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

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!.

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

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.

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

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.

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

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.

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

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.

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.

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

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.

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 🔎.

While pulling a 38ft 5th wheel camper on an incline with the cruise control set at random the vehicle completely dies. It experiences a total shutdown of the engine, which in return causes a complete loss of power steering, brakes etc. The truck will not restart until you push the off button and open the drivers door to shut the entire system down.

On October 3, 2025 our 2020 Ford f250 king ranch 6. 7 diesel broke down with no start and check engine light. We contacted Ford. We towed the vehicle, at our expense to the dealership we purchased it from approximately one year ago on October 6, 2025. I contacted Ford on October 3, 2025 and received a claim number. On October 7, 2025 the Ford dealership contacted us to inform us the high pressure fuel pump catastrophically failed. It cracked the pump housing. It is a 12,000. 00 repair. It is a safety recall. The pickup on has approximately 56,000 miles. The 5 year power train warranty ended September 15, 2025. I have contacted Ford twice sense January 0f 2025 to see if there was a resolution to this recall and they stated there is no fix as of this time. The dealership and I have contacted Ford customer service several times. I have left several messages for the representative handling our case and was promised call backs but never did. On October 10, 2025 there was a new case generated due to the lack of communication. Both the dealership and I were promised a call back and we did not receive one. We use this pickup for work and we are losing income. I asked for a loaner and I was told that was not possible. I pulled a carfax on this pickup and found that possibility this vehicle was bought back twice. When we purchased it, the service record give to us did not show that information. We would like for the repairs to be completed in a timely manner. The dealership stated on October 8, 2025 that the entire fuel system would need to be replaced and could have it completed in three business days. I am not feeling comfortable knowing the pickup has been bought back from Ford two other times and not informing us. Also I am worried it may have caused engine damage.

Nhtsa complaint text (copy/paste) vehicle: 2020 Ford F-250 super duty 6. 7l power stroke recall: 24s78 – powertrain control module (pcm) software update complaint: Ford has issued recall 24s78 for the high-pressure fuel pump defect on my 2020 F-250, but the company has not provided an actual remedy. The recall shows as open on my VIN, and Ford’s documentation says a pcm software update is the fix, but Ford released the software and then pulled it back within a week. My dealership confirmed Ford removed the remedy from their system, so they cannot perform the recall at all. This leaves my truck exposed to a known safety defect with no available repair. The high-pressure fuel pump failure this recall addresses can cause sudden loss of power, engine stall, or complete shutdown while driving. Until a working remedy is released, I’m driving a truck that Ford has admitted has a serious safety defect, but they have not provided any fix or timeline. I am requesting NHTSA investigate why the remedy was withdrawn, why no replacement remedy has been provided, and why Ford is leaving owners with a known safety risk for an extended period. This is an expensive vehicle, and the defect can cause catastrophic engine damage and create a hazardous situation on the road. Owners deserve an effective recall remedy that is actually available. Not exactly sure when the recall was first brought to light but I do know it has been months now.

Ford diesel 250 flat out stalled while driving on a very congested highway. Full tank of diesel. No warning. Complete stall at 65mph, no brakes, no power steering, no lights. Was almost killed when the truck almost crashed into a bus. Happened (4) more times as we made our way back home. Internet search shows that Ford motor company is fully aware of this common failure of their fuel system. Federal regulators need to pressure Ford for a recall before someone is killed.

The fuel pump blew up in our f250 while driving a main road on Thursday [xxx]. The vehicle was towed to the nearby facility to investigate the situation. It was discovered today 9/8/2025 that the fuel pump had sent metal shavings through the whole fuel systems which all needs to be replaced now. Information redacted pursuant to the freedom of information act (foia), 5 u. S. C. 552(b)(6).

1. Fuel pump failure occurred September 4th 2025 2. While towing a travel trailer from raleigh nc to surf city nc. When the truck stalled we lost all power and power steering and there was no clear path to pull off the single lane road with no shoulder. With a line of vehicle's behind us, including tractor trailers this created very serious safety situation not only for us but other travelers heading toward us and behind us. We were fortunate that the tractor trailer behind us was alert. I was able to restart the vehicle and drive to a safe location. We left the travel trailer at the coast, and returned vehicle to capital Ford on or about September 9th. So yes, our safety and the safety of other was in serious risk. 3. No the problem has not been reproduced. 4. Yes the dealer, capital Ford, inc of raleigh, nc has inspected and confirmed root cause to be fuel pump recall. 5. As I recall the truck hesitated, check engine light came on, and truck stalled ( unsure if light came on before or after stall) in a very short period of time. I do not recall the exact amount of time but I do recall the hesitation, I told my wife something is not right, engine stalled and we lost all power. Currently it has been 8 months since notification and, for the safety of the driver and other on the road, we have been unable to use vehicle for reason purchased since the incident.

On [xxx], I was driving westbound on [xxx], between kerrville and junction, texas. I noticed a diesel fuel smell and pulled off the highway to investigate the source. Upon stopping, fire erupted from the engine compartment and quickly spread to the front dashboard and front passenger seating area. No warning lamps, no high temp or abnormal gage levels. The mountain home, TX volunteer fire dept arrived about 30 minutes after we called 911 and extinguished the remaining flames. They commented that a cracked / failed secondary fuel filter housing could be to blame. My insurer, state farm, under claim #[xxx], now has possession of the vehicle remains. I told state farm that NHTSA opened an investigation into possible fuel filter housing failures / fires. I do not know what their intentions are with the vehicle remains. Information redacted pursuant to the freedom of information act (foia), 5 u. S. C. 552(b)(6).

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

100k miles and the high pressure fuel pump is failed. Created small metal particles that got into fuel lines. Everything needs to be replaced. There’s a recall on over 80k trucks with the same issue. Local Ford said this is the same issue as all the recalls but because we don’t have the recall on our VIN, we have to pay $20k for replacement.

Engine long cranks before starting. Sometimes hesitates starting out or at speed. Possible fuel pump issue.

Fuel leaking from above fuel filter housing located on undercarriage of truck. Fuel leak is considerable and was a sudden failure versus developing over time.

My 2020 Ford F-250 king ranch with a 6. 7l v8 turbo diesel engine experienced severe engine failure while I was driving. The engine was completely destroyed and had to be replaced. My warranty company paid to install a new engine into the truck, but did not pay to have the remaining components fixed that were directly damaged by the engine failure. There was severe damage done to the fuel pump, def system, and wiring harnesses that caused the truck to be permanently into a mode called "limp mode" which electronically governs the truck to 50 mph. There was and still is an unresolved recall on the truck. The recall is as follows: #24s78 powertrain control module software update biodiesel deposit accumulation. The NHTSA number NHTSA: #24v957. There were absolutely zero (0) warning signs that alerted me that this was an issue before the engine failed. No alerts or warning lamps were illuminated on the truck before it failed. All I got was a letter in the mail stating that the engine could fail due to this components and that there is no known solution to fixing the problem. This issue caused my engine to fail while I was driving to work. There are issues with the truck still that were directly caused by this issue that the warranty will not cover including this recalled component that has no available solution. I have a 2 month old son and a wife that rely on me having this truck. I have risked the safety of my family, and others on the roads, unknowingly by operating this truck on the roads. I am asking that Ford motor company be held liable for all damages to my truck, and the repurchase of the truck for full price. This is unacceptable from a company as big as Ford motor company.

On July 31st, I was driving my 2020 F-250 in town, traveling approximately six miles from one location to another. Upon arriving at my destination, I noticed smoke coming from under the engine bay. When I opened the hood, I discovered diesel fuel had leaked throughout the engine compartment. I immediately contacted my local dealership and brought the truck in for inspection. I was informed that the fuel filter was cracked. After doing some research, I learned that this appears to be a common issue with similar models, and in some reported cases, it has even led to vehicle fires. Fortunately, this did not occur while I was driving a longer distance, which could have put me and my family at serious risk. I’m raising this concern in hopes of further investigation and a resolution, given the potential safety implications.

My fuel pump on this truck went out at 130,000 miles. This repair is quoted at $12,500. When this pump went out it caused the truck to stall while driving. This truck stalled while crossing two lanes of traffic on a highway with a speed limit of 55-60mph. When I got into the turn, I had to coast across the two lines of traffic with no throttle due to the malfunction. Luckily, there was no collision. However, it was a very close call at high speeds.

Hi. I took my 2021 f250 6,7 to the Ford dealership as it was having trouble starting, and just wasn’t running great. They changed the batteries, and told me it was a nox sensor. So I went and got my truck to fix the sensors myself; because they wanted to charge me close to 3 grand. The next day I got up, lo and behold it wouldn’t crank. I had to have it towed back to the dealership. I tested codes before I had it towed, and took a video of it not cranking. The following codes showed. P2291 pcm - injector ctrl press too low - engine cranking p2209 pcm - nox sens heater sense circ range/perf bank 1 sens 1 u029d pcm - lost comm with nox sensor a p2535 pcm - ignition switch on/start pos circ high u300a bcm - ignition switch it’s been in the shop a week , they called Friday saying it was starting, and there was nothing wrong with it. So I replied with all the codes, and told them there was definitely something going on. So they checked it again Monday and it wouldn’t start. Now today (Aug 5 tues. ) they say it may have a vacuum leak. Although non of the codes point to vacuum leak. I have no idea what to do now.

On or around July 14, 2025, my truck failed to start. The engine would turn over but would not fire. My vehicle was at home and had been driven within the past day before this incident. On July 14, 2025, I had my vehicle towed to burns Ford of york for a diagnosis. Upon inspection, the Ford technician determined that the high-pressure fuel pump was damaged, causing metal to contaminate the fuel system. At the time of this failure, my odometer had 67,452 miles. A "fuel system replacement" kit and element were ordered - Ford parts #s pc3z-9n184c & lc3z-9b246b. As explained to me, the entire fuel system and components had to be replaced because the high-pressure fuel pump "exploded. " knowing there is an active recall on the fuel system (campaign 24s78/24v957) a request was made to Ford to cover the repair costs since the active recall dealt with a known issue of aged biodiesel causing issues, including a failure to start, which I experienced. Ford failed to approve the repair costs, causing a total expense around $17,000, with approximately $7,000 being out of pocket after my extended warranty company paid the remaining balance. The issue is that there was no intentional direct cause for the fuel pump to fail and given it did so with an active recall on the fuel system and with only 67,000 miles I believe the active recall is associated with my failure and should be on Ford to cover repairs and acknowledge a permanent fix.

Ford has a problem where the 34 gallon gas tank only reads as a 20-25 gallon gas tank. They have a service bulletin on it and the number for that is 17-0046. After calling multiple dealerships I was told thousands would have to come out of my pocket because of their factory defect. The fix includes replacing the whole fuel tank and also replacing the fuel level sender. My vehicle being within the dates are clearly affected by this defect and I don’t understand why it should be coming out of my pocket. Thank you for your help!.