The contact owned a 2024 Ford F-450 SD. The contact stated that while his fiancée was driving with cruise control set to 57 MPH, there was an abnormally strong smoky odor inside the cabin of the vehicle. No warning light was illuminated. The driver pulled over to the side of the road and there were flames coming from the engine bay. The driver called 9-1-1. The driver attempted to extinguish the fire with assistance using three fire extinguishers but failed to extinguish the fire. The vehicle became fully engulfed in flames before the Fire Department arrived on the scene. The fire department extinguished the fire; however, the entire vehicle burned, leaving only a fraction of the tailgate intact. Neither a Fire Department nor a Police report was filed. The contact's dog sustained a burn injury; however, the driver was not injured. The vehicle was towed to a tow yard and was pending the decision of the insurance company. The manufacturer was notified of the failure, but no assistance was provided, and the contact was referred to the insurance company for assistance. The failure mileage was approximately 9,707.
NHTSA complaint #11757734 — an unverified report by a vehicle owner.
n October 28th, I left Atlanta, Georgia with a load going to Pittsburgh–Philadelphia. On October 29th, 2025, around 12:30 a.m., I was approximately two miles north of Birch River, West Virginia. While driving uphill at a steady speed of about 60–65 mph, I suddenly heard a loud popping sound, as if something had exploded or blown inside the engine. Right after that, the truck immediately lost power, and I pulled over to the shoulder as quickly as I could. As I was stopping, I saw flames coming through the hood directly in front of me, mostly from the driver’s side. I grabbed the fire extinguisher from inside my cab and opened the hood. On the driver’s side of the engine, I saw heavy flames coming out under high pressure. I emptied the entire extinguisher, but the fire did not stop. Then I ran to get my second extinguisher from the trailer and used it completely as well, but the flames kept burning. I noticed that strong flames were also coming from underneath the front driver’s side wheel area.
NHTSA complaint #11714467 — an unverified report by a vehicle owner.
VEHICLE SHUT DOWN WHILE IN MOTION ON HIGHWAY WHICH CAUSED FOR BRAKES AND STEERING TO FAIL. VEHICLE WAS TOWED TO SUN STATE FORD DEALERSHIP WHERE THEY DID A DIAGNOSIS. THEY FOUND EXCESSIVE AMOUNTS OF METAL IN THE HIGH PRESSURE FUEL SYSTEM. THEY HAD TO REPLACE THE ENTIRE FUEL SYSTEM PLUS REPLACED ALL INJECTORS WHICH NOW HAS AN OPEN INVOICE OF $15,923.97. AFTER RESEARCH WE FOUND OUT THAT THERE IS A RECALL ON THE CP4 WHICH IS THE MANUFACTIRE RECALL NUMBER 24S78 AND NHTSA RECALL NUMBER 24V957. FORD IS NOT WILLING TO COVER THE COST OF THE RECALL REPAIRS AND THE DEALERSHIP IS NOT COOPERATING AS WELL. THIS IS A COMPANY VEHICLE LOSING THE COMPANY $3K PER DAY.
NHTSA complaint #11676722 — an unverified report by a vehicle owner.
Vehicle was being driven by a driver service to be delivered to the home garage after production was completed at the manufacturer. During transit, the operator reported that the low fuel pressure warning light came on immediately followed by flames in the engine compartment.
NHTSA complaint #11661929 — an unverified report by a vehicle owner.
The contact owns a 2022 Ford F-450SD. The contact stated while driving 50-65 MPH, the vehicle lost drive power and the instrument panel lights started flickering. The check engine warning light was illuminated. The contact was able to pull over to the side of the road. The vehicle was able to restart, and the contact resumed driving. The contact stated that the failure recurred while driving on several occasions. The vehicle was taken to the dealer, where it was diagnosed and determined that both batteries had failed and needed to be replaced. The vehicle was repaired. The manufacturer was notified of the failure, but no assistance was provided. The failure mileage was approximately 75,000. The VIN was not available.
NHTSA complaint #11641049 — an unverified report by a vehicle owner.
High pressure fuel pump failed while driving towing a trailer. Was able to pull over safely, entire fuel system needs to be replaced. Unknown if anything else was damaged yet. Vehicle is still in for repairs, estimate is between 9-13k parts and labor. I hope it didn't destroy the entire engine.
NHTSA complaint #11633674 — an unverified report by a vehicle owner.
on 6/7/24, while driving around the Baltimore beltway towing a 44' RV in rush-hour traffic a battery warning light appeared. Within 1 min, the vehicle dashboard information went out and the engine stalled. I immediately put the vehicle in neutral and was able to coast to the shoulder without advantage of turn signals on either the RV or truck as a result. Once there I popped the hood and was able to get out to open it, however, there was a fire and my fingers were singed. After opening the hood, I noticed a full engine fire. I yelled for my wife to get out ASAP. I was able to extinguish the fire (thanks to the RV extinguisher), however, a secondary fire started, and a Samaritan help extinguish that fire. A fire department truck appeared, and they cut the batter cable since it seemed to have started the fire. The vehicle was towed back to the dealership where it was purchased. The insurance agent stated a mechanic had informed him; they believe it was the battery that was the cause. All vehicle maintenance was conducted by the dealership due to warranty AND an extended vehicle maintenance plan purchased at the time of sale. Ford has failed to acknowledge any problems with the vehicle and refused to honor the warranty.
NHTSA complaint #11619319 — an unverified report by a vehicle owner.
I was towing my 5th wheel trailer on a highway and up an incline. Almost at the top of the hill a notification appeared on the dash screen stating, "low power mode". As I was on top of a hill, towing a trailer, on a highway, and with no available offramps, I coasted down the hill trying to find a place to pull off of the highway. At the bottom of the hill I heard a loud noise from the engine, noticed smoke in my rearview mirror, and lost all power to the vehicle including power steering. I managed to pull off to the side of the busy highway. I exited the vehicle and removed my kids from the car, moving them up a hill on the side of the highway as it was the safest place I could find. It was at that point I noticed flames coming from the right font front wheel well. I quickly opened my trailer, grabbed my fire extinguisher, and doused the flames. Had I not acted quickly the entire truck, trailer, and hillside would have caught fire. The vehicle is still at the dealership waiting on Ford Motor Company to approve the repairs. The vehicle has approximately 26,000 miles on it and is unmodified.
NHTSA complaint #11602753 — an unverified report by a vehicle owner.
The contact owns a 2022 Ford F-450 SD. The contact stated that while starting the vehicle, he started to hear a loud knocking noise coming from the engine. No warning lights were illuminated. The vehicle was towed to the dealer where it was diagnosed and determined that the engine needed to be replaced. The manufacturer was notified of the failure and advised the contact to reach out to the NHSTA Hotline for assistance. The failure mileage was 168,000.
NHTSA complaint #11583404 — an unverified report by a vehicle owner.
The contact owned a 2022 Ford F-450. The contact stated that while her driver was driving at an undisclosed speed, her driver smelled a burning odor and noticed smoke at the hood of the vehicle. The contact then stated that the driver then stopped and exit the vehicle when the vehicle suddenly inflamed. No injuries were sustained. A fire department was notified however, the vehicle had burned. A fire report was filed. Additionally, the contact stated that on several occasions, she attempted to start the vehicle however, the engine failed to engage. The contact also stated that prior to the failure, while driving at undisclosed speeds the vehicle stalled without warning. The undisclosed dealer was notified of the failure and an appointment was scheduled for the following week. The vehicle was not repaired. The vehicle was towed to a tow lot and deemed a total loss by the insurance company. The manufacturer was notified of the failure and the contact was advised to contact her insurance company. The failure mileage was approximately 17,000.
NHTSA complaint #11539426 — an unverified report by a vehicle owner.
TL* THE CONTACT OWNS A 2005 FORD F-450. THE CONTACT STATED THAT WHILE DRIVING APPROXIMATELY 55 MPH, THE VEHICLE STALLED AND THE DASHBOARD ILLUMINATED. THE VEHICLE WAS TOWED TO AN UNKNOWN DEALER IN NEVADA WHERE A DIAGNOSTIC TEST WAS PERFORMED. THE TECHNICIAN STATED THAT THE ENGINE NEEDED TO THE REPAIRED. A COMPLETE DIAGNOSIS OF THE FAILURE WAS NOT PROVIDED. THE VEHICLE WAS THEN TAKEN TO ANOTHER INDEPENDENT MECHANIC WHO KEPT THE VEHICLE FOR A WEEK AND REPAIRED AN UNKNOWN FAILURE. THE VEHICLE LOST POWER WHEN IT WAS STARTED AND THEN HAD TO RESTARTED. THE VEHICLE WAS TAKEN TO A THIRD INDEPENDENT MECHANIC WHO REPLACED EIGHT INJECTORS. THE VEHICLE OPERATED AS INTENDED FOR A WHILE HOWEVER, THE FAILURE RECURRED. THE VEHICLE WAS NOT REPAIRED ANOTHER TIME. THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURE. THE FAILURE MILEAGE WAS APPROXIMATE 125,000. THE VIN WAS NOT AVAILABLE.
NHTSA complaint #11299334 — an unverified report by a vehicle owner.
FUEL TANK DELAMINATION LEADING TO BLOWN ENGINE X2 AND FUEL PUMP REPLACEMENT X2. I USE NO ADDITIVES AND BUY ONLY COMMERCIAL FUEL ALMOST EXCLUSIVELY IN NORTHEAST GEORGIA.
NHTSA complaint #11166041 — an unverified report by a vehicle owner.
WHEN TRAVELING DOWN THE HIWAY,SOMETIMES YOU WILL LOSE POWER. YOU WILL FEEL A JERK. THE ENGINE IS STILL RUNNING BUT NO POWER TO THE WHEELS. PRETTY SCARY WHEN YOU ARE TRYING TO PASS A VEHICLE ON THE INTERSTATE. YOU TRY TO PULL OVER TO THE SIDE OF THE ROAD. YOU HAVE NO MEANS OF MOVEMENT. YOU CAN NOW TURN OFF THE VEHICLE AND PUT IT IN NEUTRAL AND RESTART THE ENGINE,YOU CAN NOW CONTINUE DOWN THE HIWAY UNTIL IT HAPPENS AGAIN. THIS HAS HAPPENED MULTIPLE TIMES. WE HAVE DRIVEN WITH OUR HORSE TRAILER DOWN TO ARIZONA 3 TIMES AND THIS HAS HAPPENED 3-4 TIMES EACH WAY. FORD DEALER WHERE PURCHASED HAS NO CLUE WHAT IS CAUSING THIS. THIS VEHICLE WAS PURCHASED BRAND NEW. WE HAVE HAD THIS PROBLEM SINCE NEW.
NHTSA complaint #11096659 — an unverified report by a vehicle owner.
ENTERED ON 10/04/2016 AT 2:45:07 PM EDT (GMT-0400) BY NHTSA.WEBMASTER@DOT.GOV: SENDER NAME: SENDER EMAIL: SUBJECT: FORD F-450 COOLING SYSTEM FAILURE AND ENGINE PROBLEMS COMMENTS: I PURCHASED THIS TRUCK NEW IN 2008 AND DROVE IT CROSS COUNTRY TOWING MY 5TH WHEEL. AT 4,544 MILES THE RADIATOR BLEW APART. (DRIVING HIGHWAY/TOWING) THIS WAS REPLACED UNDER WARRANTY AFTER FIGHTING WITH FORD. AT 6,065 MILES I HAD ANOTHER COOLING SYSTEM LEAK.(DRIVING LOCAL) THEY HAD TO REPLACE THE "SMALL" RADIATOR, THE "FUEL AND TURBO" COOLER. AT 21432 MILES THE POWER STEERING PUMP WENT AND HAD TO BE REPLACED.(DRIVING/TOWING/LOCAL) SHOP STATED THAT "FLUID WAS CONTAMINATED" (THIS TRUCK HAS ONLY BEEN SERVICED BY FORD) AT 22215 MILES I HAD TO HAVE THE LEFT REAR AXLE SEAL, BRAKE PADS AND LOWER CAC HOSE FOR TURBO REPLACED.( DRIVING HIGHWAY/TOWING) NOW AT 29,017 MILES THE RADIATOR TANKS HAVE SEPARATED FROM THE CORE AND NEED TO BE REPLACED AGAIN ALONG WITH THE CRANK SEAL AND ANOTHER POWER STEERING PUMP.( COMBINATION, HIGHWAY/LOCAL/TOWING? NOT TOWING) I HAVE CHECKED WITH FORD AND THEIR CUSTOMER SERVICE DEPARTMENT AND THEY REFUSE TO COVER ANY OF THIS, OR ANY PART, UNDER WARRANTY. I HAVE ALSO DONE RESEARCH ON THESE TRUCKS HAVING FOUND MANY OTHER OWNERS HAVING THE SAME COOLING SYSTEM ISSUES ALONG WITH OTHER ISSUES THAT FORD REFUSED TO COVER. PLEASE LOOK INTO THIS ISSUE, I THINK THEY NEED TO HAVE A RECALL ON THE COOLING SYSTEMS IN THEIR TRUCKS. THANK YOU FOR TAKING THE TIME TO READ THIS. I WOULD APPRECIATE A RESPONSE. CHECK EDMUNDS FORD F-450 SD TURBO DIESEL REVIEW, MULTIPLE COMPLAINTS OF COOLING SYSTEM FAILURE, ENGINE FAILURE.
NHTSA complaint #10913839 — an unverified report by a vehicle owner.
ENGINE AND ENGINE COOLING:EXHAUST SYSTEM:EMISSION CONTROL:GAS RECIRCULATION VALVE (EGR VALVE)
TL* THE CONTACT OWNS A 2008 FORD F-450. WHILE DRIVING 40 MPH, THE VEHICLE STALLED WITHOUT WARNING. THE VEHICLE WAS ABLE TO BE RESTARTED AFTER THE CONTACT REMOVED AND RECONNECTED THE BATTERY. THE FAILURE RECURRED INTERMITTENTLY. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC WHERE IT WAS DIAGNOSED THAT THE EXHAUST FUEL RECIRCULATION VALVE FAILED AND NEEDED TO BE REPLACED. THE VEHICLE WAS REPAIRED, BUT THE REMEDY FAILED. THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURE. THE FAILURE MILEAGE WAS UNKNOWN.
NHTSA complaint #10883654 — an unverified report by a vehicle owner.
THE HIGH PRESSURE FUEL PUMP FAILED. FORD CLAIMED THAT THIS WAS FROM CONTAMINATED FUEL. FORD HAS TWO FUEL FILTERS AND A WATER SEPARATOR. I PERSONALLY ADDED TWO ADDITIONAL FILTERS AND AN ADDITIONAL WATER SEPARATOR, FOR A TOTAL OF FOUR FILTERS AND TWO SEPARATORS. FORD ALSO HAS A WATER IN FUEL LIGHT THAT IS SUPPOSED TO ALERT THE DRIVER TO CONTAMINATION. AT NO TIME DID THIS LIGHT COME ON. IN SHORT, I BELIEVE FORD HAS A DEFECTIVE FUEL PUMP AND A DEFECTIVE FILTRATION AND WATER ALERTING SYSTEM. THIS TRUCK SHUTDOWN, WITH NO WARNING AT 70 MPH ON A LIMITED ACCESS HIGHWAY. FORD REFUSES TO ADDRESS THE PROBLEM AND CONTINUES TO BLAME THE OWNER. THIS IS A SAFETY ISSUE AND I WAS FORTUNATE THAT THERE WAS LIGHT TRAFFIC AND I WAS ABLE TO SAFELY STEER THE POWERLESS TRUCK TO THE SIDE OF THE ROAD. IN RESEARCHING THIS ISSUE, I'VE SEEN THAT THERE ARE NUMEROUS REPORTS OF THE SAME PROBLEM ON THE 6.7 LITER POWERSTROKE DIESEL ENGINE FROM 2011 ON.
NHTSA complaint #10871640 — an unverified report by a vehicle owner.
TL* THE CONTACT OWNS A 2008 FORD F-450 SD. AFTER WATER WAS ADDED TO THE RADIATOR, THE CONTACT NOTICED THAT WATER LEAKED OUT OF THE HOSE. THE VEHICLE LEAKED RADIATOR FLUID FROM THE HOSE. IN ADDITION, THE EGR COOLER MALFUNCTIONED AND CAUSED THE AIR CONDITIONER TO OPERATE INTERMITTENTLY. THE VEHICLE WAS TAKEN TO THE DEALER WHERE IT WAS DIAGNOSED THAT THE EGR COOLER, RADIATOR, AND HOSES NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURES. THE FAILURE MILEAGE WAS APPROXIMATELY 95,000.
NHTSA complaint #10860944 — an unverified report by a vehicle owner.
TL* THE CONTACT OWNED A 1995 FORD F-450 SD. THE CONTACT STATED THAT THE VEHICLE CAUGHT FIRE INDEPENDENTLY. THE FIRE DEPARTMENT EXTINGUISHED THE FIRE AND FILED A REPORT. THERE WERE NO INJURIES. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE VEHICLE WAS DESTROYED. THE VIN AND FAILURE MILEAGE WERE UNKNOWN.
NHTSA complaint #10851336 — an unverified report by a vehicle owner.
RADIATOR LEAK AT 43,000 FROM THE JOINT BETWEEN THE PLASTIC END CAP AND ALUMINUM CORE, DRIVER'S SIDE NEAR BUMPER. COST TO REPAIR ESTIMATED AT 1400-1800$ AT ONLY 7K MILES OUTSIDE OF FACTORY WARRANTY. VEHICLE IS USED DAILY WITHIN RECOMMENDED WEIGHT CAPACITIES TO MOVE MATERIALS AND TRAILERS, BUT FOLLOWS A VERY STRICT MAINTENANCE PROGRAM TO ENSURE LONG LIFE.
NHTSA complaint #10818765 — an unverified report by a vehicle owner.
INVESTIGATION NEEDS TO BE DONE ON 2008 FORD F450SD 6.4L TRUCKS ON THE BOLTS THAT ARE USED IN THE ENGINE COMPARTMENT FOR THE EXHAUSTS. HAVE A BOLT THAT BROKE THAT IS NOW CAUSING A WHISTLING SOUND UNDER ACCELERATION AND EXHAUST FUMES TO ESCAPE. ON THE DRIVER SIDE FOUR OTHER BOLTS HAVE BROKEN OFF IN THE HEAD UNIT THAT WILL REQUIRE FOR THE ENGINE OR CAB TO BE REMOVED IN ORDER TO REPLACE THE BOLTS. THE REPAIR FACILITY MY TRUCK IS LOCATED HAS FOUR OTHER 6.4L FORD SUPER DUTY TRUCKS SITTING THEIR FOR THE SAME REPAIRS. SEEMS TO ME THERE IS AN ISSUE WITH THE TYPE OF STUDS AND BOLTS THE MANUFACTURER USED. RECALL NEEDS TO BE ISSUED TO FIX THIS ISSUE. THE OTHER TRUCKS WERE F250, F350, AND F450 SUPER DUTY 6.4L TURBO DIESEL. THE EXHAUST FUMES IS DEFINITELY A SAFETY HAZARD.
NHTSA complaint #10764446 — an unverified report by a vehicle owner.