2020 Ford F-250 SD engine problems

ENGINE

The contact owns a 2020 Ford F-250 SD. The contact stated that the vehicle was repaired under NHTSA Campaign Number: 24V957000 (Fuel System, Diesel); however, while driving 40 MPH approximately two months later, the vehicle was running rough and stalled. The check engine warning light was illuminated. The contact pulled over to the side of the road. The vehicle was towed to a dealer, where it was diagnosed with a high-pressure fuel pump failure, causing the fuel system to become contaminated. The dealer determined that the fuel system needed to be replaced. The dealer submitted a diagnostic report to the manufacturer. The contact notified the manufacturer of the failure, and a case was filed. The vehicle was not repaired and was pending the manufacturer's decision regarding the coverage of the repair. The failure mileage was approximately 103,000.

NHTSA complaint #11756201 — an unverified report by a vehicle owner.

ENGINE

Vehicle experienced loss of power while in travel down a mountain. After inspection by a mechanic, CP4 pump had a catastrophic failure sending metal shards throughout the fuel system. This was less than a month after Fords SAFETY RECALL 24S78 that failed to remedy the problem, but before recall Number26V158 was issued.

NHTSA complaint #11728380 — an unverified report by a vehicle owner.

ENGINE

While driving cross country, my dash warning light came on and said " In 50 miles your vehicle will lose power and you won't be able to drive more than 5 mph. DEF problem". I spent $70,000 on this vehicle used with 50K miles on it. Recall from 2024, this is unacceptable. Now another recall for steering. The steering column disengagement. I am afraid to drive it. The dealer keeps telling me no fix yet. FORD has no email to complain. I am not sure what can be done. This is my first FORD, never again.

NHTSA complaint #11716649 — an unverified report by a vehicle owner.

ENGINE

On October 3, 2025 our 2020 Ford F250 King Ranch 6.7 diesel broke down with no start and check engine light. We contacted Ford. We towed the vehicle, at our expense to the dealership we purchased it from approximately one year ago on October 6, 2025. I contacted Ford on October 3, 2025 and received a claim number. On October 7, 2025 the Ford dealership contacted us to inform us the high pressure fuel pump catastrophically failed. It cracked the pump housing. It is a 12,000.00 repair. It is a safety recall. The pickup on has approximately 56,000 miles. The 5 year power train warranty ended September 15, 2025. I have contacted Ford twice sense January 0f 2025 to see if there was a resolution to this recall and they stated there is no fix as of this time. The dealership and I have contacted Ford Customer Service several times. I have left several messages for the representative handling our case and was promised call backs but never did. On October 10, 2025 there was a new case generated due to the lack of communication. Both the dealership and I were promised a call back and we did not receive one. We use this pickup for work and we are losing income. I asked for a loaner and I was told that was not possible. I pulled a Carfax on this pickup and found that possibility this vehicle was bought back twice. When we purchased it, the service record give to us did not show that information. We would like for the repairs to be completed in a timely manner. The dealership stated on October 8, 2025 that the entire fuel system would need to be replaced and could have it completed in three business days. I am not feeling comfortable knowing the pickup has been bought back from Ford two other times and not informing us. Also I am worried it may have caused engine damage.

NHTSA complaint #11692966 — an unverified report by a vehicle owner.

ENGINE

My 2020 Ford F-250 King Ranch with a 6.7L V8 Turbo Diesel engine experienced severe engine failure while I was driving. The engine was completely destroyed and had to be replaced. My warranty company paid to install a new engine into the truck, but did not pay to have the remaining components fixed that were directly damaged by the engine failure. There was severe damage done to the fuel pump, DEF system, and wiring harnesses that caused the truck to be permanently into a mode called "LIMP Mode" which electronically governs the truck to 50 MPH. There was and still is an unresolved recall on the truck. The recall is as follows: #24S78 POWERTRAIN CONTROL MODULE SOFTWARE UPDATE BIODIESEL DEPOSIT ACCUMULATION. The NHTSA number is: NHTSA: #24V957. There were absolutely zero (0) warning signs that alerted me that this was an issue before the engine failed. No alerts or warning lamps were illuminated on the truck before it failed. All i got was a letter in the mail stating that the engine could fail due to this components and that there is no known solution to fixing the problem. This issue caused my engine to fail while I was driving to work. There are issues with the truck still that were directly caused by this issue that the warranty will not cover INCLUDING this recalled component that has no available solution. I have a 2 month old son and a wife that rely on me having this truck. I have risked the safety of my family, and others on the roads, unknowingly by operating this truck on the roads. I am asking that Ford Motor Company be held Liable for all damages to my truck, and the repurchase of the truck for full price. This is unacceptable from a company as big as Ford Motor Company.

NHTSA complaint #11688169 — an unverified report by a vehicle owner.

ENGINE

Engine making heavy ticking noise from front of engine because of a cracked oil pump gear and the front main seal is now weeping oil. Ford is aware of this known issue as a TSB. Afraid to drive truck because I normally haul a large travel trailer into the mountains and the technician said the oil pressure could drop causing the motor to seize up.

NHTSA complaint #11680497 — an unverified report by a vehicle owner.

ENGINE

My truck lost power on the Highway. Had to coast down the off-ramp and ended up blocking a turning lane when the engine failed to start back up. Called a someone to tow me back to my house and parked it where it’s been there for months since Ford has not yet issued a solution to the recall.

NHTSA complaint #11676362 — an unverified report by a vehicle owner.

ENGINE

While driving on the interstate, my truck began to lose power and decelerate. A fuel pump and engine warning light appeared. I began to lose power steering while decelerating. When I finally stopped and the truck turned off, I tried restarting which resulted in a cranking noise and was not successful in starting. I had to contact a towing company for assistance and my truck has been undriveable since this date (7/6).

NHTSA complaint #11672666 — an unverified report by a vehicle owner.

ENGINE

High Pressure Fuel Pump Failure: On [XXX] While driving on the highway our 2020 F250 Super Duty Vin # [XXX] experienced a complete and sudden loss of power in the fast lane, creating an extremely dangerous situation. Our safety and the safety of others were at risk due to us merging across 4 lanes in heavy traffic with no power steering and no motor function, parking in a very narrow shoulder area and requiring a tow from the highway. After towing and a diagnostic evaluation, it was determined that the high-pressure fuel pump (HPFP) failed, a known safety concern with a recall issued our truck being built in Kentucky on August 2, 2020 The cost of repairs are around $15,000. This vehicle is housed at a local diesel mechanic, and is available for inspection upon request, and has not been inspected by anyone currently. When will this recall be remedied? INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA complaint #11667426 — an unverified report by a vehicle owner.

ENGINE

The contact owns a 2020 Ford F-250. The contact stated while driving 40 MPH, the vehicle stalled, with the check engine warning light illuminated. The contact received notification of NHTSA Campaign Number: 24V957000 (Fuel System, Diesel); however, the part to do the recall repair was unavailable. The vehicle was towed to the dealer, where it was diagnosed and determined that the high-pressure fuel pump had failed and needed to be replaced. The dealer confirmed that parts were not yet available. The contact stated that the manufacturer had exceeded a reasonable amount of time for the recall repair. The manufacturer was made aware of the failure. The failure mileage was approximately 113,000. VIN tool confirms parts not available.

NHTSA complaint #11663108 — an unverified report by a vehicle owner.

ENGINE AND ENGINE COOLING

The contact owns a 2020 Ford F-250. The contact stated that while stopped in the driveway, the vehicle shut off and failed to restart. The hill assist, traction control, brake, fuel empty, and the engine overheating warning lights were illuminated. The vehicle went into battery-saving mode. The local dealer was not contacted. The vehicle was not diagnosed or repaired. The manufacturer was contacted and opened a claim and referred the contact to the NHTSA Hotline. The failure mileage was approximately 139,000.

NHTSA complaint #11638997 — an unverified report by a vehicle owner.

ENGINE

THIS MAY RESULT IN A LOSS OF MOTIVE POWER, WHICH INCREASES THE RISK OF A CRASH NO FIX FOR A PROBLEM THAT MAY CAUSE A CRASH? FORD HAS NO SOFTWARE TO FIX A PROBLEM THAT COULD CAUSE A CRASH? YET I STILL CAN DRIVE VEHICLE? I NEED HELP

NHTSA complaint #11636625 — an unverified report by a vehicle owner.

ENGINE

The contact owns a 2020 Ford F-250. The contact stated while driving 45 MPH, the vehicle sputtered and lost power. The vehicle was towed to the residence. The contact stated that a mobile mechanic diagnosed the vehicle and determined that the engine needed to be replaced. The manufacturer was notified of the failure. The contact related the failure to NHTSA Campaign Number: 24V957000 (Fuel System, Diesel); however, the VIN was not included in the recall. The failure mileage was approximately 200,000.

NHTSA complaint #11633589 — an unverified report by a vehicle owner.

ENGINE

The contact called on behalf of her husband who owns a 2020 Ford F-250. The contact stated that while her husband was driving on the highway at 70 MPH, the vehicle stalled, with the “Low Power Mode” message displayed, and within 3-5 seconds there was a large cloud of smoke coming from the front end of the engine bay, and the vehicle proceeded to slow down. The driver pulled over onto the side of the highway. The vehicle was not able to be restarted; however, while attempting to restart the vehicle there was an abnormal knocking sound coming from the engine. The vehicle was towed to a local dealer where the vehicle was diagnosed. The contact was advised that the high-pressure fuel pump was faulty and had exploded, causing metal shards to enter the engine. The contact was informed that the engine and the fuel pump needed to be replaced. The vehicle was not repaired. The manufacturer was notified of the failure. The approximate failure mileage was 175,000.

NHTSA complaint #11633751 — an unverified report by a vehicle owner.

ENGINE

Ref: Ford Customer Satisfaction Program 24B27 VIN: [XXX] I own a 2020 Ford F-250 that is part of the above program. I have not been contact by Ford to have my truck software updated. I am concerned for my families safety driving this truck. The software update for my truck was to be available October 1st of 2024. What can I do to get this update done? [XXX] / [XXX] / [XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA complaint #11631405 — an unverified report by a vehicle owner.

ENGINE

The contact owns a 2020 Ford F-150. The contact stated that while accelerating from a stop, the vehicle lurched forward and hesitated to accelerate. Additionally, while driving at various speeds, the transmission randomly shifted gear and the gear selector failed to match the gear selection. During the failure, the check engine warning light was illuminated, and the “WRENCH” symbol was displayed. The cause of the failure was not yet determined. The local dealer and manufacturer were notified of the failure, but no assistance was offered. The contact was informed that the VIN was not included in NHTSA Campaign Number: 20V197000 (POWER TRAIN). The contact indicated that the vehicle had experienced the failure listed in the recall. The failure mileage was 65,000.

NHTSA complaint #11618838 — an unverified report by a vehicle owner.

ENGINE AND ENGINE COOLING

The contact owns a 2020 Ford F-250. The contact stated that while driving at approximately 40 MPH, another driver on the road informed the contact that the vehicle was leaking diesel fuel with an abnormally strong diesel odor. No warning lights were illuminated. The vehicle was towed to the local dealer where it was diagnosed and determined that an unstated filter needed to be replaced. The vehicle was not repaired and remained with the dealer. The manufacturer was not made aware of the failure. The failure mileage was approximately 64,000.

NHTSA complaint #11588780 — an unverified report by a vehicle owner.

ENGINE

Intake Manifold failure. 2/5

NHTSA complaint #11579024 — an unverified report by a vehicle owner.

ENGINE

The contact owns a 2020 Ford F-250. The contact stated that after turning the ignition switch to the off position and removing the ignition key, the engine remained running. Additionally, the maintenance wrench icon illuminated, and the warning message "Reduced Power Mode" was displayed. The cause of the failure was not yet determined. The manufacturer and local dealer were notified of the failure. The failure mileage was 50,000.

NHTSA complaint #11562267 — an unverified report by a vehicle owner.

ENGINE

There is a pinging noise coming from engine. Sounds like a loud lifter(s)

NHTSA complaint #11514682 — an unverified report by a vehicle owner.

ENGINE

The contact owns a 2020 Ford F-250. The contact stated while driving 75 MPH with the Adaptive Cruise Control activated, the vehicle started shuddering and lost motive power. The message "Engine Failure" was displayed. The vehicle was towed to the dealer, where it was diagnosed with high-pressure fuel pump failure. The dealer diagnosed that the fuel injectors, the high-pressure fuel pump, and the fuel lines needed to be replaced, Additionally, the Diesel Exhaust Fluid (DEF) fuel tank needed to be cleaned. The dealer informed the contact that the repair was covered under warranty. The vehicle was not repaired. The manufacturer was made aware of the failure. The failure mileage was 20,942.

NHTSA complaint #11499037 — an unverified report by a vehicle owner.

ENGINE

Engine developed ticking noise. After doing research many 250 7.3 owners are describing same ticking noise with their vehicles

NHTSA complaint #11492841 — an unverified report by a vehicle owner.

ENGINE

The contact owns a 2020 Ford F-250. The contact stated that while driving approximately 55 mph on the highway, the check engine warning light illuminated, and the vehicle went into limp mode causing the speed to suddenly reduce to 30 MPH. The vehicle was taken back to the dealer who diagnosed that the failure was due to an engine software update. A software update was performed but the failure reoccurred. The vehicle was taken back to the dealer and the NOX sensor was replaced; however, the failure reoccurred. The manufacturer was notified of the failure and the contact was informed that an engineer would be sent to examine the vehicle. No further information was available. The vehicle was not yet repaired. The failure mileage was 72,000.

NHTSA complaint #11449507 — an unverified report by a vehicle owner.

ENGINE

Severe hesitation when accelerating from a crawl. There is a definite issue with either the 10 speed trans or the throttle.

NHTSA complaint #11425611 — an unverified report by a vehicle owner.

ENGINE

MOTOR HAS A NKOCKING TAPPING SOUND LIKE AND OLD SCHOOL TYPE WRITER AND GETS LOUD AT TIMES WHEN IDELING AND SOME TIME REALLY LOUD ANFTER DRIVING IT FO RW WHLLE, (DIESEL ENGINE DOESN'T SOUND LIKE THAT),FORD ENGINEERING AT FACTORY KNOWS WHAT THE PROBLEM IS BUT REFUSES TO ALLOW DEALERSHIP TO REPAIR IT AND REPLACE THE PARTS. TRANSMISSION HAD SNECOR AND VALVE BODY GO OUT CAUSED TRANSMISSION TO LOCK UP IN 10TH GEAR AND STALLING OUT. DEALERSHIP REPLACED THE PARTS WITH NEW ONES, BU TDID NOT CORRECT THE PROBLEM AND NOW STALLES AND SLIPPES WHEN SHIFTING GEARS, OR SOMETIMES SHIFTS SO HARD IT SHAKES THE TRUCK (F250 DIESEL). HAS A GRINDING NOISE WHEN DOWN SHIFTING FROM 5,4,3 GEARS. WHEN DRIVINING THE TRUCK AND GO TO PASS AROUND ANOTHER VEHICLE IS SLIPS GEARS ARE STALLES DOWN UNTIL IT CAN CATCH ITS GEAR TO GO HAPPENED SEVERAL TIMES. VEHICLE ONLY HAS 6,500 MILES ON IT AND WAS PURCHASED AUGUST 26, 2020 AND SHOULD NOT HAVE THESE ISSUES AND PROBLEMS. MOST OF ALL THE FACTORY ENGINEERS SHOULD NOT DENY THE DEALERSHIP TO FIX AND REPLACE WHAT IS WRONG AND CAUUSING THE LOUND AND UPNOGCHIS KNOCKING TICKING SOUND EVEN AFTER DOING A BLACK BOX FLIGHT RECORDER TO DETERMINE WHERE THE PROBLEM IS COMING FROM. THEY SAID TO KEEP DRIVING UNTIL ENOUGH COMPLAINTS COM IN TO HAVE A RECALL SENT OUR ARE UNTIL IT BRAKES AND GOES OUT. THIS IS A SAFETY HAZARD TO EVERYONE ON THE ROAD AND COULD POSSIBLY CAUSE HARM TO INISANT PEOPLE, SUCH AS MYSELF, MY FAMILY, AND OTHERS OUT ON THE ROAD. PLEASE HAVE THIS LOOKED INTO AND HELP GET IT TAKEN CARE OF.

NHTSA complaint #11413605 — an unverified report by a vehicle owner.

ENGINE

CHECK ENGINE LIGHT CAME ON WHILE DRIVING AT HIGHWAY SPEEDS ON THE FREEWAY. TRUCK BEGAN TO SPUTTER SLIGHTLY WHEN COMING TO A STOP. VEHICLE WAS STILL DRIVABLE AND I WAS ABLE TO MAKE IT HOME. LATER DIAGNOSIS AT DEALERSHIP SHOWED THE PROBLEM TO BE A DEFECTIVE SPARK PLUG WIRE. I HAVE SINCE READ THAT THIS IS A COMMON PROBLEM WITH THE NEW 7.3 GAS ENGINE BY FORD.

NHTSA complaint #11394915 — an unverified report by a vehicle owner.

ENGINE

VEHICLE DEMONSTRATES REPEATABLE UNCOMMANDED ACCELERATION WHEN SHIFTING FROM 2ND TO 3RD GEAR. ALSO DEMONSTRATES UNCOMMANDED ACCELERATION WHEN ENGINE BRAKING ENGAGES. OCCASIONALLY VEHICLE OPERATES AT A UNCOMMANDED HIGH IDLE OF 1200-1500 RPM VS THE NORMAL 600. MOSTLY HAPPENS WHEN SLOW MANEUVERING SUCH AS IN A PARKING LOT OR OTHER TIGHT SPACE. IT HAS HAPPENED EVER SINCE NEW AND IT HAS 5100 MILES ON IT NOW. PURCHASING DEALER SAID IT WAS NORMAL. OTHERS ARE REPORTING THE SAME ISSUE IN FORUMS ONLINE.

NHTSA complaint #11389163 — an unverified report by a vehicle owner.

ENGINE

WHILE TRAVELING ON AN INTERSTATE, I NOTICE MY VEHICLE WAS SMOKING. SOON MY ENGINE HIGH TEMPERATURE LIGHT CAME ON AND MY SPEED DROPPED FROM 65 MPH TO 20 MPH. I WAS IN THE CENTER LANE WHEN THIS HAPPENED. I SCRAMBLED TO GET THE TRUCK AND THE TRAVEL TRAILER I WAS PULLING OVER INTO THE RIGHT LANE AND MEDIAN, DOING ALL I COULD TO PREVENT AN ACCIDENT. ONCE I REACHED THE MEDIAN I WAS APPROX. 1/4 MILES FROM AN EXIT. I DROVE TO THE EXIT AT MY VEHICLES MAX SPEED OF 20 MPH. ONCE STOPPED I REVIEWED MY TRUCK AND NOTICED ENGINE COOLANT POURING FROM A LINE THAT HAD DISCONNECTED. UPON REVIEW THE LINE DID NOT HAVE A CLAMP PRESENT AND THERE WERE NO WITNESS OR COMPRESSION MARKS ON THE HOSE. THE VEHICLE WAS TOWED TO A DEALERSHIP FOR DIAGNOSIS AND THE DEALER CONFIRMED THE DEFECT OF NO HOSE CLAMP OR THE HOSE WAS INSTALLED IMPROPERLY AT THE FACTORY.

NHTSA complaint #11363125 — an unverified report by a vehicle owner.

ENGINE

THE LOWER COOLING HOSE CAME LOOSE ON MY FORD 2020 F250 WITH1650 MILES ON THE VEHICLE, WHILE TRAVELING ON A INTERSTATE TOWING A LOAD OF APPROXIMATELY 7000LBS. THE ENGINE LOST POWER AND WE MANAGED TO SAFELY EXIT OF THE INTERSTATE. THE MAX. SPEED OF THE VEHICLE WAS 20 MPH WHILE TRYING TO EXIT THE INTERSTATE SAFELY, IT WAS AN INTENSE MOMENT TO GET OFF THE BUSY INTERSTATE SAFELY. THE VEHICLE WAS TOWED TO A FORD DEALERSHIP, AND WE ARE AWAITING A DIAGNOSIS.

NHTSA complaint #11362811 — an unverified report by a vehicle owner.