603 of the
5,142 complaints filed about the Ford F-350 SD
are about the engine —
12% of everything owners reported.
The worst model year for it is 2005.
When the truck idles it randomly shuts off completely and shows a sign on dash of 'vehicle may not start/restart please service' then it will disappear. It never shows any codes when hooked to machine in repair shop. This is a huge safety concern while driving and hauling trailers with equipment since all power is lost when it happens. It has been looked at by the dealership 3 times and they were unable to locate issue as stated on service receipt. No warnings prior and truck was purchased 3/2025 and the issue started 1/26 and still continues.
NHTSA complaint #11758159 — an unverified report by a vehicle owner.
The contact called on behalf of a Federal Agency that owned a 2019 Ford F-350. The contact stated that while driving 55 MPH, the check engine warning light illuminated, and the message "Reduce Power Mode" was displayed. The driver pulled over to the side of the road, and the vehicle shut off. The driver became aware of smoke coming from underneath the hood of the vehicle. The driver opened the hood and became aware that the engine compartment was engulfed in flames. The driver attempted to extinguish the fire with fire extinguishers; however, the fire persisted, and the vehicle was completely burned. The fire was extinguished by the Fire Department. The contact believed that a Fire Department report was filed. A Police report was filed. No injuries were sustained. There was no property damage. The vehicle was towed to a tow yard and was deemed a total loss. The contact related the failure to NHTSA Action Number: PE24014 (Fuel System, Diesel, Fuel System, Other). The manufacturer was notified of the failure. The failure mileage was approximately 120,000.
NHTSA complaint #11752108 — an unverified report by a vehicle owner.
I am filing this complaint regarding my Ford F-350, VIN [XXX], which caught fire on XXX. The truck had approximately 130,000 miles, which I consider low mileage for a properly maintained diesel Ford F-350. These trucks are known for long service life, and many Ford diesel trucks routinely remain in service for 20 years or more and exceed 250,000 miles when properly maintained. For that reason, I did not expect a sudden and catastrophic fire in a truck with only 130,000 miles. While driving, passing motorists alerted us the truck was on fire. The fire appeared to originate in the engine compartment and spread extremely rapidly. Within a very short period, the front of the truck was engulfed in flames and sustained catastrophic damage. Based on the speed and severity of the fire, I am concerned a failure in the engine compartment, fuel system, electrical system, or another vehicle component may have caused or contributed to the fire. This truck has been well maintained, kept clean, and responsibly cared for. I followed the manufacturer’s maintenance guidelines and did not expect a sudden engine-compartment fire. After the fire, I found reports of other F-350 fires and references to fire-related complaints and investigations. This raises serious concerns Ford may have known of a potential fire risk involving these trucks. This incident created major safety hazard not only to the occupants of the truck, but to other motorists and anyone nearby. Had passing drivers not alerted us, the outcome could have been far worse. The severity of the fire required a major emergency response, including multiple fire trucks and police. A vehicle fire of this magnitude presents an obvious risk of serious injury or death. I request NHTSA investigate Ford F-350 and vehicle fire incidents to determine whether a defect involving the fuel system, electrical system, or related parts may cause these trucks to catch fire without warning. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)
NHTSA complaint #11749325 — an unverified report by a vehicle owner.
Description On your vehicle, it may be possible to experience a noisy, partially inoperable, or completely inoperable heating ventilating and air conditioning HVAC blower Motor. Safety Risk An inoperable or partially inoperable HVAC blower Motor may affect windshield defrost and defogging capability, which can decrease visibility under certain driving conditions, increasing the risk of a crash. Remedy Parts are available to repair your vehicle. Ford Motor Company has authorized your dealer to inspect and possibly replace the blower Motor assembly. Free of charge. Next Steps Contact your dealer for more information to schedule the free service.
NHTSA complaint #11743721 — an unverified report by a vehicle owner.
The contact owns a 2020 FORD F-350. The contact stated while driving at an undisclosed speed, he had a loss of motive power and check engine warning light was illuminated when driving, almost causing an accident due to not being able to accelerate. The vehicle was taken to a dealer where it was diagnosed to have metal shavings in the combustion system. The contact received notification of NHTSA Campaign Number: 24V957000 (FUEL SYSTEM, DIESEL); however, the SSSC (Special Service Center assistance request) was declined by Ford agency (SSSC), due to the issue not having metal shavings although the dealer technician stated there were shavings. The vehicle was not repaired. The manufacturer was not notified of the failure. The failure mileage was 126,136.
NHTSA complaint #11739265 — an unverified report by a vehicle owner.
The component/system that failed or malfunctioned is the SCR (Selective Catalytic Reduction) NOx Catalyst Efficiency system, triggering DTC P20EE – SCR NOx Catalyst Efficiency Below Threshold (Bank 1). This issue began immediately after Ford Recall 24S78 (PCM software update) was performed on April 29, 2026 at Ferman Ford of Countryside. The truck had zero emissions or check-engine issues prior to the recall flash and was perfectly maintained to Ford standards with Howes diesel treatment every tank. The problem has been reproduced and confirmed multiple times by the dealer: After the May 4 PCM reprogram per TSB 21-2248 After replacement of both NOx sensors on May 5 (code returned in under 17 miles) After replacement of the DEF injector (code returned again) The dealer only performed one manual DPF regeneration instead of the two required by Ford SSM 49202 and pinpoint test RD15, and they did not complete the SCR Parameter Reset. They are now quoting an additional ~$2,000 out-of-pocket for a DPF replacement after partial goodwill assistance was approved. The vehicle has been repeatedly inspected and repaired by Ferman Ford. No independent inspection yet. Ford Customer Service has been contacted and partial goodwill was approved, but significant out-of-pocket costs remain. Warning lamps/messages (Service Engine Soon light + “exhaust emission control system is not operating as expected”) first appeared immediately after the April 29 recall PCM flash and have continued ever since. Safety risk: A loss of motive power, entry into limp mode, or reduced power while driving could result in a crash or inability to maintain highway speed. This appears to be a direct consequence of the Recall 24S78 PCM software update tightening emissions monitoring. All repair orders, photos of warnings, and supporting documents are attached for your review. There is 12. I was not able to upload the last of the documents.
NHTSA complaint #11736551 — an unverified report by a vehicle owner.
While sitting at a stop sign, the fuel supply line blue off the fuel filter under the hood. Straying diesel fuel all over. The white clip that hold the hose on had crumbled apart, It soaked the engine with fuel and we were lucky it did not start a fire. The fuel line was reattached and it then blew off again. I had to replace the entire fuel line at a cost of around $1000. Prior to the first event the filter had been on the truck and was being serviced every other oil change in line with the manufactured guidelines. When looking on line this is a major problem with the fuel line and under hood filters causing fires. This needs a repair before more people are hurt
NHTSA complaint #11730641 — an unverified report by a vehicle owner.
Vehicle has gone into LIMP mode multiple times. Was driving the vehicle and the check engine light went on and the vehicle reduced its speed to 25 mph. This is very dangerous because the traffic was moving at 70 mph and could have rear ended me. The F350 has been at the dealership since March 18. The dealer has diagnosed it but claim they cannot get the part they need to fix it. They insist I return the loaner and drive the F350 home with the problem.
NHTSA complaint #11726373 — an unverified report by a vehicle owner.
ENGINE AND ENGINE COOLING:EXHAUST SYSTEM:EMISSION CONTROL:UREA INJECTION SYSTEM (DEF)
The contact owns a 2025 Ford F-350 SD. The contact stated that while driving at an undisclosed speed, the DEF (Diesel Exhaust Fluid) level reading became inoperable with the message “500 Miles to Empty - Refill Soon” displayed. The vehicle was taken to the dealer but was not diagnosed. The contact was informed that the DEF gauge had been replaced by the dealer. The vehicle was repaired; however, the failure recurred. The manufacturer was made aware of the failure. The failure mileage was approximately 15,512.
NHTSA complaint #11725341 — an unverified report by a vehicle owner.
ENGINE AND ENGINE COOLING:EXHAUST SYSTEM:EMISSION CONTROL:UREA INJECTION SYSTEM (DEF)
The contact owns a 2021 Ford F-350. The contact stated that while operating the vehicle, the check engine warning light remained illuminated. The vehicle was taken to the local dealer who diagnosed that the DEF Pump, DEF Pump Lines needed, and DEF heater element needed to be replaced. The vehicle was not repaired. The manufacturer was not notified of the failure. The failure mileage was 92,567.
NHTSA complaint #11719362 — an unverified report by a vehicle owner.
Cold side intercooler boost tube cracked due to constant vibration impact from coolant overflow hose routed directly above and on top of it. Part and vehicle is available for inspection. The split in the boost hose caused me to loose power while attempting to merge onto a road, almost being hit by another vehicle. After research there are multiple other instances of complaints of the same thing happening to others and multiple aftermarket manufacturers producing replacement and upgraded parts with references and warnings of the same thing happening for the last 10 years. No warning lamps or symptoms prior to failure. After failure no warning lamps but could hear an audible hiss. The vehicle has not yet been inspected by the dealer or police. I was told by their parts people it is a regular failure and the part costs typically around $200 and they only sold it as a full part and not just the rubber replacement hose althought they are separate parts connected with hose clamps.
NHTSA complaint #11719097 — an unverified report by a vehicle owner.
I have about 54000 miles on a 2019 ford super duty 350 with the Power stroke 6.7. Engine light went on and its at Willowbrook ford in Illinois. Emission problem with Particular Sensor code 22e02. The cost of repair is between $816 plus another $1259 if it is cracked. This is absolutely ridiculous. After researching this is a big Ford problem. So they sold some trucks without them and have eliminated them on their 22 models. I think Ford should be responsible for the cost.
NHTSA complaint #11713899 — an unverified report by a vehicle owner.
Driving uphill at approx 20mph near my home. Loud bang/explosion from engine or front driver-side wheel well. Red alarm flashed on instrument cluster (something like “Front Brake Failure”) and strong odor of fuel or exhaust entered cab. I immediately pulled into a pullout and put vehicle in park when I noticed flames coming from the engine compartment through the gaps in hood and wheel well. I splashed a small amount of water on the driver side front tire, but the fire continued to grow. I backed away to a safe distance and called 911. Within 5 minutes, the entire engine compartment was on fire and I captured on video explosions as the fire raged Local fire department arrived within 15 minutes, but the entire engine and cab had already been destroyed by fire. Had I been driving at high speed or with passengers, this incident could have resulted in serious burn injuries and death. Had I been driving during summer months, this incident would have caused a devastating wildfire. Had I been in traffic, I may have caused a multi-car wreck. There were absolutely no warning indicators that such a violent incident could occur. Tow truck driver said it may have been a fuel filter issue which has caused other Super Duty’s to experience sudden and catastrophic engine compartment fires. Minimal research showed me that NHSTA is investigating Ford Super Duty for this very issue. My F350 is model year 2017. I also have video of fluids dripping from the burning vehicle and the droplets are on fire which leads me to believe that leaking fuel — possibly from a cracked plastic filter — may be to blame for this incredibly dangerous incident. The vehicles remains have been searched by California Highway Patrol and the remains are currently being investigated by State Farm Auto Insurance claims experts.
NHTSA complaint #11709814 — an unverified report by a vehicle owner.
After using manual mode and brakes to slow down I went back to automatic mode without coming to a stop. I was turning left and it felt like I had let off the gas completely but I was pressing harder and harder but my truck wouldn't do anything and the gas pedal did nothing. Then a second later it aggressively accelerated and went back to normal. It did it once 2 weeks ago also when I was turning right and I thought it was just the proximity sensor or something thinking I was too close to a car or something and cut power but there was no beeping. I have it on the dash camera if that helps.
NHTSA complaint #11709484 — an unverified report by a vehicle owner.
I have a 2017 F-350 SuperDuty with the Engine Block Heater option, two recalls have been issued related to a condition that can cause overheating of the power cord with the possibility of a fire. Recall 18V-894 and 19V-278 have both been applied and verified by Ford Customer Service. During the recent cold weather in the Houston, Texas area, the engine block heater was used to keep the engine warm to assist with starting. When I disconnected the power cord the was hot enough to have melted the plug to the point where the blades in the plug were loose and I had to use gloves to separate the engine heater cord from the extension cord. This should have been fixed under one or both of the previous recalls. It represents an electrical hazard that could lead to fire and loss of property. I asked Ford to remedy the situation under case XXX and they have declined to resolve the hazard. Please review this case and have Ford issue a third recall to remedy this safety issue. I have provided pictures to assist in your determination. Regards, [XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)
NHTSA complaint #11703099 — an unverified report by a vehicle owner.
I have the 7.3 gas engine. It is now sounding like a typewriter. I've been told I could have a $8,000 to $13,000 repair or total engine replacement. My truck is just under 97,000 miles and this has been a known issue for the Job 1 engines. Ford is not taking ownership of these lifter/cam issue. I was told I could have my engine lock up on me while driving. I am autistic and have an autoimmune issue that cause me to have a disabilities. It does not seem right, that a long term, multiple Ford owner now could have their engine fail or lock up while I'm driving, not to mention I may need a complete new engine from this design error. From what I've read, the Job 2 of these engines they've enlarged oil recyclers or something to correct this issue. Can you help us that have this major saftey issue?
NHTSA complaint #11703037 — an unverified report by a vehicle owner.