Diesel Fuel System Problems of Ford F-450 - part 1

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.

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The contact owns a 2020 Ford F-450. The contact stated that after starting the vehicle, the engine ran for several minutes before the vehicle independently shut off. No warning lights were illuminated. The contact attempted to restart the vehicle however, the vehicle failed to start. The vehicle was towed to the residence. The local dealer was contacted; however, the vehicle was not diagnosed or repaired. The contact referenced NHTSA campaign number: 24v957000 (fuel system, diesel) as probable cause for the failure. The manufacturer was not notified of the failure. The approximate failure mileage was 184,000.

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The contact owns a 2020 Ford F-450. The contact stated that while driving 60 mph, there was an abnormal knocking sound coming from the vehicle, with the "reduced engine power" message displayed on the instrument panel. The contact pulled over to the shoulder of the highway, and the vehicle shut off. The contact stated that the vehicle failed to restart after several attempts. Due to the failure, the vehicle was towed to a dealer where a diagnostic test was performed, and it was determined that the high-pressure fuel pump had failed. The contact was informed that the entire fuel system needed to be replaced. The contact then 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 made aware of the issue and informed the contact that the remedy for the recall was a software update. The contact was informed that due to the fuel pump failure, the vehicle was no longer qualified for the recall repair. The dealer referred the contact to the manufacturer who offered to cover 50% of the cost for the repair. The contact stated that the recall repair was not a permanent repair and that the recall remedy failed to adequately address the failure. The vehicle was not repaired and remained in the possession of the dealer. The failure mileage was approximately 40,000. VIN tool confirms parts not available.

The contact owns 2020 Ford F-450. 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 contact stated that while started, the "low fuel pressure" message was displayed. The contact stated that while driving at an undisclosed speed, the vehicle lost power. The vehicle was towed to an independent mechanic where it was diagnosed and determined that the fuel filter had exploded and needed to be replaced. The vehicle was then towed to a dealer where it was diagnosed and determined that the fuel system was contaminated with metal and that the entire fuel system needed to be flushed and replaced. The vehicle was not repaired. The manufacturer was not notified of the failure. The failure mileage was approximately 103,000. VIN tool confirms parts not available.

The contact owns a 2020 Ford F-450. The contact received notification of NHTSA campaign number: 24v957000 (fuel system, diesel). The contact stated that wile hauling an RV at 65 mph, with the cruise control feature activated, the message that the "engine has stopped - pull over immediately" was displayed, and the vehicle stalled. The vehicle was steered to the side of the road and the contact attempted to restart the vehicle. The contact stated that the engine was turning over however, the vehicle failed to start. The vehicle was towed to a dealer to be diagnosed and the dealer retrieved dtc: p0087. Additionally, there were metal shavings found in fuel system. The contact was informed that the fuel pump and the entire fuel system needed to be replaced. The vehicle was repaired. The manufacturer was notified of the failure. The failure mileage was 104,717.

The contact owns a 2020 Ford F-450 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 made aware of the issue and confirmed that parts were not yet available. The contact stated that the manufacturer had exceeded a reasonable amount of time for the recall repair. The manufacturer was not made aware of the issue. The contact had not experienced a failure.

The contact owns a 2019 Ford f450. The contact stated that when the vehicle was started, the check engine warning light illuminated. The contact stated that while driving at an undisclosed speed, the vehicle went into limp mode. The vehicle was taken to the dealer where it was diagnosed and determined that the diesel particle filter (dpf) had failed. The sensor was replaced. The contact stated that the failure persisted. The vehicle was taken back to the dealer. The sensor had been replaced four times. The manufacturer was made aware of the failure and referred the contact to the nhsta hotline for assistance. The approximate failure mileage was 19,000.

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The contact owns a 2020 Ford F-450. The contact stated that while driving at 65 mph, the vehicle lost motive power. The vehicle was towed to the dealer and diagnosed with metal shards in the fuel system. The dealer informed the contact that the fuel system kit needed to be replaced but parts were on backorder. The vehicle was not repaired and remained at the dealer. The manufacturer was made aware of the failure and a case was opened. The failure mileage was 33,875.

10/17/13 I was driving on the interstate with a load of cattle running fine and just lost power going on the interstate going from 65 to 10 miles an hour. Traffic zipping by. I thought it was the fuel filters but it done the same after I changed them. I took it to a garage and he said he the tank liner was coming apart now it messed up my injectors, and I think Ford should have a recall on something like that before someone gets killed or severly hurt!!!! it is in the shop now and I think Ford should pay something on this.

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The truck began to shake and lose power, eventually not even being able to stay running. The mechanic upon review found the tank liner had delaminated from inside fuel tank and had plugged up fuel sender. Both needed to be replace at a cost of $2800, Ford dealer stated there was nothing they could do.

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2010 Ford F-450. Consumer writes in regards to diesel fuel getting into oil due to open injectors. The consumer also stated engine light illuminated and the exhaust was emitting smoke.

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At appx. 80,000 miles on our 2004 f450 sd fuel tank delaminated causing fuel system failure which resulted in sudden loss of power. We have always purchased high quality diesel from reputatable gas stations (chevron, shell). Vehicle repaired at Ford and had contacted Ford motor company regarding reimbursement of cost and was declined.

2008 Ford f450. Consumer writes in regards to a safety concern of an auxiliary fuel tank the consumer stated he purchased the fuel tank and it was installed on June 1, 2011. The tank was made of the same material as tool boxes for truck beds. Recently, a single bolt attached on the passenger side became loose and slipped an inch and a half out of the hole securing the tank to the bed of the truck. The bolt threads were stripped up to the end of the bolt. The nut was at the end of the threads of the bolt. The bolt was protruding outward in the bed of the truck and was bent at a 45 degrees. With the bolt bent over, the tank slid an inch forward in the bed of the truck. The driver side bolt had also loosened, but was still secure with a nut. The establishment where the consumer made the purchase, informed him he tank was supposed to be movable. They stated it was supposed to be secured with one bolt on each end.

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The contact owns a 2004 F-450 sd. While driving, the contact stated that the vehicle would loose power and would stall intermittently. The dealer diagnosed that there was delamination found in the fuel tank lining, which was flaking off and causing a leak in the fuel filter and fuel pump. The manufacturer was not notified of the failure. The vehicle was repaired. The failure mileage was unavailable and the current mileage was 34,000.

The contact owns a 2006 Ford F-450. The contact stated that the fuel tank began to deteriorate due to corrosion from the diesel fuel; the contact was informed during a routine oil change. The mechanic stated that the lining was being eaten through by the fuel. The manufacturer offered no assistance. The current and failure mileages were approximately 21,000. The consumer was informed there was condensation in the fuel tank causing it to rust.

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2007 Ford F-450, fuel tank is delaminating on inside. Plugged fuel filters(every 1200 miles), pump and injectors also contaminated from tank. Numerous problem through out the united states. Needs to be recalled by Ford.

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The contact owns a 2006 Ford F-450 diesel tow truck. The contact stated that while driving approximately 65 mph, the vehicle stalled and was unable to be restarted. The vehicle was towed to a local repair shop where the contact was informed that the failure occurred because the fuel tank had delaminated. The vehicle was repaired. The failure mileage was approximately 100,000.

2001 Ford f450 diesel fuel tank liner failed and resulted in fuel delivery while towing. This caused 10 mph speed on the interstate while pulling a horse trailer. Just spent $1800. 00 for new tank and was told that it would happen again. This problem should have been resolved with the new tank and not just installing another one that will fail also.

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10/5/2010 brighton,mi my truck started to blow white smoke and the engine stopped running while driving down the road. I had it towed to my dealer and was told it has a delamination problem in the fuel tank and the cause was from bio-diesel contamination and I would now need to replace or reseal the tank and install a new fuel pump along with one new injector at a cost of $2643. 00 plus tax. I had the repairs done because I need the truck for work I also saved the old parts. Hopefully Ford(if they want to sell me another truck in the future) will participate in this repair.

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Vehicle would quit pulling. Had to pull to shoulder and shut off. After fifteen or twenty minutes, it would start and run fairly normal for a few miles and then do the same thing over again. This went on until I got to my destination which was a couple hundred miles.

Ford f 450 diesel fuel tank is delaminating causing the truck to stall causing a dangerous situation on the road. From research on the internet, this is not an isolated problem. Apparently Ford is ignoring the problem and shifting the blame to fuel. My chevy nor my fathers Dodge have this problem. It is very expensive to fix.

The egr, ficm, and injectors on this vehicle have caused traffic hazards. We can not pull out without the engine spitting and sputtering. We have replace all of the above, some more than once. Last time in to the Ford dealer they suggested that we use a thinner oil to lubricate the injectors better. This also doesn't work. We have read many people on the internet that have the same problem with their diesel engines so we know it's not just ours. We paid $8,000. 00 to repair and nothing is better. Ford refuses to admit there is a problem. Please help those of us that are stuck with these trucks. The dates of incidents have been ongoing.

A Ford 6. 0 diesel engine.

Ford f450 diesel delaminating fuel tanks cause the vehicle to stall on the highway causing a safety hazard. The delamination causes the fuel system to not work properly such as the injectors causing the vehicles to loose power and stall. It has happened three times to me without warning. The tank is being re-coated but after doing some investigation about the problem and even the Ford service tech said it could happen again. . . And most likely will because the diesel fuel is interacting with whatever they put on the tanks causing it to erode. Ford will not cover this. I have found information saying it seems to be happening to tanks with these two identification numbers yc35-9k007-f8 and 5c34-9k007-ra. I guess if Ford acknowledged this they would be responsible for replacing these defective tanks. But by blaming the diesel fuel. . . They are not held responsible. However it doesn't happen on other trucks such as Dodge, chevy, etc. Something really needs to be done to warn others before someone stalls and causes a wreck. Alot of these trucks are used in business and carry heavy loads.

F450 stake body dump truck started hesitating at all speeds. Found out that the diesel fuel gas tanks are delaminating on the inside and clogging the fuel system. This repair costs $2,400. A big truck driving down the road that is running fine and then all of a suddenly starts to hesitate is extremely dangerous. Ford trucks seem to be the only ones having this problem. I feel Ford should be required to recall these trucks and fix the problem for safety purposes.

Fuel tank delamination. Trucks started running bad, would eventually stop. Has left me and my employees stranded several times, sometimes in unsafe traffic areas. New fuel tanks installed, fuel pumps injectors put in new. Entire fuel system cleaned. Just under $5000. 00 each time. Ford says biofuel is the cause. Never have used biofuel in anything.

A faulty fuel line on a 2000 Ford f450 brush fire truck failed, spraying diesel fuel onto the engine, causing a small engine fire, during an emergency response to a fire. Fire was quickly controlled with onboard afff/water mixture. Called to have repaired, mechanic came out to station, and replaced 2 steel fuel lines. Mechanic stated he is surprised these fuel lines were never recalled, he had changed his out for a same failure weeks ago. Apparently, the support bracket, that came on the original lines, the rubber inside the bracket wears out, so the line rubs against metal and weakens it. The new replacement lines do not come with this line. Apparently this is a common problem according to the mechanic. Old part is not available, mechanic threw it away.

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2004 Ford F-450 super duty. Truck was running as if it was running out of fuel, got to a stop light and the truck stalled. Got the truck to restart. That evening I had the fuel filters changed thinking that was the problem, then the truck ran fine. Two days later the truck did the same thing, and I was driving at 25mph, truck would not run any faster, then the truck stalled in the middle of a two lane road. The truck at this time did not restart. I had to get the truck towed. I got advice from a mechanic and he drained the tank and he found silver flakes in the tank. I called universal Ford in richmond virginia and they had it towed there to look at the truck, and the technician verified that the tank was contaminated from the tank due to delamination of the interior of the tank. Ford motor company said that the cost was $783. 93 for parts and $258. 10 for labor, for a total of $1042. 03 and Ford motor was willing to pay only $312. 00. This is only for a tank replacement, not the filters, fuel pump or injectors if these parts are contaminated. I refused the service, on the fact that the service manager said that this will probably happen again with the new tank as well. I have found someone that can fix my tank for less money, but I would like results and this needs to be addressed before someone does get killed, if they haven't already. Ford is saying to my knowledge that this is the low-sulfur diesel fuel and not there fuel tanks. I have contacted a lawyer and he is dealing with other clients with the same issue.

While traveling on the 290 hwy around buffalo NY the truck stalled in the middle lane at 60 mph fortunately the driver was able to coast over to the right shoulder. Upon examination of the problem we found the fuel filters plugged with debris from the deteriorating liner of the fuel tank. When I contacted the dealer it was found that Ford was replacing these under its emissions warranty and that if past that you were on your own , to the tune of $1000. 00. We have had Ford diesels since 1974 and over 250,000 miles on them without this problem. What ever Ford did is causing fuel pump, injecter , and gas tank issues on the 6. 0 diesel, which is the worst diesel Ford ever made. This truck has 90,000 miles and a very frequent repair history,in 10,000 miles it will be out of their engine warranty leaving owners like me saddled with expensive repairs from the service managers to their customer relations dept. , you get the same song, there is nothing we can do!!!! I have samples of the deteriorated liner and fuel. If it had been rush hour when the truck quit, I am sure there would have been an accident.

We have a Ford 2005 F-450 rack body truck. In 2007-08 we paid a Ford dealership approx. $4000 to replace fuel tank, fuel pump and injectors on said vehicle. Just this week, a different Ford dealership informed us that the original problem happened again and we would incur similar expenses because Ford does not consider this a defect on their part but a problem with the fuel.

I brought my companies 2005 Ford f450 super duty to the dealer for oil leaks & running poorly . The fuel tank has delaminated & they will not cover the repair .

My 2004 Ford F-450 has a fuel tank corrosion/delamination problem. Ford refuses to fix the defect. The delamination is causing a clogging of the fuel system which causes the engine to shut down while driving. I have changed the injectors and change/clean the fuel filters regularly I have read online the complaints of numerous other owners of the same types of truck.

2006 Ford F-450. The lining on the inside of the fuel tank is disintegrating, plugging the filters and causing fuel related problems. The truck only has 54,000 miles on it. The dealership is wanting to charge me $2100 for a new fuel tank. I told them this is a manufacturing defect and Ford should stand behind it. They said it was caused by fuel. I cannot afford to have the vehicle repaired.

The coating on the interior of Ford diesel fuel tanks corrodes and collects as sediment in the fuel system. The sediment, collects at the botton of the fuel tank and is sucked into the fuel system. In this incident, the failure began with the check engine light illuminating. The dealer, replaced the sensor, then at a second time the fuel element, and finally the entire fuel system required replacement. The fuel lines become fouled, the fuel pumps become clogged and require replacement. As the coating continues to deteriorate, the only recourse it to change the fuel tank, the sensors, and entire fuel delivery system. We have had 3 Ford vehicles f series experience this problem. In this case in less than 18 months from date of purchase, the fuel elements and sensors required replacement we are reporting this as it seems to be a defect in all the Ford diesel fuel systems. As the fuel systems become clogged, the vehicles lose power without warning and create a safety issue and driving hazard not only to the vehicle operator but other motorists.

Our 2004 Ford f450 diesel truck lost power when driving on the highway. We took it to Ford and they told us the liner in the fuel tank was coming apart and they wanted $2100 to replace the tank. I saw on several web sites that this is a common problem that Ford is well aware and refuses to take responsibility for. I saw over 1,000 blogs from people who have had the same problem and Ford tells them it is the fuel they are getting and not a default in the tank design. I believe they should own up to their mistake and recall these tanks instead of making money off of replacing them.