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

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.

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

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).

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.

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

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.

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

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.

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

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!.

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

A message was displayed to reduce the truck speed. Then the speed started to reduce itself, I wasn't able to increase the speed. I was on a hwy and the speed limit was 65 mph and on a slight hill the trucks speed was only 39 mph. I put the flashers on hoping to alert the cars passing me that I had a problem. Then the engine died so I steered it over to the side of the road. I tried to re-start it and the truck shook before it died again. I had it towed to a Ford dealer in boerne, TX. They called me the following day and said the high-pressure fuel pump came apart. They said they saw metal parts in the fuel and their estimate to fit the truck was $18,000! I had it towed to another automotive place, I just needed another opinion. Then I heard about 2 recalls Ford had this year, 1 in January and another just ramping up. The description of the problem sounds exactly like my issue however it didn't cover the 2017 models! I let chandler automotive, in castroville, TX know and they said they would look in to it.

While driving on the interstate, my truck began to lose power and decelerate. A fuel pump and engine warning light appeared. I began to lose power steering while decelerating. When I finally stopped and the truck turned off, I tried restarting which resulted in a cranking noise and was not successful in starting. I had to contact a towing company for assistance and my truck has been undriveable since this date (7/6).

Ford just announced recall 25v455 for bad fuel pump for certain Ford trucks from 2021-2023 models. I purchased brand new 2020 Ford f250 sd with the 7. 3 gas motor and from day one its had fuel pump issues. The vehicle hard starts like its starved for fuel. After several trips to the dealer they said it was a battery so I changed the battery. Didn't fix it. Then they said it was some other part and they replaced it, didn't fix it. I tried getting Ford to replace the fuel pump and the wouldn't. I've read forums online that discuss the same issue with many current Ford models. I'm glad to see Ford do the recall but they need to extend the recall to include 2020 models. My truck has exhibited the same issues in this current recall and it gets worse during the hot south carolina summer months. This is going to create a long term problem and Ford needs to include 2020s in their recall. I purchased the truck from billy howell Ford in cumming, GA then moved to columbia, SC where jim hudson Ford has been serving my truck.

It keeps throwing a check engine light for miss fire but ive replaced all of the ignition and fuel parts and it keeps happening now its loosing power and getting hot for no reason.

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

Fuel pump loses prime at the fuel rail, causing 6. 2 gas engines to crank for a long time. Faulty check valve. It seems Ford made a revision on the pump and never did a recall.

Only had my truck for 6 months, my suspension is worn out causing a known issue known as death wobble. I was driving at 65mph with my family and extreme shaking occurred. Yes by a Ford dealership. Yes the truck and the area was inspected and confirmed to needing replaced parts. No warning lamps/lights appeared due to it being mechanical, I went to another shop after I already took it in to Ford, and they told me a missing component that may be the leading issue of it was deleted never there to begin with when I bought the vehicle at the Ford dealership. •truck details (2019 F-250 XLT 4x4, 88k miles) •death wobble at highway speeds •firestone confirmed factory stabilizer was deleted •def system not working •worn tie rods, drag link •low oil at purchase (indicating no inspection) •dealer is refusing to help •Ford corporate says there’s no active program — but I know TSB 19-2274 and csp 20n04 exist.

High pressure fuel pump failure: on [xxx] while driving on the highway our 2020 f250 super duty VIN # [xxx] experienced a complete and sudden loss of power in the fast lane, creating an extremely dangerous situation. Our safety and the safety of others were at risk due to us merging across 4 lanes in heavy traffic with no power steering and no motor function, parking in a very narrow shoulder area and requiring a tow from the highway. After towing and a diagnostic evaluation, it was determined that the high-pressure fuel pump (hpfp) failed, a known safety concern with a recall issued our truck being built in kentucky on August 2, 2020 the cost of repairs are around $15,000. This vehicle is housed at a local diesel mechanic, and is available for inspection upon request, and has not been inspected by anyone currently. When will this recall be remedied? information redacted pursuant to the freedom of information act (foia), 5 u. S. C. 552(b)(6).

Vehicle will often crank and not start pointing toward something is going bad with the fuel system.

Fuel pumps failure causing the truck to loose power while in traffic. I have spent 8 thousand dollars in repairs and I am still all of a sudden low fuel pressure pops up on the screen and it looses power. Has left me stranded 200 miles from my house. Ford has told me that they can't get it to happen for their tech and told me to drive it. Same thing happened again 200 miles away from my house. I feel like Ford knows what it does and doesn't want to correct the problem. These trucks are very expensive to buy and to operate with all the service that has to be done to keep it on the road. I have been driving Ford trucks for over 35 years and this has got to be the worst one ever also the most expensive.

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

Its a recall for aged biodiessel deposits to accumulate in the high pressure fuel pump.

We were on the interstate and our truck had reduced power and then failed. The diesel particulate filter light came on as well as the service engine soon warning. We were hauling our 40 foot 5th on the way home from a trip. We were able to make it to the side of the road but it would not start. It would crank for a while then quit. We were stuck on a very busy/dangerous highway for over 2 hours waiting on a tow truck to get us. It cost $500 to be towed to the Ford dealership 2 miles away. We were nearly 3 hours from home. Our truck and 5th wheel are both still at the dealership. We were told today that the fuel pump exploded leading to shards of metal throughout the system and that it would be $15000-18000 to repair. There isn’t a solution with the recall but it will be covered under our powertrain warranty. We are left without a truck and have no way to get our camper home until it’s repaired.

•I was driving the truck from houston to dallas. I got a warning on the dash of reduced power and the check engine light came on. •safety was somewhat of a concern because of reduced power while on the highway. Being able to get to my destination was in question as was keeping up with traffic. •the dealer quickly diagnosed the issue as a a failure of the cp4 high pressure fuel pump. This is a known and widespread issue with this truck and engine. •truck has been inspected by the dealership. •there was no warning until the failure itself.

My truck lost power on the highway. Had to coast down the off-ramp and ended up blocking a turning lane when the engine failed to start back up. Called a someone to tow me back to my house and parked it where it’s been there for months since Ford has not yet issued a solution to the recall.

As I was driving, the truck stopped running and then under the engine compartment it started on fire and fully engulfed the engine compartment in front half of the truck.

See all problems of the 2023 Ford F-250 🔎.

I own a 2017 Ford F-250 6. 7l power stroke diesel with a cp4 fuel pump that recently failed. Ford has already recalled this exact part for 2020-2022 models (recall 24v-841) due to known defects, but they refuse to assist owners of earlier models like mine, even though the issue is the same. The cp4 failure can cause sudden fuel system failure, which is dangerous while driving. Ford should extend the recall to cover all affected vehicles before more owners are left with costly repairs or safety risks.

I have a 2019 Ford f250 with a 6. 7 turbo diesel with the cp4 fuel pump which was recalled on the 2020-2024 models but they have used this same pump since 2011. With many many of them blowing up and causing 12-17,000. 00 repairs and law suits against Ford motor company. This repair is costing me over 16,000. 00 !!! they need to make the recall for all years that the cp4 pump is used.

On Tuesday, [xxx], at approximately [xxx] pm, I was driving southbound on [xxx] near coalinga, CA, when my truck suddenly experienced a failure. I noticed smoke in the side mirror and asked my passenger to confirm. Moments later, a "low fuel pressure" message appeared on the dashboard, and smoke began coming from the hood. I immediately pulled over and attempted to pop the hood, at which point flames erupted from the engine bay. The fire quickly spread, fully engulfing the vehicle within minutes. Emergency responders, including cal-fire and chp, arrived on the scene. The truck was towed by cal-state towing service in huron, CA. The fire captain on site provided an incident card, but the full fire report is expected to take at least a week to obtain. There were no prior indications of mechanical issues before this incident, and no recent repairs or modifications to the fuel system or engine. However, I recently became aware of an ongoing NHTSA investigation into fuel leaks and fire risks in Ford super duty trucks equipped with the 6. 7l diesel engine (tfl truck report). The investigation highlights a potential issue with fractures in the secondary fuel filter housing, which could lead to fuel leaks and fire hazards. Given that my truck displayed a low fuel pressure warning immediately before catching fire, I strongly suspect this failure may be related to the issue under investigation. The truck is currently in tow yard storage and is available for inspection upon request. This incident posed a serious safety risk to myself, my father and others on the roadway, and I believe it warrants further examination by NHTSA. Information redacted pursuant to the freedom of information act (foia), 5 u. S. C. 552(b)(6).

Driving down freeway truck started to shutter knock and sqaul making noise and wouldn’t accept any throttle , truck died and coasted to shoulder , hauled to shop on wrecker had mechanic diagnose issue resulting in several fuel system codes all stating correlating cylinder imbalance low fuel pressure on all circuits etc , pics were to large to upload below but could send via email if needed.

The fuel line has broken twice now, causing the truck to stall while in motion on the interstate and spill fuel everywhere I know several other 2019 f250 owners, one of which their truck has caught on fire from the same thing also, when the truck tow truck driver picked me up, they see said yes, we see this all the time also, Ford has data on this, but has it under a confidentiality agreement and will not release it.

Cp4 failure- whole fuel system replacement.

Truck started leaking fuel and then the engine shut down the next day it was drove, while driving! I’ve received 2 quotes and need the whole fuel system replaced due to cp4 pump failing which will cost about $13,000! this is the same issue as the 24s78 Ford recall but my truck doesn’t fall in the correct year! I still owe 10k on this vehicle so it’s basically totaled now.

See all problems of the 2011 Ford F-250 🔎.

The fuel pump failed , yes it is available for inspection upon request. Truck cut off in middle of busy road way , unable to move to shoulder creating a high risk to be hit or someone to be hit . Independent service center diagnosed was made aware this is a common problem . No warning lights or previous symptoms before engine cut off . We have been informed this is a recurring issue with Ford f250 creating a dangerous enviorment when driving for the driver and all other vehicles on the road .

The 2017-2019 f250 equipped with the 6. 7l powerstroke diesel engine has the same cp4 high pressure fuel pump that is the subject matter of the recall for the 2020-2022 f250 with the same engine. I would like to see what the chances are to get the recall added to the aforementioned year range. I have a 2019 model and worry every time I take it on the highway. I should not be concerned with a well maintained $40,000 vehicle.