Other Fuel System Hoses Lines/piping, And Fittings problems of the 2011 Ford F-350

While drivingmy Ford f350 crew cab longbed diesel 4x4 at 70 mph on interstate 10, a 4 lane hwy in each direction, the truck lost all engine power and power assist to the brakes and power steering. Luckily the traffic was light and I was able to maneuver the off the hwy without coming in contact with another vehicle. The truck was towed to a Ford dealership and it was determined that the high pressure fuel pump came apart and put metal shaving everywhere throughout the fuel system. Ford recommended replacing all of the high pressure system this included all new fuel injectors. This repair cost $9,000. . A search of the internet revealed that this is a known failure. I had an independent lab test the fuel. There were no contaminants in the fuel except the metal shaving from the pump. ( the Ford fuel system recirculates the excess fuel back to the tank) the truck has 115000 miles. I had the Ford maintenance agreement with the 5000 mile services option. Ford has provided all of the service including the ones after the maintenance agreement ended. This is a very expensive repair to undertake on a 7 year old vehicle. Engineering changes could have prevented the extent of the damage. A post pump filter or screen would have prevented the rest of the high pressure system from needing replacement. An advisory about the potential pump failure and replacing the pump before failure would have costed less than $2000. Had I been towing near full gcwr, 21,000 lbs and come up on los angeles stop and go traffic, this could have be a terrible accident.

Stopped at bp gas station in pocahantas, IL for diesel. Pump handle and button were green. Apparently was 85 octane gasoline. Drove approximately 7 miles east on I-70 when unleaded fuel hit the fuel injectors and lost power while hauling a 3,300 lb camper and 21' fiberglass boat with tandem axle while in the #2 (high-speed) lane attempting to pass a slower vehicle at approximately 70 mph. Lost all power, check engine light came on and signaled immediately for right turn, and pulled to the side of the highway. Called three Ford dealerships in the local area and two said they couldn't even look at it for a week. Paid additional towing to have it towed to schmidt Ford, salem, IL and it sat until Monday before I was called and told it would cost me $8,500 estimate to replace the entire fuel system (injectors, fuel rails, high and low pressure pump, tank, and fuel filter). Service rep told me if I didn't do the repairs they would have to notify Ford of the warranty violation against Ford's job-aid for this continued problem. I researched the issue on multiple forums and discovered there is a DE-lamination issue occurring with the fuel tanks that is causing high pressure pump failures. Since I didn't drive it for a prolonged period I instructed the service tech to drain the entire system including the return line, to which they told me that would require dropping the tank, and I told them to drop the tank, empty it of all contents, inspect for delamination, change the fuel filter, and put fresh diesel fuel into it and run it and call me back. They did not call me back and when I called 5 minutes before close of business on Tuesday they said it's fixed and running fine. I had to ask how much the bill was and was told it was $640 (approx). Returned to the dealership on Thursday (10 July 14) and picked up the vehicle, paid the bill and returned home (896 miles).