146 of the
630 complaints filed about the Ford F-450 SD
are about the fuel system —
23% of everything owners reported.
The worst model year for it is 2006.
The contact owns a 2022 Ford F-450 SD. The contact stated that while driving at 25 MPH and depressing the accelerator pedal, the vehicle failed to respond and shut down unexpectedly. The check engine warning light was illuminated. The vehicle was restarted and operated as intended. A dealer was contacted. The vehicle was taken to the dealer to be diagnosed, and it was determined that the fuel system needed to be replaced. The vehicle was not repaired. The contact associated the failure with NHTSA Campaign Number: 24V957000 (FUEL SYSTEM, DIESEL); however, the VIN was not included in the recall. The manufacturer was not notified of the failure. The failure mileage was 59,350.
NHTSA complaint #11723855 — 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.
The contact owns a 2021 Ford F-450 SD. 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 made aware of the issue. The contact had not experienced a failure.
NHTSA complaint #11687332 — 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.
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.
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.
TL* THE CONTACT OWNS A 2007 FORD F-450 SD. WHILE DRIVING 50 MPH, THE VEHICLE STALLED WITHOUT WARNING. THE VEHICLE WAS ABLE TO RESTART AFTER VARIOUS ATTEMPTS; HOWEVER, THE FAILURE RECURRED. THE VEHICLE WAS TOWED TO THE CONTACT'S RESIDENCE. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. IN, ADDITION THE CONTACT STATED THAT THERE WAS NO FUEL COMING THROUGH THE FUEL FILTER. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE FAILURE MILEAGE WAS 41,768.
NHTSA complaint #10948703 — an unverified report by a vehicle owner.
6.7 DIESEL FUEL INJECTOR HOLD DOWN CLAMP BROKE AND FUEL INJECTOR BLEW OUT OF CYLINDER HEAD SPRAYING FUEL ALL OVER ENGINE COMPARTMENT. VEHICLE WAS ALWAYS SERVICED BY AUTHORIZED FORD DEALERS PER SCHEDULE. VEHICLE IN MOTION ON HIGHWAY. HAS 98,000 MILES ON IT, BUT IS A FEW MONTHS OVER THE 5 YEAR POWERTRAIN WARRANTY. LOCAL FORD TECH SAYS ITS A COMMON PROBLEM FOR THIS ENGINE, AND FORD HAS RECOGNIZED IT AND IS MAKING ENGINEERING CHANGES TO REPLACEMENT PARTS. THIS MAY BE, BUT HAVING A HIGH PRESSURE FUEL SYSTEM BLOW APART ON THE ROAD IS NOT COMMON FOR ME. AND OF COURSE NO WARRANTY COVERAGE SO I HAVE TO COVER ALL COSTS. I HAVE NO NOTIFICATION FROM ANYONE ABOUT RECALLS OR TSBS EFFECTING THE VEHICLE.
NHTSA complaint #10907073 — 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.
"DELAMINATION OF FUEL TANK" AFTER ONLY HAVING THE VEHICLE FOR SHORTLY OVER FOUR MONTHS, THE TRUCK WOULD NOT CRANK. THE TRUCK WAS PARKED ON A CITY STREET IN WASHINGTON, DC WHERE I RACKED UP 2 PARKING TICKETS. I HAD IT TOWED TO THE DEALER AND THEY SAID THAT THE TANK IS CORRODING. I'VE HAD ISSUES WITH THE TRUCK SINCE I PURCHASED IT. THE GAS GAUGE WOULD GO OUT PERIODICALLY ALONG WITH THE POWER. I CALLED THE DEALER AND HAD IT CHECKED OUT, AND THEY SAID THEY COULDN'T FIND ANY ISSUES. NOW THAT THE 90 DAY WARRANTY IS OVER, THE GOES OUT COMPLETELY IN 120 DAYS. IT TOOK THE DEALER A MONTH TO DELIVER THE TRUCK TO ME AFTER I PURCHASED IT.
NHTSA complaint #10822431 — an unverified report by a vehicle owner.
I HAVE 2008 FORD F450 WITH 60 K MILES AND RADIATOR START LEAKING AT THE BOTTOM AND IT WAS BUILDING PREASSURE ON THE TOP OF ATIFREAZE BOX AND HEAT AIR STOPED WORKING AND FORD DEALER THAT I BOUGHT FROM DISNT COVER THE WARRANTY I PAID 1400$ TO GET PROBLEM FIXED AND IT SECOND RADIATOR THAT I CHANGED FROM MY POCKET !!!! I THINK FORD NEEDS TO DO SOMETHING WITH THAT IT SHOULD BE A RECALL FOR ALL 2008-2014 POWER STROKE DIESEL ENGINES
NHTSA complaint #10821300 — 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.
I WAS MAKING A LEFT HAND TURN AFYER STOPING AT A TRAFFIC LIGHT AND LOSS POWER. THE ENGINE LIGHT CAME ON AND THE TURBO PRESSURE GAUGE DROPPED. I TOOK THE TRUCK INTO THE DEALER AND THE DEALER TOLD ME THAT A MANAFOLD BOLT HAD BROKEN WHICH CAUSED A BAD EXHUAST LEAK. REPAIR COST WAS $3500. I DROVE THE TRUCK LESS THAN 50 MILES OVER THE NEXT TWO DAYS AND THE PROBLEM HAPPENED AGAIN WITH LOSS OF POWER AND ENGINE LIGHT ON. I TOOK THE TRUCK BACK THE DEALER AND WAS INFORMED THAT THE HIGH PRESSURE FUEL PUMP HAD EXPLODED AND SENT METAL DEBRIS THROUGH OUT THE FUEL SYSTEM. I WAS THEN TOLD THE REPAIR COST WERE GOING TO $7500 ($6000 FOR PARTS AND $1500 FOR LABOR). THIS IS A BAD FORD ENGINEERING DESIGN PROBLEM AND SHOULD BE PAID FOR BY FORD AS WELL AS A RECALL ON ALL MODELS USING THE SAME HPFP ASSEMBLY.
NHTSA complaint #10730584 — an unverified report by a vehicle owner.
WE ARE ORIGINAL OWNERS.TRUCK ONLY USED TO HAUL DRINKING WATER. THAT IS WHY THE MILEAGE IS LOW. IN MARCH WE SMELLED GASOLINE IN DRIVE BUT WE HAVE SEVERAL CARS AND COULDN'T PINPOINT PROBLEM OR SEE GAS ON GROUND. WE HAD FILLED UP THE TRUCK AND THOUGHT MAYBE SOME GAS HAD SPILLED. AFTER THAT WE HAD SEVERAL INCIDENCES OF DRIVING DOWN ROAD 40-60 MPH AND TRUCK SLOWED TO 20MPH. IT STALLED AND CAME TOA COMPLETE STOP ON A FEW OCCASIONS. WE WERE ABLE TO RESTART IT. LOCAL SHOP RAN DIAGNOSTIC CHECK AND NOTHING WAS EVIDENT. TOOK IT TO FORD DEALER TODAY AND MECHANIC SAYS THE GAS TANK HAS IMPLODED DUE TO CRACK AND DIRT GOT IN AND FUEL PUMP IS CLOGGED. WE HAVE NEVER HAD ANY INCIDENCE OF DAMAGE TO OUR VEHICLE AND NO INCIDENT THAT WOULD CAUSE THE FUEL TANK TO SPLIT. WE FOUND ON THE INTERNET A CLASS ACTION LAWSUIT IN 2012 FOR THE SAME PROBLEM AND MODEL OF VEHICLE WE HAVE.WE WERE NEVER NOTIFIED OF A RECALL OR POTENTIAL PROBLEM. THIS IS A SAFETY ISSUE AS THE VEHICLE SUDDENLY LOSES POWER AND IT IS DIFFICULT TO STEER TO THE BERM.
NHTSA complaint #10730696 — an unverified report by a vehicle owner.
TL* THE CONTACT OWNS A 2005 FORD F-450 SD. WHILE DRIVING 35 MPH, THE ENGINE STALLED. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC, WHO DIAGNOSED THAT THE FUEL INJECTION AND MOTOR NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 34,772.
NHTSA complaint #10715167 — an unverified report by a vehicle owner.
TRUCK WAS PULLING MY 16K 5TH WHEEL CAMPER OVER THE PASSES BETWEEN MONTANA AND IDAHO IN TOW HAUL MODE UP AND DOWN. THESE ARE ONLY 4,200 FOOT PASSES BUT STEEP. USUALLY IN 6TH GEAR BUT SOMETIMES 4TH GOING 50-55; OIL TEMPS SHOW AS 220 TO 239 THEN THE BIG FAN KICKS IN TO COOL IT. ON ONE OF THE SMALLER PASSES, SHORTLY AFTER I CRESTED THE HILL THE TRUCK SHARPLY DOWN SHIFTED (I THINK IT SKIPPED 4TH AND WENT INTO 3RD. IMMEDIATELY THEREAFTER THE "CHECK ENGINE" LIGHT CAME ON, ?TOOL? EMBLEM SHOWED ON DASH, "LOW POWER" NOTICE SHOWED ON DASH, AND I BARELY HAD TIME TO GET HALFWAY OFF THE ROAD BEFORE I LOST POWER STEERING AND BRAKES. THIS COULD HAVE BEEN A HORRIFIC DISASTER ON JUST ABOUT ANY OTHER INTERSTATE HIGHWAY LOCATION, LET ALONE TWO LANE ROADS THAT WE HAVE BEEN WITH OUR TRUCK/TRAILER. AS IT WAS, IT WAS ONE VERY SCARY TEN SECONDS. I HAD NO POWER STEERING OR BRAKES. LATER I LEARNED THAT IF IT HAPPENS AGAIN THAT I SHOULD KEEP IT ABOVE 5 MPH TO GET OFF ROAD AND LINED UP, THEN STOMP ON BRAKES BECAUSE YOU ONLY HAVE ONE CHANCE. ON THE SIDE OF THE ROAD, "?CHECK ENGINE" LIGHT IS RED, BUT NO OTHER WARNING LIGHTS NOW. I CAN GET NO REVS OUT OF ENGINE. I TURN OFF KEY AND SHUT DOWN. CHECK FLUIDS UNDERNEATH, AND UNDER HOOD ALL IS WELL. TRY PHONE - NO COVERAGE. CLOSEST TOWN IS 16 MILES. RESTART ENGINE AFTER 5 MINUTES. IT WAS ABOUT 60 OUTSIDE AT THE TOP OF THE PASS, AND I CAN NOW REV ENGINE, BUT ENGINE LIGHT IS ON. HEAD TO TOWN, GET CELL COVERAGE ON NEXT RISE AND CALL AHEAD TO NEAREST FORD DEALER FOR DIRECTIONS. ANOTHER PASS IS BETWEEN US - 4TH OF JULY, A TALLER ONE THAN THE SHUTDOWN EVENT. IDAHO DEALER ([XXX], LAKE CITY FORD) KINDLY SQUEEZES ME IN. SEE ENGINE LIGHT ON. TECH [XXX] SEES LIGHT AND RUNS SCAN AND SEES NO RECORD OF ANY CODES IN ANY SYSTEMS. WHAT THE?? NEXT MORNING, FORD TOLD DEALER THAT THERE IS NO WAY THAT A CODE DID NOT REGISTER IF THE LIGHT WAS ON. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6).
NHTSA complaint #10689858 — an unverified report by a vehicle owner.
TL* THE CONTACT OWNS A 2006 FORD F-450 SD. THE CONTACT STATED THAT THE INNER LINING OF THE FUEL TANK WOULD FLAKE CAUSING THE FUEL SYSTEM TO BECOME CLOGGED. AS A RESULT, THE VEHICLE WOULD LOSE POWER WHILE DRIVING. THE FAILURE RECURRED NUMEROUS TIMES. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC, WHERE IT WAS DIAGNOSED THAT THE INJECTORS AND FRONT FUEL TANK HAD TO BE REPLACED. THE VEHICLE WAS REPAIRED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE FAILURE MILEAGE WAS 156,000.
NHTSA complaint #10681504 — an unverified report by a vehicle owner.
THE VEHICLE INVOLVED IS A HORTON AMBULANCE ON A FORD F450 CHASIS. WHILE ON AN EMERGENCY CALL THE UNIT STOPPED OPERATING AND THEN ENGINE WOULD NO LONGER START. THE VEHICLE WAS TOWED TO TED BRITT FORD'S TRUCK REPAIR CENTER IN CHANTILLY. UPON EXAMINATION THEY FOUND THAT DUE TO THE FUEL TANK DELAMINATING, DEBRIS HAD DAMAGED THE FUEL PUMP AND FUEL SYSTEM. SPOKE WITH FORD IN REGARDS TO RECALL OR REPAIR ASSISTANCE AS THIS IS A HIGHLY DOCUMENTED ISSUE. FORD REFUSES TO ACKNOWLEDGE THIS AS AN ONGOING ISSUE AND WILL NOT TAKE OWNERSHIP FOR THE DEFECTIVE FUEL TANKS. AT THIS TIME WE ARE CONSIDERING HAVING TO REPLACE ALL OF OUR FORD STEEL FUEL TANKS AS WE HAVE NO WAY TO PREVENT THIS DAMAGE TO OUR VEHICLES AND FORD REFUSES TO RESOLVE THE ISSUE.
NHTSA complaint #10667924 — an unverified report by a vehicle owner.