2002 Ford F-250 SD fuel system problems

FUEL SYSTEM, DIESEL

2002 FORD F250 SUPERDUTY. CONSUMER WRITES IN REGARDS TO A STRONG DIESEL FUEL ODOR AND FINDING FUEL ON THE PASSENGER SIDE OF THE ENGINE COMPARTMENT IN THE CAB OF THE VEHICLE. THE DEALER INFORMED THE CONSUMER, THE DIESEL ENGINE WAS DESIGNED WITH COPPER SLEEVES OR CUPS AROUND THE FUEL INJECTORS. THE PURPOSE OF THE CUPS WERE TO SEPARATE THE ENGINE COOLING SYSTEM FROM THE PRESSURIZED FUEL SYSTEM. OVER A PERIOD OF TIME, THE ENGINE COOLANT REACTED WITH THE COPPER CUPS AND CREATED SMALL PIN HOLES OR CRACKS IN THE INJECTOR CUPS. SINCE THE FUEL SYSTEM WAS PRESSURIZED IT INJECTED DIESEL FUEL INTO THE COOLANT CIRCULATING IN THE ENGINE. EVENTUALLY THE DIESEL FUEL CAME OUT OF THE RADIATOR OVERFLOW AND ALL OVER THE PASSENGER SIDE OF THE ENGINE COMPARTMENT. SINCE THERE WAS NO WAY TO TELL, WHICH INJECTOR CUP WAS BAD, ALL OF THEM WOULD HAVE TO BE REPLACED ALONG WITH THE COOLANT HOSES AND THE RADIATOR WOULD NEED TO BE FLUSHED. THE ENGINE WOULD HAVE TO BE TAKEN APART, THE HEADS WOULD HAVE TO BE REMOVED AND THE INJECTOR CUPS REPLACE.*JB UPDATED 02/13/13

NHTSA complaint #10495681 — an unverified report by a vehicle owner.

FUEL/PROPULSION SYSTEM

WHILE DRIVING I BEGAN TO HEAR A LOUD POPPING NOISE COMING FROM THE ENGINE. AFTER STOPPING AND CHECKING THE ENGINE I NOTICE I HAD A BLOWN OUT SPARK PLUG AND BUSTED IGNITION COIL. I HAVE A 2002 FORD F 250 SD. I HAVE ATTEMPTED TO PUT IN A NEW PLUG BUT IT WILL NOT SCREW INTO THE HOLE. DAMAGE ESTIMATES ARE FROM $150.00 ON LABOR FEES AND $75-100 ON A TEMP. FIX HELICOIL OR HEAD REPLACEMENT FOR $2500.00. FORD MECH. SAID IT HAPPENS ALL THE TIME, DUE TO POOR DESIGN.

NHTSA complaint #10468123 — an unverified report by a vehicle owner.

FUEL SYSTEM, DIESEL

THE WIRING HARNESS FOR THE INJECTORS STARTED FALLING APART. DEALER WHERE I BOUGHT THE TRUCK NEW SAID THEY HAVE BEEN HAVING PROBLEMS WITH THE HARNESS. THEY SAID THEY HAVE A NEW AND IMPROVED HARNESS THAT WILL NOT FALL APART.

NHTSA complaint #10374739 — an unverified report by a vehicle owner.

FUEL SYSTEM, GASOLINE

MY 2002 FORD F250 V10 WITH AN IMMACULATE MAINTENANCE RECORD AND 70,000 MILES ON IT, STARTED TO TIC, TIC, TIC? I BROUGHT IT TO THE DEALER TODAY TO GET CHECKED OUT, HE GOT IN THE TRUCK AND REVVED THE ENGINE AND....BOOM! A SPARK PLUG SHOT OUT RIGHT BEFORE MY EYES AND GASOLINE/OXYGEN MIST REPEATEDLY SHOT OUT OF THE HOLE!!!. SIMPLY PUT, TIRES WEAR OUT, BALL JOINTS WEAR OUT, WHEEL BEARINGS WEAR OUT. SPARK PLUGS DON'T SHOOT OUT OF CYLINDER HEADS UNLESS THE CYLINDER HEAD IS DEFECTIVE!!!!!!!!!!!! THE REPAIR COST ME $600.00! THERE ARE 1000'S OF COMPLAINTS ON THE WEB OF THE SAME THING HAPPENING TO MANY PEOPLE. FORD NEEDS TO BE HELD ACCOUNTABLE......AND I WANT MY MONEY BACK!

NHTSA complaint #10353839 — an unverified report by a vehicle owner.

FUEL SYSTEM, OTHER:DELIVERY:FUEL PUMP

LOSS OF FUEL PUMP AT HIGHWAY SPEED.

NHTSA complaint #10196055 — an unverified report by a vehicle owner.

FUEL SYSTEM, OTHER:FUEL INJECTION SYSTEM

I HAVE MY TRUCK AT THE DEALERSHIP TODAY AND AFTER DIAGNOSTIC THEY FIND OUT THAT MY PROBLEM IS CAUSED BY THE CAM SENSOR. MY PROBLEM START ABOUT TWO WEEKS A GO WHEN MY TRUCK JUST WITH NO ALERTS/LIGHTS JUST SHUT OFF ON THE MIDDLE OF THE ROAD BUT ON TUESDAY 24TH OF 2007 I WAS DRIVING ON AN SMALL ROAD I'M PULLING A 6X12 CARGO TRAILER WHEN MY TRUCK DID IT AGAIN BUT THIS TIME BECAUSE MY TRAILER ON THE BACK WAS VERY DIFFICULT TO DRIVE WITH NO POWER STEERING AND NO BRAKES. I DID A SEARCH JUST NOW AND FOUND OUT THAT IS A PROBLEM THAT FORD IS AWARE OFF AND THEY JUST DON'T WANT TO ADMIT PLEASE ADVICE ME TO WHAT I NEED TO DO. DEALER ESTIMATE TO FIX THE PROBLEM IS ABOUT $500.00 LABOR AND PARTS.

NHTSA complaint #10188899 — an unverified report by a vehicle owner.

FUEL SYSTEM, GASOLINE:DELIVERY:HOSES, LINES/PIPING, AND FITTINGS

WHEN I TOOK MY TRUCK IN FOR SERVICE, THE AUTO TECH NOTICED A FUEL LEAK NEAR THE FUEL FILTER. AGREEING WITH THE TECH THAT THE LEAK WAS FROM THE FILTER, I TOOK THE TRUCK HOME AND REPLACED THE FUEL FILTER. ON INSPECTION OF THE FILTER AFTER INSTALLATION, THE TRUCK STILL CONTINUED TO LEAK FUEL. I DETERMINED THAT THE LEAK WAS COMING FROM A FUEL RETURN LINE, AT A POINT WHERE THE LINE IS HELD IN PLACE BY A METAL TAB. I TOOK THE TRUCK IN TO THE REPAIR SHOP, WHERE THE EMPLOYEES AGREED THAT THE LEAK OCCURRED FROM THE METAL TAB WEARING A HOLE IN THE FUEL RETURN LINE. THE REPAIR THEN INVOLVED REPLACING THE ENTIRE FUEL LINE ASSEMBLY (WHICH INCLUDES BRAKE, FUEL, AND ANY OTHER LINES THAT RUN FROM THE ENGINE TO THE REAR OF THE VEHICLE) AVAILABLE ONLY FROM A DEALER. THE OLD LINES ARE AVAILABLE IF THEY ARE NEEDED.

NHTSA complaint #10161426 — an unverified report by a vehicle owner.

FUEL SYSTEM, DIESEL

WITHIN A TOTAL OF 11 MONTHS THE FORD DEALERSHIP HAS HAD TO CHANGE OUT THE FUEL PUMP TO OUR FORD F250.

NHTSA complaint #10156607 — an unverified report by a vehicle owner.

FUEL SYSTEM, OTHER:DELIVERY:HOSES, LINES/PIPING, AND FITTINGS

THE POWER STEERING FLUID WAS LEAKING FROM UNDERNEATH THE VEHICLE WHILE PARKED. THE VEHICLE WAS TOWED TO THE DEALER, WHO INFORMED THE CONSUMER THAT THE METAL LINE THAT WENT TO THE POWER STEERING PUMP AND TO THE BRAKING ASSIST MOTOR ERUPTED, AND NEEDED TO BE REPLACED. *AK THERE WAS BRAKE PULSATION, THE ACCELERATOR PEDAL WAS FAULTY, THE STEERING WAS HARD TO TURN DURING NORMAL MANEUVERS, WHEN THE 4 X 4 WAS HIGH OFF THE ROAD, THE WHEEL TURNED AND LOCKED TO THE STOPPER, LUNGED, AND THE REAR WHEELS SPUN AROUND.

NHTSA complaint #10099274 — an unverified report by a vehicle owner.