515 of the
9,519 complaints filed about the Ford F-250 SD
are about the fuel system —
100% of everything owners reported.
The worst model year for it is 2020.
NHTSA Vehicle Safety Complain To whom it may concern, My Name is [XXX] I am submitting this complaint regarding my 2019 Ford F-250 Super Duty equipped with the 6.7L Power Stroke diesel engine (VIN: [XXX]). At approximately 137,900 miles, my vehicle suddenly lost engine power while driving and stalled without warning, creating a serious safety hazard. After stalling, the truck would not restart and had to be towed to a repair facility. The repair shop diagnosed a catastrophic failure of the diesel high-pressure fuel injection pump. According to the repair invoice, fine metallic flakes were found throughout the entire fuel system, contaminating the fuel lines, fuel tank, injectors, and related components. Because of this contamination, the shop determined that the entire fuel system required replacement, including replacement of all eight fuel injectors, cleaning of the fuel tank and fuel lines, replacement of the fuel filter, and installation of an upgraded diesel injection pump. The estimated repair cost exceeded $11,000, resulting in a significant financial burden. I understand that Ford Safety Recall 24S78 addresses a high-pressure fuel pump issue on certain 2020–2022 Ford Super Duty trucks equipped with the same 6.7L Power Stroke diesel engine. Although my 2019 model is not included in the recall, my vehicle experienced what appears to be a very similar failure that resulted in sudden loss of engine power while driving and complete contamination of the fuel system. I am not asserting that my vehicle is covered by the current recall. Rather, I respectfully request that NHTSA investigate whether the same or a substantially similar defect may also affect certain 2019 Ford F-250 Super Duty vehicles equipped with the 6.7L Power Stroke diesel engine. If the investigation determines that these vehicles are affected by the same safety defect, I ask that the recall be expanded accordingly. I have retained the repair invoice documenting the diagnosis INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA
NHTSA complaint #11763171 — an unverified report by a vehicle owner.
The contact owns a 2019 Ford F-250 SD. The contact stated that while driving 70 MPH, there was an abnormal diesel odor on the inside of the vehicle. The contact stated that the vehicle failed to exceed 65 MPH, and there was white to gray smoke coming from under the hood. The contact pulled over with the engine still running and after opening the hood, the contact became aware of diesel fuel squirting out from the secondary fuel filter. The contact stated that the fire consumed the vehicle. The fire was coming from underneath the driver's side hood and driver’s side wheel well. The Fire Department was contacted and extinguished the fire coming from the vehicle. The vehicle was towed to an impound lot, and it was deemed a total loss by the insurance company. The manufacturer was contacted by phone and was made aware of the failure. The failure mileage was approximately 144,000.
NHTSA complaint #11762856 — an unverified report by a vehicle owner.
The contact owns a 2022 Ford F-250 SD. The contact stated that while driving at an undisclosed speed on the highway, the vehicle suddenly lost power, came to a full stop, and was unable to be restarted. The contact received notification of NHTSA Campaign Number: 25V455000 (Fuel System, Gasoline); however, the part to perform the recall repair was not yet available. The local dealer was contacted but was unable to recreate the failure. The contact stated that while attempting to restart the vehicle, there was an abnormal exhaust odor. The contact stated that the manufacturer had exceeded a reasonable amount of time for the recall repair. The manufacturer was made aware of the issue.
NHTSA complaint #11762899 — an unverified report by a vehicle owner.
The contact owns a 2022 Ford F-250 SD. The contact received notification of NHTSA Campaign Number: 25V455000 (Fuel System, Gasoline). The contact stated that while driving on several occasions at various speeds, the vehicle lost power and stalled. The vehicle was able to restart after each failure after two minutes. The contact stated that the failure persisted. The contact stated that during one failure while hauling a trailer, the vehicle immediately stalled. The contact stated that during the last failure, the check engine warning light illuminated. The vehicle was not diagnosed or repaired. The failure mileage was approximately 32,000.
NHTSA complaint #11762088 — an unverified report by a vehicle owner.
The contact owns a 2020 Ford F-250 SD. The contact stated that the vehicle experienced a no-start condition and was towed to a dealer, where it was diagnosed and determined that the high-pressure fuel pump had failed and needed to be replaced. However, the contact was informed that the repair was not covered under NHTSA Campaign Number: 24V957000 (Fuel System, Diesel); because there were not enough metal shavings found in the fuel system. The check engine warning light was illuminated. The contact used a vehicle scanner to retrieve DTC: P2291. The contact notified the manufacturer of the failure and was referred to the dealer for assistance. The failure mileage was approximately 134,000.
NHTSA complaint #11761676 — an unverified report by a vehicle owner.
I was traveling down the highway at approximately 55mph when truck suddenly lost power. I was able to pull over and had the vehicle towed as truck would not start. It was later determined that the cp4 high pressure fuel pump grenaded causing complete fuel system replacement costing over $11,000 in repairs. Shards of aluminium was sent throughout the fuel system.
NHTSA complaint #11760167 — an unverified report by a vehicle owner.
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.
The contact owns a 2021 Ford F-250. The contact stated that while driving 55 MPH, the engine warning light illuminated and the message "LIMP Mode in 34 Miles" was displayed. The dealer was contacted. The vehicle was diagnosed with a diesel emission fuel injector failure. The contact associated the failure with NHTSA Campaign Number: 24V957000 (Fuel System, Diesel); however, the VIN was not included. The vehicle was being repaired. The manufacturer was not made aware of the failure. The failure mileage was approximately 56,000.
NHTSA complaint #11751901 — an unverified report by a vehicle owner.
The contact owns a 2021 Ford F-250. The contact received notification of NHTSA Campaign Number: 25V455000 (Fuel System, Gasoline); however, the part to do the recall repair was not yet available.The contact stated that the manufacturer had exceeded a reasonable amount of time for the recall repair. Neither the manufacturer nor the dealer was made aware of the issue. The contact had not experienced a failure.
NHTSA complaint #11748757 — an unverified report by a vehicle owner.
The contact owns a 2022 Ford F-250. The contact received a recall notification of NHTSA Campaign Number: 25V455000 (Fuel System, Gasoline); however, the part to do the recall repair was not yet available. The contact stated that while the contact's husband was driving at an undisclosed speed, the accelerator pedal was depressed, but the vehicle failed to accelerate as intended and lost motive power. The vehicle was driven to the shoulder of the road, and the engine seized. The check engine warning light was illuminated. The driver attempted to restart the vehicle, but the vehicle failed to restart. The vehicle was towed to the dealer, where it was diagnosed with a failed fuel pump. The contact was informed that the fuel pump needed to be replaced. The vehicle was repaired; however, the failure recurred while traveling out of the State on vacation, with a trailer hitched to the vehicle. Additionally, the contact stated that the outside temperature was extremely hot, and the tow truck operator took three hours to arrive. The manufacturer was not made aware of the failure. The failure mileage was approximately 53,000.
NHTSA complaint #11748781 — an unverified report by a vehicle owner.
I took a functional vehicle to Swant Graber Ford in Barron, WI in on [XXX] for Recall 24S78 and since then I have had numerous vehicle issues involving the PCM that they flashed. I have up to 16 different codes when the check engine light comes on including numerous communication U-codes indicating faulty software download causing no run/no start problems along with severe safety concerns while driving. I returned the vehicle to Swant Graber today July 1, 2026 after 2 weeks being this was their earliest appointment availability. They then deleted the codes and told me to drive it until there is more issues which is a severe safety concern considering the condition of the PCM of this vehicle they returned to now which is unfunctional and not road worthy INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)
NHTSA complaint #11747789 — an unverified report by a vehicle owner.
The contact owns a 2020 Ford F-250. The contact received notification of NHTSA Campaign Number 24V957000 (Fuel System, Diesel); however, the part to do the recall repair was not yet available. The local dealer was contacted. The contact stated that the manufacturer had exceeded a reasonable amount of time for the recall repair. The manufacturer was not made aware of the issue. The contact stated that the vehicle had become inoperable due to a transmission failure. The contact associated the transmission failure with the recall; however, the dealer advised that the transmission repair would be at the owner's expense. The approximate failure mileage was 60,000.
NHTSA complaint #11743767 — an unverified report by a vehicle owner.
10 day roundtrip from [XXX] to [XXX]. 5 incidents of catastrophic engine failure on interstates. Truck started to jerk, sputter, lost power at an alarming rate. No engine light until failure ocurred. Very dangerous with heavy holiday traffic. Lives were in danger, us and other vehicles around us. No one expects travel to go from 70 mph,to 50, 30, 15 in such a short period of time. Pulled over to "investigate" code failures we deemed as o2 sensors. Afterwards the truck started back up, no engine lights and drove as normal. Started using premium gasoline, hoping it would help. Started driving in right lane as much as possible but had a failure ocurr right in front of on ramp as well at interstate speeds. Had another family following us so they also witnessed and pulled over all incidents. Brought into Ford 7/18/24 upon return home. Paid $125 inspection fee, concern not present, come back if happens again. Makes no sense that codes not present to pull. 12/13/2024 engine light on, catalytic converter replaced. 06/19/25 truck had catastrophic failure returning from work on hwy. XXX on [XXX], just two miles from leaving home another failure with no warning lights in heavy Friday traffic in construction zone. Couldn't clear the traffic lane completely. Very scary. Waited for clearing and limped it to a nearby off ramp. Same jerking, loss of power. Vehicle towed to shop for 2 weeks, testing, fuel pump replaced. Picked up 07/07/25. Next day received recall notice 25S75 in the mail 7/08/25. Everything made sense. 1/24/26 - Battery failed inspection @ 40% during oil change. Replaced battery ourselves from Costco. 04/23/26- Warning light, P0420 pulled, shop recommended engine tune -up. Paid $175 inspection fee + $671.20 tune up. 5/29/26 engine light on, P0420 pulled, recommend catalytic convertor replaced but not under factory warranty anymore so wants us to pay $4000 bill. Escalated up through Ford. As of 6/5/26 - Ford will pay half. I refuse. Should be covered by recall. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF I
NHTSA complaint #11742882 — an unverified report by a vehicle owner.
Cp4 pump failed and truck died pulling out onto the highway and won't restart! Luckily I didn't get hit by other vehicles and couple people helped push it out of the road!!! (I DO HAVE FORD DEALER REPORT STATING CP4 PUMP FAILURE!!!!!)
NHTSA complaint #11740514 — an unverified report by a vehicle owner.
The contact owns a 2021 Ford F-150. The contact stated while driving at 60 MPH, the accelerator pedal was depressed, however the vehicle failed to accelerate as intended. The contact stated that several unknown warning lights illuminated and the engine seized. The contact stated while attempting to start the vehicle, the vehicle failed to start. The vehicle was towed to the residence. The independent mechanic diagnosed the vehicle with metal shavings on the fuel injectors. The contact was informed that the fuel system and fuel injectors needed to be replaced. The vehicle was not repaired. The contact was informed of the recall, NHTSA Campaign Number: 24V957000 (Fuel System, Diesel). The vehicle was towed to the dealer where it was diagnosed with a failed high pressure fuel pump. The contact was informed that the high pressure fuel pump needed to be replaced. The vehicle was not repaired. The contact was informed of a gasoline odor in the fuel system. The contact was informed that the repair was not covered under the recall. The manufacturer was made aware of the failure and a case was filed. The contact was advised to take the vehicle to the dealer for diagnostic testing. The manufacturer was informed that the dealer denied the repair. The failure mileage was approximately 124,000.
NHTSA complaint #11739540 — an unverified report by a vehicle owner.
On 5/8/2026 at 1555 hours, while driving at normal freeway speed under normal driving conditions, vehicle began an exhaust system regeneration cycle. During the course of the region cycle, vehicle began to smoke excessively and realizing this wan not normal, I was able to yield to the right shoulder of the roadway. Almost immediately the vehicle ignited on fire and completely burned to the ground. The fire appeared to have commenced in the engine compartment, driver side near the firewall. The location of which appears to be consistent with reports of fuel filter failures I have read about in the past. The resulting fire ignited nearby brush which burned several hundred feet of brush and resulted in the spillage of diesel fuel and coolant which combined from the resulting melting of the coolant system and fuel tank and lines. This incident put both me and surrounding communities at risk, particularly from the resulting fire and HAZMAT spill. The vehicle was in good running condition prior to this incident. The incident was investigated by the Templeton California Highway Patrol.
NHTSA complaint #11738194 — an unverified report by a vehicle owner.
The contact owns a 2020 Ford F-250. The contact stated that he received NHTSA Campaign Number: 24V957000 (Fuel System, Diesel). The local dealer was contact who confirmed there were metal shaving in the fuel injectors. The vehilce was not repaired. The manufacture was not contacted. The failure mileage was approximately 30,000.
NHTSA complaint #11737777 — an unverified report by a vehicle owner.
I am reporting a serious safety issue involving my 2017 Ford F-250 diesel truck. While towing a 34-foot fifth wheel trailer and traveling from [XXX] to [XXX] , the vehicle experienced a sudden and dangerous failure near [XXX] . The engine warning light appeared, the vehicle went into low power mode, and then completely shut down on the highway. This created a serious safety hazard, particularly while towing a large trailer at highway speeds. The vehicle was towed to a repair facility where it was determined that the high-pressure fuel pump had catastrophically failed. The pump had developed a significant crack and released metal debris throughout the entire fuel system. This required extensive repairs, including: - Replacement of the high-pressure fuel pump - Replacement of fuel lines - Full fuel system cleaning, including the fuel tank The total repair cost exceeded $14,000 USD (near $20,000 CAD). The mechanic indicated that this type of failure should not occur under normal operating conditions. Additionally, the Ford parts dealer advised that the failed fuel pump could be returned for credit, suggesting the failure may not be consistent with normal wear and tear. This failure occurred suddenly, without warning, and resulted in a complete loss of power while driving, which I believe represents a significant safety concern. I respectfully request that NHTSA investigate this issue as a potential safety-related defect involving high-pressure fuel pumps in diesel vehicles. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)
NHTSA complaint #11737588 — an unverified report by a vehicle owner.
Original Fuel pump stated intermittent long cracks about 35,000 miles. And continues to do so. It seems like FORD uses the all time favorite “ we cannot recreate the issue” in order to send the customer on their way and not take ANY responsibility whatsoever ,WOW! Its rediculous that they don’t want to acknowledge the issue after thousands of customers complain. Our whole family has been riding in this vehicle when the truck experienced the truck lag and turn off at highway speeds. Does someone have to be hurt or killed by this for this company to finally own up? I hope none does!!! Make it right FORD!!! Yet they changes and updated the newer trucks pumps after this, why? REDICULOUS
NHTSA complaint #11737324 — an unverified report by a vehicle owner.