Other Fuel System Problems of Ford F-250 - part 1

Leak in upper fuel filter. The part is plastic and fumes are getting in can of truck and fuel on engine.

See all problems of the 2021 Ford F-250 🔎.

Fuel leak from plastic fuel filter housing caused fire.

See all problems of the 2016 Ford F-250 🔎.

My vehicle has been at Ford of harvey since 8/31/26. Dealer replaced ignition coil 8/18/26. Light and rough idle returned and the dealer determined a new engine would be needed. Dealer says Ford warranty only wants to replace cam shaft. Metal in oil was found and dealer has fought corporate warranty for over a month, ripping apart my engine. The fear is engine could seize at highway speeds as a result of internal damage. Caused by circulating debris. Truck still sits at dealer.

See all problems of the 2022 Ford F-250 🔎.

On October 9, 2026 at approximately 8:30 am, my 2019 Ford F-250 6. 7l power stroke diesel, with 76,512 miles, suffered a catastrophic high-pressure fuel injection pump failure while traveling approximately 55 mph on fm 3351 near camp stanley, texas. The vehicle displayed “speed limited” and “reduced engine power” warnings, then lost throttle response and propulsion and the engine shut down while moving. Steering and braking effort increased substantially after the engine stopped. The truck would crank but would not restart. Alamo diesel service, an independent diesel repair facility, confirmed no fuel-rail pressure, fuel leaking in the engine valley, and that the injection pump had “blown and cracked the head. ” inspection revealed metallic debris and extensive fuel-system contamination requiring replacement/repair of the pump, injectors, rails, fuel lines, return lines and filters, plus cleaning of the tank and cooler. The estimate is $11,193. 97. Diagnostic codes included p0087 (fuel rail/system pressure too low) and p2291. P0087 freeze-frame data recorded the vehicle at 54. 68 mph and 1,300 rpm, confirming the fuel-pressure failure occurred while driving. There were no prior fuel-system problems and the fuel filters were recently replaced. I am concerned because there is a long, documented history of failures involving this type of high-pressure diesel fuel pump, including failures that can introduce metal into the fuel system and cause loss of propulsion. Ford has also recalled certain later-model 6. 7l super duty trucks for high-pressure fuel pump failures that can cause loss of drive power. I am requesting NHTSA evaluate whether my 2019 failure may be related to a broader safety defect. Ford has been notified under case cxh-09644112-l1w2n0 but has not inspected the vehicle. The vehicle and failed components are currently available for inspection.

See all problems of the 2019 Ford F-250 🔎.

My 2021 Ford f250 super duty pickup truck experienced a catastrophic failure of the bosch cp4 high pressure fuel pump. This has been confirmed by the dealer's service center. As a result of this part failure, metal shards were introduced into the entire fuel system. This now requires the fuel pump and the entire fuel system (every component) to be replaced. My truck has 74,9xx miles. This is a known and well publicized issue. Rather than recall the high pressure fuel pump, Ford instead issued a recall (24s78) to reflash the pcm software with the intent to reduce the risk of the fuel pump failure. I had the 24s78 recall work completed, and my fuel pump failed still. No indication in advance of this failure.

My 2020 Ford F-250 super duty suffered failure of the high-pressure fuel pump resulting in catastrophic engine failure directly caused by the unperformed defect targeted under Ford safety recall 24s78 / 26s17. The vehicle went into limp mode in the middle of the road while driving. There was no warning, and the vehicle had no previous check engine lights or issues. The Ford service department has physically inspected the vehicle and confirmed the presence of metal shards and mechanical contamination inside the engine and fuel system, which is the definitive physical proof of failure of the high-pressure fuel pump. Despite physical proof Ford refuses to provide the mandated free recall remedy or cover the consequential engine damage justifying the denial strictly on a electronic reporting technicality. They are saying that if the vehicle doesn’t show specific engine codes, then they will not cover repairs. This denial makes no sense because an independent mechanic already verified and recorded the required diagnostic codes before the truck arrived at Ford. I believe that Ford is intentionally and systematically masking/ filtering out engine diagnostic codes to avoid paying for the damage cause by this unperformed recall. I believe that this is unethical and potentially illegal. From my research I believe that Ford altered computer thresholds, programming Ford's proprietary diagnostic system to filter out or ignore raw pressure drops that standard, independent obd-ii code readers immediately catch. Additionally, Fords own service manager explicitly stated she believes the engine damage was caused by the recall. She even submitted a special service center assistance request despite not having the codes, because she believed it would be approved due to the physical and mechanical evidence of the engine failure. I also visited another Ford service center where the manager said that he was having the same problem with Ford rejecting engine repairs linked to this recall.

See all problems of the 2020 Ford F-250 🔎.

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.

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).

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.

See all problems of the 2017 Ford F-250 🔎.

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).

My 6. 7 cp4 pump failed and damaged the entire fueling system.

See all problems of the 2014 Ford F-250 🔎.

Cp4 pump continuous failure sending metal into the fuel system. Ford still uses an inferior product causing truck owners up to $18000 in repairs.

See all problems of the 2012 Ford F-250 🔎.

The secondary fuel filter is leaking and Ford has told me my vehicle was manufactured 1 month too early and doesn’t qualify for a previous recall…they know about the secondary fuel filter housing cracking and being an issue!.

Failure of bosch cp4 fuel pump causing me to be stranded on the side of the road. No recalls currently issued and cannot afford a $15,000 fix.

Hello,  I am reporting a safety issue involving my Ford f250 vehicle related to safety recall 25s75 (low-pressure fuel pump failure). Approximately one month ago, while driving on the freeway at approximately 65 mph, my vehicle experienced a sudden loss of power. This created a dangerous situation as I was traveling at highway speed and the vehicle became unable to maintain normal operation. The vehicle is now inoperable. The failure is consistent with the condition described in recall 25s75. This is not a preventative concern — the defect has already occurred and has rendered the vehicle undrivable. I contacted Ford customer relations and explained that the failure matches the recall condition. However, my case was closed without resolution, without any determination of responsibility, and without conducting a repair or transportation support. Ford has indicated that the official recall remedy is not yet available. Despite this, I have been told I may be responsible for out-of-pocket repair costs, even though the failure is consistent with an active safety recall.   this situation presents both a safety concern and an unreasonable financial burden, as the vehicle cannot be safely operated and no interim remedy or support has been provided. I am requesting that NHTSA review this matter, as the manufacturer is not addressing a recall-related failure that has already occurred and resulted in a loss of power at highway speed. If you need any additional details, please do not hesitate to reach out.   thanks, [xxx]   information redacted pursuant to the freedom of information act (foia), 5 u. S. C. 552(b)(6).

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.

Without warning while I was driving at ~70 mph on the highway the engine in my truck died and left me with no power brakes or power steering in busy traffic. This is a very scary situation to be in. I pulled over and checked the truck best I could. Started it back up and carefully pulled back out onto the highway when it died again. I took it to the closest Ford service center and after diagnosis, they told me the cp4 pump is failing and will need to be replaced at a cost of ~$14,000. My research shows this is a common issue for Ford for a certain year range which my truck is in and they have recently paused the recall addressing the issue so the recall is not showing up when searching my VIN. I would appreciate Ford claiming that this is a safety issue and reimburse me for my out of pocket costs.

My husband was driving our 2019 f250 on the highway at over 75 mph and the truck totally shut down/stalled without warning, could have killed him or another person, lucky he was able to coast to the shoulder and stop, we took to the Ford dealership and was caused by the faulty cp4 fuel pump the truck was made with that has had class action lawsuits and recalls, we are out of pocket over $14,000 to rebuild entire fuel system due to the fact that fuel pump is not compatible with our diesel fuel leading to metal shavings build up in fuel system. Our truck still has no recall on this and it should and we should be reimbursed for the extremely expensive and lengthy repair, this is a very dangerous issue. The mechanic also stated he "duplicated" the stall when he go on the highway and hit speeds over 60 mph, thank goodness he is ok as well.

2 different issues- 1st issue was Ford factory fuel filter leaked at a seam. Resulting in fuel loss all over engine! 2nd issue is fuel filter inlet line retaining clip comes unclipped on its own resulting in fuel loss all over the engine. Both incidents happened during long distance travel which also resulted in several gallons of fuel drenching whole undercarriage of vehicle.

The fuel tank is leaking fuel from the top where hose connects, it is cracked where the hose barb is connected to the tank.

My cp4 fuel pump failed on my 2020 Ford f250 and died while towing my 7000lb trailer for my business and had to get towed to shop to find out the entire fuel system needs replaced and Ford dealer has it and says because recall 24s78 for my vehicle is on pause that there is nothing they can do about it and I’m stuck without my truck which I need for my business and believe Ford is responsible to replace the fuel system with no charge to me when the cp4 pump is such a common failure in my trucks!.

02/04/2026 69k miles. I brought my vehicle in because I got a check engine light on the dash and had loss of power. Was informed that my fuel pump had failed and sent metal shards through the whole fuel system. The damage was covered by the recall, which also included reprogramming of the tcm and pcm. Was then told that the reflash of those systems was a failure, and that the Ford motor company was working on a remedy. My dealership has since completed a full fuel system replacement, and there still isn't a fix for the programming issue. This is a revenue generating vehicle, and the only one, for my small business. I lost many clients due to inability to perform the work I was contracted to do. My dealership did offer me a loaner vehicle, but it's not one that can perform the work that my truck was able to do, and was told not to use the vehicle for any commercial work or towing, as thats not allowed. Ive reached out to customer relations to get updates, and have had no help from them, save for telling me they're working on it, and will hope to have a remedy soon.

This past year I experienced catastrophic failure with my bosch, cp4 fuel pump in my 2017 Ford f250 with a 6. 7 l diesel. Recalls have been published by Ford, but not beyond a 2018 vehicle. After seeing metal fragments in my fuel water separator, I was forced to flush my entire fuel system, replace the cp4 fuel pump with a cdr high pressure pump (replacement), flush the entire fuel rail system and replace my fuel injectors. This repair cost me approximately $13,000. I find it difficult to understand why my 2017 vehicle was not included in the recall when it had the defective item as the later models had. The truck has 129,000 miles on it currently. Certainly, these are not excessive miles given the year of the vehicle. I would like to know what can be done for older models(the bosch cp4 fuel pump goes all the way back to 2011). Thank you for your consideration and attention to this.

I have a 2026 F-250 diesel with 6k miles on it that caught fire about 3-5 minutes after using it to jumpstart a utv. I ensured to cook all cables up correctly, as I've jumpstarted many times, but the first time with this vehicle, utilizing the drivers side battery. Jumping the utv went just fine as expected, and I disconnected the cables and shut the truck hood with no sparks, smoke, or flames at the time. Within 3-5 minutes, I noticed there were flames coming from inside my truck at the center dashboard area. We attempted to extinguish the fire ourselves, but the fire department was ultimately called. If my son had not gotten out of the truck to get into the utv with me, he would have been in the back seat when the fire started. The truck was pulled close to my barn when the fire started, which caused damage to the barn. A fire investigator hired by my insurance, and the fire marshal came out to my home to inspect the truck, and both determined it was not my fault the truck caught fire. There were no warning labels indicating the drivers side battery should not be used to jump start vehicles. The fire investigator stopped at a local Ford house, and none of the employees were aware the drivers side battery should not be used to jumpstart vehicles either. I found information online that mentions fires occurring in 2025 & 2026 due to cracked fuel return lines, and engine heater block problems. The fire investigator stated if I was able to find that information online, that the manufacturer likely knows there are problems, and chose to sell the vehicles anyways. My truck is currently waiting to be inspected by a Ford engineer to try and determine the cause. This fire put myself, my son, barn, and animals at risk. If Ford knows about any potential fire hazards, they should have never released the truck for sale. Due to the fire, I had smoke inhalation, and visited my pcp a few days after. I'm still waiting for the fire departments report.

Vehicle: 2022 Ford F-250 super duty component: door latch / door ajar sensor system this complaint concerns a latent manufacturing defect involving the door latch / door ajar sensor system on a 2022 Ford F-250. The defect causes the vehicle to falsely indicate that doors are open when they are fully closed, triggering alarms and safety warnings and impairing normal vehicle operation. This failure was detectable during the warranty period and manifested shortly after expiration of the bumper-to-bumper warranty, consistent with a latent defect rather than wear or maintenance. The same defect has occurred on multiple Ford vehicles purchased by the same family, including an identical repair performed on another Ford truck for the same door latch sensor failure. This demonstrates a patterned manufacturing issue, not an isolated incident. Numerous owner reports document this same failure mode on 2022 Ford F-250 vehicles, frequently occurring immediately following warranty expiration. The dealership declined to classify the failure as a defect and limited review to warranty dates only, refusing to provide a written determination or pursue goodwill consideration. Because this defect affects vehicle security systems and driver safety alerts, it warrants investigation as a systemic manufacturing defect. The dealership has also failed to repair recalls on the vehicle due to part shipment delays per their service team.

We believe the fuel line came off of the fuel filter. The truck caught fire and went up in flames. There is nothing left of the truck other than the frame. Chp and the fire department came to the scene. They put the fire out and the truck has been taken to the tow yard. Nothing has been inspected yet.

My 2019 Ford F-250 diesel truck stopped running and had to be towed. The high-pressure fuel pump failed and sent contamination through the entire fuel system. The dealership first replaced the fuel injectors, then later said the whole fuel system had to be replaced. Ford and the dealership blamed fuel contamination and refused to cover it under warranty, so I paid for the repairs myself. This fuel pump problem made the truck shut off without warning, which is a safety danger. Also, after the second repair, the dealership told me the brakes were not working properly. I have not driven the truck since. It was towed to another shop. In total, I paid $18,865. 05 out of my own pocket for these fuel system repairs.

The vehicle experienced a sudden loss of motive power and became inoperable due to failure of the high-pressure fuel system. This VIN is subject to an active safety recall (NHTSA 24v957 / Ford 24s78) addressing high-pressure fuel pump failure that can result in loss of motive power while driving. Prior to failure, the vehicle exhibited reduced engine performance and drivability issues consistent with fuel system malfunction. No water-in-fuel warning or alert was displayed prior to the failure. The vehicle was inspected by an authorized Ford dealership. Ford and the dealership asserted “fuel contamination” as the cause and refused to repair the vehicle under the recall or warranty unless the customer paid for diagnostic teardown. The recall repair was not performed. The vehicle remains unrepaired and was removed from the dealership. The loss of motive power created a safety risk to the occupants and other motorists. We are concerned that a recalled safety defect affecting the fuel system is not being remedied and is being mischaracterized to avoid recall repair.

2019 F-250 6. 2 84k miles fuel pump check valve has gone back no a new issue it’s all over the web with problems most are seeing it with even 40k when you put a new one in you get less then that or equal amount and it goes out.

We get a power reduced code and the truck shuts down while driving. We have to pull over and put it in park and restart it. When we are on the freeway we can’t get over we put it in neutral and turn off the truck and restart it. It is very scary and dangerous! this has been happening since June of 2025.

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.

We have had this truck a total of two months. The dealer told us that there were not recalls on it, come to find out there are two. The recalled part froze up and shattered that shot metal shavings all through the fuel system. This caused the truck to lose all power and shut down on a busy road which could have led to a major accident had it not been after rush hour. After towing the truck to a repair shop, we found out about the recalls. Come to find out, the warranty company nor Ford will pay to fix the vehicle due to nothing available. How are we the consumer liable for this when it is under recall and Ford has been working on a fix for a year? we have been told a fix would be around $10,000.

Low fuel pressure alert came on the truck. It went away and then came on again a few days later. We took the truck to joe meyers Ford in houston, TX. They verified the code/alert and replaced the fuel filter, then re-tested. The alert returned and once they continued their diagnosis, it was determined that the fuel pressure control valve had failed, allowing fuel, def, and water into the fuel filter. The fuel pressure would no increase to minimum spec of 55 psi. Ford then said that without replacing the fuel pressure control valve, fuel pump, fuel filters, and flushing all the lines, the risk for the engine to seize up was very likely. They noted this was a similar issue happening to 2020 and older trucks, but all the same parts and issues. Upon repairing the truck, we have read up on recall 24v957 and feel the issues we encountered are identical in complexity and costs. We paid nearly $20,000 in repairs.

See all problems of the 2018 Ford F-250 🔎.

After sitting for extended durations the engine experiences a no start or long crank condition. Research and discussion with local mechanic indicate this is an issue with a failed/failing fuel pump and/or fuel pump module. It is my understanding a recall exists for similar failures on other Ford models.

Truck has just turned 20,000 miles. After having the def system serviced at the Ford dealership truck has to go thu the particulate filter regen sooner and sooner. Now every 75 miles. Which causes truck too lose power and produce excesive exhaust temperatures which can potentully cause a fire. Ford is telling me the exhaust emisssion system is out of waranty yet truck just has 20,000 miles. This is unacceptable and a danger to myself, my family, and anyone nearby.

See all problems of the 2013 Ford F-250 🔎.