've basically had an operational truck for about 5 out of the last 30 days). Funny thing is that I keep telling them that the only "uncommon" thing about my parking spot is that its near some transformers and this appears to be the most common location where I have the problem.

Anyone ever hear of these trucks having external EMF or radio interference issues? I asked the service writer this morning if they tried parking it near some transformers as I had asked and could tell he was just going along with me. Ended conversation insisting that they park it near their transformers and I'll pick it up (if it starts) from there.

$52k spent on a truck that won't run reliably after only 77k miles and can't be honestly sold/or traded in. Now I remember why I swore off Ford in the early 2000's because of the only other Ford I ever owned. It was a Ford Taurus and basically went to hell in a hand basket at 70k miles (new fuel pump, radiator, trans and engine before 100k).

I am about at my wits end.

 

I think lots of people trade trucks and cars that they are having trouble with. Can't hurt having a look.

 

When you say "no start, then started" how exactly are you starting the truck?

I ask because my truck had been flaking out, not wanting to start via the ignition, but starting fine via the remote start keyfob, a month/two ago. Dunno what happened, I just used my remote start everytime, but then a few weeks back I tried the ignition again, and it's been behaving ever since....

Never have gotten to the bottom of what it was

 

I'm glad to hear that your truck's been on its best behavior lately, BlackBeest, but if this issue pops up again, you might try replicating it for your dealer. As always, I'll hang around here in case you need my assistance.

Crystal