2016 Ford F-250 SD engine problems

ENGINE

On September 3, 2023, the fuel pump failed while the truck was in the corner of an on-ramp for an interstate. The truck immediately lost power while in the corner causing a loss of control of steering. This resulted in a near collision with a concrete dividing wall while attempting to maintain control of the vehicle until the vehicle came to a stop. There were no warnings, check engine lights, or other issues with the truck prior to the incident. The truck was inspected by a diesel repair company where it was determined that the Bosch CP4 fuel pump failed resulting in a catastrophic fuel system failure with metal shavings contaminating the complete fuel system. This required a complete fuel system replacement.

NHTSA complaint #11727559 — an unverified report by a vehicle owner.

ENGINE

The contact owns a 2016 Ford F-250. The contact stated while driving at an undisclosed speed, the check engine warning light illuminated. The vehicle was taken to the dealer but was not diagnosed or repaired. The manufacturer was made aware of the failure and referred the contact to the NHSTA Hotline for assistance. The failure mileage was approximately 16,000.

NHTSA complaint #11612413 — an unverified report by a vehicle owner.

ENGINE AND ENGINE COOLING

The contact owns a 2016 Ford F-250. The contact stated while driving at an undisclosed speed, the vehicle inadvertently lost motive power. The contact was able to pull over to the shoulder of the roadway, where the vehicle failed to restart. The check engine warning light was illuminated. The vehicle was towed to the dealer, who diagnosed a failure within cylinder #2, resulting in damages to the engine. The contact was informed that the engine needed to be replaced. The vehicle was not repaired. The manufacturer was notified of the failure but provided no assistance. The failure mileage was approximately 126,000.

NHTSA complaint #11603428 — an unverified report by a vehicle owner.

ENGINE AND ENGINE COOLING:ENGINE:DIESEL

The contact owns a 2016 Ford F-250. The contact stated that while driving at an unknown speed, the check engine warning light illuminated. The vehicle was parked and restarted when it locked itself into idle mode and would not move. The vehicle was taken to a dealer where it was diagnosed that the reduction heater needed to be replaced. The vehicle was not repaired. The manufacturer was notified of the failure. The failure mileage was 70,000

NHTSA complaint #11549671 — an unverified report by a vehicle owner.

ENGINE

I was attempting to access the interstate when my truck began to immediately shut down at 70 miles per hour. I received a warning as the engine shut down stating that my engine power was reduced. At the exact moment the message displayed, the truck immediately died at 70 mph leaving me to be forced to wrestle the steering wheel to maneuver the truck to the side of the interstate as I had no power steering due to the failure. I have been informed that my truck is a victim of a catastrophic engine failure as a result of a failed CP4 OEM Bosch high-pressure fuel pump. The failure has resulted in the complete contamination of the fuel system requiring a complete overhaul with parts cost at $6,600.00 and approximately $4,000.00 in labor for a total of more than $10,600.00. on a low mileage diesel.

NHTSA complaint #11547948 — an unverified report by a vehicle owner.

ENGINE

I recently received a warning for P20BA informing me that the truck had a failed DEF heater. The unit was not in warranty and parts estimate for this is $360.00-$400.00 with an additional $400.00 dollars in labor for a total cost at minimum of $800.00 to $1,000.00 to replace a part that Ford Motor Company knew was a high failure rate part that would not meet industry standards.

NHTSA complaint #11547951 — an unverified report by a vehicle owner.

ENGINE AND ENGINE COOLING:EXHAUST SYSTEM:MANIFOLD/HEADER/MUFFLER/TAIL PIPE

The contact owns a 2016 Ford F-250. The contact stated that while driving at an undisclosed speed, the interlock brakes started grinding and then inadvertently activated. The vehicle was taken to the dealer to be diagnosed. The contact was informed that the intake manifold needed to be replaced. The vehicle was not repaired. The contact stated that the failure recurred. The manufacturer was made aware of the failure. The failure mileage was approximately 144,000.

NHTSA complaint #11528156 — an unverified report by a vehicle owner.

ENGINE AND ENGINE COOLING:EXHAUST SYSTEM:EMISSION CONTROL:CATALYTIC CONVERTOR

The contact owns a 2016 Ford F-250. The contact stated that while driving at an undisclosed speed, an unknown message was displayed on the instrument panel. The vehicle was taken to the dealer, where it was diagnosed and determined that the exhaust filter assembly was clogged and needed to be replaced. The dealer replaced the exhaust filter assembly. The manufacturer was made aware of the failure and advised the contact to file a complaint with the NHTSA Hotline. The failure mileage was 93,538.

NHTSA complaint #11526167 — an unverified report by a vehicle owner.

ENGINE

The contact owns a 2016 Ford F-250. The contact stated that the check engine warning light was illuminated. The vehicle was taken to the dealer for a diagnostic test; the diagnostic test showed that the rear knock sensor was defective and needed to be replaced. The contact was informed by the dealer and the manufacturer that the vehicle was not covered under warranty. The contact was referred to NHTSA Hotline for assistance. The vehicle was not repaired and remained in the possession of the dealer. The failure mileage was approximately 71,000.

NHTSA complaint #11522931 — an unverified report by a vehicle owner.

ENGINE

The contact owns a 2016 Ford F-250. The contact stated that the check engine warning light illuminated intermittently. The vehicle was taken to several independent mechanics, where the warning light was reset; however, the failure persisted. The vehicle was taken to the dealer, where it was diagnosed that the reductant heater had failed and needed to be replaced. The contact became aware that the VIN was included in Ford Service Campaign Number: 20M01; however, the dealer informed the contact that the vehicle could not be repaired under the Service Campaign due to the mileage. The dealer referred the contact to the NHTSA Hotline for assistance. The vehicle was not repaired. The manufacturer was not notified of the failure. The failure mileage was approximately 117,000.

NHTSA complaint #11517876 — an unverified report by a vehicle owner.

ENGINE AND ENGINE COOLING

The contact owns a 2016 Ford F-250. The contact stated that the check engine warning light illuminated intermittently. The vehicle was taken to several independent mechanics, where the warning light was reset; however, the failure persisted. The vehicle was taken to the dealer, where it was diagnosed that the reductant heater had failed and needed to be replaced. The contact became aware that the VIN was included in Ford Service Campaign Number: 20M01; however, the dealer informed the contact that the vehicle could not be repaired under the Service Campaign due to the mileage. The dealer referred the contact to the NHTSA Hotline for assistance. The vehicle was not repaired. The manufacturer was not notified of the failure. The failure mileage was approximately 117,000.

NHTSA complaint #11517876 — an unverified report by a vehicle owner.

ENGINE

Maintained Truck and did all required maintenance. Truck blew up while driving. All oil leaked out. Ford found hole in upper oil pan. Truck had poor fuel Truck has exhaust issues and ford can’t correct Lost truck and a lot of money , engine needs to be replaced.

NHTSA complaint #11512492 — an unverified report by a vehicle owner.

ENGINE

The contact owns a 2016 Ford F-250. The contact stated that the check engine warning light illuminated on the instrument panel with error code P2002. The vehicle was taken to the dealer and the contact was informed that the diesel exhaust fluid (DEF) needed to be replaced. The vehicle was not repaired. The manufacturer was contacted and the contact was referred to the NHTSA Hotline. The failure mileage was 106,000.

NHTSA complaint #11482023 — an unverified report by a vehicle owner.

ENGINE AND ENGINE COOLING:EXHAUST SYSTEM:EMISSION CONTROL:CATALYTIC CONVERTOR

If you have bad converters do not install Walker 50370 and 73004 Converters. I am on my second set first set lasted 2181 miles, second set less than 1500 Federal law states these should last 80,000

NHTSA complaint #11476148 — an unverified report by a vehicle owner.

ENGINE

Check engine code P2002. Dealer indicated the diesel particulate filter needs replaced. Found Ford Customer Satisfaction Program 20M06 which based on the description covers the issue but Ford says 20M06 is not attached to my VIN even though it represents the exact same issue.

NHTSA complaint #11472980 — an unverified report by a vehicle owner.

ENGINE

My engine light has come on as a result of an emissions problem. I have taken my truck to Ford service dept. 5 times, each time, they make an adjustment and claim there is nothing else to be done. How can I resolve this problem?

NHTSA complaint #11453804 — an unverified report by a vehicle owner.

ENGINE

Diagnostic Trouble Code P21B0 Reductant level sensor C circuit high I know several people that have had this same issue concerning the DEF tank assembly costing close to $1000. A recall was issued for earlier models but doesnt cover my truck that now has this same issue. It's this type of failure that makes owners of diesel vehicles contemplate deleting these pollution reducing systems. Please consider an expanded recall.

NHTSA complaint #11447252 — an unverified report by a vehicle owner.

ENGINE

The contact owns a 2016 Ford F-250. The contact stated that an unknown recall repair was completed on the vehicle however, two hours after the repair, the check engine warning light illuminated. The vehicle was towed to the dealer who diagnosed that the DEF heater needed to be replaced and the contact would be responsible for the cost of the repair. The manufacturer was notified of the failure and referred the contact to the dealer. The vehicle was not repaired. The approximate failure mileage 120,000.

NHTSA complaint #11435919 — an unverified report by a vehicle owner.

ENGINE

WHILE OPERATING IN BELOW FREEZING TEMPERATURES ON THE HIGHWAY, THE DIESEL EXHAUST FLUID (DEF) TANK HEATER FAILED, ALLOWING THE DEF TO FREEZE INSIDE THE TANK. WITH THE DEF FROZEN, IT WAS NOT ABLE TO BE INJECTED INTO THE EXHAUST RESULTING IN HIGHER LEVELS OF NITROGEN OXIDES (NOX) TO BE RELEASED INTO THE ATMOSPHERE THROUGH THE VEHICLES EXHAUST.

NHTSA complaint #11396549 — an unverified report by a vehicle owner.

ENGINE

THE REDUCTANT HEATER AND SENDER ASSEMBLY FAILED CAUSING THE MALFUNCTION INDICATOR TO LIGHT. THIS IS THE SAME PROBLEM ADDRESSED FOR THE 2011-2015 MODEL YEAR PER CUSTOMER SATISFACTION PROGRAM 18M01. THE FAULT WAS CONFIRMED BY RIVERTOWN FORD IN COLUMBUS GA VIA DIAGNOSTIC TOOL. CLEARLY THE ISSUE PER CUSTOMER SATISFACTION PROGRAM 18M01 REMAINS AND IS AFFECTING 2016 MODEL YEAR.

NHTSA complaint #11378297 — an unverified report by a vehicle owner.

ENGINE

RADIATOR IS LEAKING AND NEEDS TO BE REPLACED. THIS IS THE THIRD TIME IN 77,000 MILES THE RADIATOR HAS NEEDED TO BE REPLACED.

NHTSA complaint #11321765 — an unverified report by a vehicle owner.

ENGINE

SERVICE ENGINE LIGHT CAME ON TWICE WHILE VEHICLE WAS UNDER WARRANTY. DEALER SERVICED BOTH TIMES AND WAS UNABLE TO RECTIFY OR UNDERSTAND THE PROBLEM. THEY ONLY CLEARED THE FAULT CODES. THE CODE IDENTIFIED WAS FOR THE REDUCTANT HEATER PUMP - LOW VOLTAGE. THE SAME CODE JUST CAME BACK ON FOR THE 3RD TIME - THIS TIME IDENTIFIED BY A DIESEL PERFORMANCE SHOP - WITH ADVICE TO REPLACE THE REDUCTANT PUMP. PREVIOUS MAKE AND MODEL SUPERDUTY TRUCKS HAVE HAD RECALLS FOR THE SAME THING. THIS IS AN OBVIOUS ISSUE, NOT SURE WHY FORD SERVICE SHOPS COULD NOT RECTIFY. TRUCK IS NOW OUT OF WARRANTY AND I AM FORCED TO PAY OUT OF POCKET. UNACCEPTABLE SERVICE AND CARE! -COLD WEATHER EACH TIME -ENGINE LIGHT COMES ON - SAME CODE EACH TIME -REDUCED SPEED AND SLUGGISH PERFORMANCE -CODE CLEARED - TRUCK PERFORMS NORMAL -OBVIOUS THAT THE REDUCTANT HEAT PUMP IS NOT DOING WHAT IT IS DESIGNED TO DO.

NHTSA complaint #11309982 — an unverified report by a vehicle owner.

ENGINE

WAS DRIVING DOWN THE ROAD AND THE TRUCK STARTED LEAKING DIESEL EVERYWHERE. WE TOOK THE TRUCK TO THE DEALERSHIP WHERE THEY SAID THAT WHEN THE FILTER CLOGS THE TRUCK DOESN'T TURN OFF IT SPRAYS FUEL OUT OF THE TOP OF THE FILTER HOUSING. THIS IS DANGEROUS AS MY WIFE WAS DRIVING THE TRUCK AND SITTING IN THE TRUCK FOR SEVERAL MINUTES WITH IT RUNNING NOT REALIZING IT WAS LEAKING . IT COULD HAVE CAUGHT ON FIRE.

NHTSA complaint #11228342 — an unverified report by a vehicle owner.

ENGINE AND ENGINE COOLING:EXHAUST SYSTEM

TL* THE CONTACT OWNS A 2016 FORD F-250. WHILE DRIVING AT AN UNKNOWN SPEED, THE VEHICLE DECELERATED TO 50 MPH AND WOULD NOT EXCEED 50 MPH. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC WHO DIAGNOSED THAT THE HEATER FOR THE DIESEL EXHAUST FLUID WAS FAULTY AND NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. BAYTOWN FORD (4110 I-10, BAYTOWN, TX) WAS NOTIFIED OF THE FAILURE. THE MANUFACTURER WAS NOT NOTIFIED. THE FAILURE MILEAGE WAS 82,000.

NHTSA complaint #11173549 — an unverified report by a vehicle owner.

ENGINE

VEHICLE HAS A HOPPING THAT OCCURS AT SPEEDS OF 40-80 MPH, HAVE TRIED SEVERAL REMEDIES, NONE OF WHICH WORK. HOPPING SENSATION IS SO SEVERE THAT I WOULD BE WORRIED TO PUT CHILDREN IN THE BACK SEAT OF THE VEHICLE. MANUFACTURER IS AWARE OF THE PROBLEM, HAS A TSB IN AN ATTEMPT TO REMEDY THE PROBLEM. THE MANUFACTURER NUMBER OF THE TSB IS 16-0087. MANUFACTURER CLAIMS ISSUE IS CAUSED BY FRAME FLEX. NO KNOWN FIX FOR THE ISSUE. ENGINE ALSO HAS A CONSISTENT ISSUE OF PUTTING DIESEL FUEL INTO THE ENGINE OIL, MANUFACTURER ALSO CLAIMS THIS ISSUE IS "NORMAL"

NHTSA complaint #11123364 — an unverified report by a vehicle owner.

ENGINE

DURING REGENERATION THERE IS A JACKHAMMERING EFFECT AND IT SHAKES THE WHOLE TRUCK. SOUNDS LIKE THE VALVES ARE GOING TO COME OUT OF THE ENGINE

NHTSA complaint #11021334 — an unverified report by a vehicle owner.

ENGINE

TL* THE CONTACT OWNS A 2016 FORD F-250. WHILE DRIVING 40 MPH, THE VEHICLE BEGAN TO BOUNCE UP AND DOWN. AT 70 MPH, THE VEHICLE SHOOK VIOLENTLY. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS MADE AWARE OF THE ISSUE. THE FAILURE MILEAGE WAS 17,000. UPDATE 01/05/2017

NHTSA complaint #10916472 — an unverified report by a vehicle owner.