2016 Ford F-250 Sd Fuel system Problems

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)

NHTSA ID

11683811

Incident

Aug 23, 2025

The contact owns a 2016 Ford F-250. The contact stated while driving approximately 25 MPH, the vehicle started losing motive power. There was no warning light illuminated. The contact was able to coast to the driveway at the residence and became aware of an oil leak underneath the vehicle. The contact stated that an unknown dealer was contacted and informed the contact that a fuel system upgrade was available; however, the vehicle was not upgraded. The vehicle was not diagnosed or repaired. The manufacturer was informed of the failure and a case was filed. The manufacturer referred the contact to the NHTSA Hotline to report the failure. The failure mileage was approximately 212,000.

NHTSA ID

11678272

Incident

Jul 28, 2025

Mileage

212,000 mi

The contact owns a 2016 Ford F-250. The contact stated while driving at an undisclosed speed, the vehicle experienced reduced power and poor fuel efficiency. The messages "DPF System Overloaded" and "Exhaust System Fault - 50 Miles Until Speed Restrict" were displayed. The vehicle was taken to the dealer on four separate occasions. The dealer performed a manual regeneration three times, but the failure persisted. The vehicle was taken back to the dealer, where it was determined that the Diesel Particulate Filter (DPF) system needed to be replaced. The vehicle was not repaired. The contact related the failure to Customer Satisfaction Program Number: 20M06 (Diesel Particulate Filter Warranty Extension with Diagnostic Trouble Code P2002) and Emission Recall Number: 20E08 (Extended Idle Diesel Particulate Filter Calibration); however, the VIN was not included. The manufacturer was made aware of the failure and advised the contact to report the failure to the NHTSA Hotline. The failure mileage was 66,634.

NHTSA ID

11677804

Incident

Apr 1, 2023

Mileage

66,634 mi

The contact owns a 2016 Ford F-250. The contact stated while driving 45 MPH, the vehicle lost motive power. There was no warning light illuminated. The contact was able to pull over to the side of the road. The vehicle failed to restart and was towed to the residence. The vehicle was then towed to the dealer, where it was diagnosed with an inoperable high-pressure fuel pump(HPFP). The dealer determined that the entire fuel system needed to be replaced. The vehicle was not repaired. The manufacturer was notified of the failure, but no assistance was provided. The failure mileage was approximately 91,000.

NHTSA ID

11662363

Incident

May 18, 2025

Mileage

91,000 mi

The contact owns a 2016 Ford F-250. The contact stated that while driving 10 MPH, the check engine warning light illuminated, and the vehicle stalled while driving through an intersection. The contact was able to safely coast the vehicle over to the side of the highway. The contact was able to restart the vehicle. The contact stated that several days later the failure reoccurred, and the vehicle was taken to a local dealer to be diagnosed. The contact was informed that there were metal particles inside the fuel system. The contact was informed that the fuel system needed to be replaced. The vehicle was not repaired. The contact referenced NHTSA Campaign Number: 24V957000 (FUEL SYSTEM, DIESEL) as a possible cause for the failure. The manufacturer was notified of the failure. The approximate failure mileage was 178,000.

NHTSA ID

11641966

Incident

Jan 31, 2025

Mileage

178,000 mi

The contact owns a 2016 Ford F-250. The contact stated while driving at an undisclosed speed, the reduced power warning light illuminated, and the vehicle lost motive power. The contact drifted over to the shoulder of the roadway. The vehicle was towed to an independent mechanic where it was diagnosed with a failed high-pressure fuel pump. The contact was informed that the high-pressure fuel pump needed to be replaced. The vehicle was repaired. The manufacturer was made aware of the failure but provided no assistance. The failure mileage was approximately 240,000.

NHTSA ID

11633903

Incident

Aug 21, 2024

Mileage

240,000 mi

The contact owns a 2016 Ford F-250. The contact stated while her husband was driving at an undisclosed speed, the accelerator pedal was depressed; however, the vehicle failed to accelerate as intended. The contact stated that the failure occurred while driving on a busy highway. The contact's husband drove the vehicle to the intended destination. The vehicle was taken to an independent mechanic. The contact stated that several warning lights illuminated, and the vehicle lost motive power. The vehicle was diagnosed with a clogged diesel particulate filter. The contact was informed that the diesel particulate filter needed to be replaced. The vehicle was not repaired. The manufacturer was made aware of the failure but provided no assistance. The failure mileage was approximately 140,000.

NHTSA ID

11605688

Incident

Jul 17, 2024

Mileage

140,000 mi

The contact owns a 2016 Ford F-250. The contact stated while driving approximately 5 MPH and hauling a trailer, the vehicle suddenly lost motive power and stalled. There was no warning light illuminated. The vehicle failed to restart. The vehicle was towed to the dealer where it was diagnosed and determined that the fuel pump had failed due to metal shavings in the fuel system. The contact was informed that the fuel system kit needed to be replaced. The vehicle was repaired. The manufacturer was made aware of the failure. The manufacturer referred the contact to the NHTSA Hotline to file a complaint. The failure mileage was 237,778.

NHTSA ID

11594731

Incident

May 16, 2024

Mileage

237,778 mi

The contact owns a 2016 Ford F-250. The contact stated that while driving at approximately 50 MPH, the check engine light illuminated, and the message “Reduced Power Mode” was displayed. The vehicle was taken to a dealer where it was diagnosed that the fuel pump, manifold assembly, fuel injectors, injector terminal seal, gaskets, vacuum pump, and left side fuel rail pressure pump needed to be replaced. The manufacturer was notified of the failure. The failure mileage was approximately 76,880.

NHTSA ID

11593655

Incident

Jun 5, 2024

Mileage

76,880 mi

The contact owns a 2016 Ford F-250. The contact stated that while driving 20 MPH, the vehicle lost motive power and stalled. The check engine warning light was illuminated, with a message stating to check the engine. The vehicle was towed to an independent mechanic where a diagnostic test was performed. The mechanic stated that the high-pressure pump created metal debris that traveled through the fuel system and the high-pressure fuel pump needed to be replaced. The vehicle was not repaired. The manufacturer was made aware of the failure and referred the contact to the NHTSA Hotline. The approximate failure mileage was 110,000.

NHTSA ID

11581075

Incident

Apr 1, 2024

Mileage

110,000 mi

Def pump or def heater there was a recall on this when I called about the air bag recall they told me that there was one now they say there isn’t one now and something wrong with 4x4 sleeping or might be transmission bought extended warranty 2 times on pickup just need it fixed thank you

NHTSA ID

11564946

Incident

Dec 20, 2022

I recently received a warning for P20BA informing me that the truck had a failed DEF heater. The unit was not in warranty and parts estimate for this is $360.00-$400.00 with an additional $400.00 dollars in labor for a total cost at minimum of $800.00 to $1,000.00 to replace a part that Ford Motor Company knew was a high failure rate part that would not meet industry standards.

NHTSA ID

11547951

Incident

Aug 1, 2021

I was attempting to access the interstate when my truck began to immediately shut down at 70 miles per hour. I received a warning as the engine shut down stating that my engine power was reduced. At the exact moment the message displayed, the truck immediately died at 70 mph leaving me to be forced to wrestle the steering wheel to maneuver the truck to the side of the interstate as I had no power steering due to the failure. I have been informed that my truck is a victim of a catastrophic engine failure as a result of a failed CP4 OEM Bosch high-pressure fuel pump. The failure has resulted in the complete contamination of the fuel system requiring a complete overhaul with parts cost at $6,600.00 and approximately $4,000.00 in labor for a total of more than $10,600.00. on a low mileage diesel.

NHTSA ID

11547948

Incident

Sep 16, 2023

Maintained Truck and did all required maintenance. Truck blew up while driving. All oil leaked out. Ford found hole in upper oil pan. Truck had poor fuel Truck has exhaust issues and ford can’t correct Lost truck and a lot of money , engine needs to be replaced.

NHTSA ID

11512492

Incident

Jan 10, 2023

DEF heater/sender assembly was replaced under Ford 21M01 recall. However, the damaged caused by these defective items caused the need to repair additional component's that was not paid for by Ford. Ford will not reimburse additional cost, and can not furnish a statement from a Ford engineer that states the defective replaced parts did not cause the additional repairs. (expense).

NHTSA ID

11503939

Incident

Jan 16, 2023

The contact owns a 2016 Ford F-250. The contact stated while driving at an unknown speed, the shifted into Limp Mode. The contact stated that the check engine warning light was illuminated. The vehicle was towed to an independent mechanic who diagnosed that the failure was due to metal chips being in the fuel. The independent mechanic advised the contact to tow the vehicle to the dealer. The vehicle was towed to the dealer where it was awaiting a final diagnostic report. The mechanic confirmed metal chips inside the fuel. The contact stated that he was informed by other mechanics that the failure was a known issue. The manufacturer was notified of the failure and advised the contact to file a complaint with the NHTSA. The approximate failure mileage was 67,000.

NHTSA ID

11474542

Incident

Jul 3, 2022

Mileage

67,000 mi

The reductant heater (DEF heater) has went out. Ford will not honor the 5 year/ 60,000 miles power train warranty or the 8 year/ 80,000 mile emissions warranty to repair the issue. According to web sources dealerships maintain a regular supply of these heaters as they replace 5 to 6 a week in the winter. My truck is 4 years and 58,000 miles.

NHTSA ID

11446068

Incident

Dec 27, 2021

FUEL FILLER NECK ROTTED AWAY ALLOWING FUEL TO RUN DOWN THE INSIDE OF THE FENDERWELL. THE FUEL CAP LIGHT DID LIGHTUP. THIS VEHICLE HAS 25730 MILES ON IT. THE FILLER NECK WAS REPLACED BY MY SERVICE CENTER. I NOTICED THE LEAK WHILE FUELING ABOUT 200 MILES FROM HOME, AND HAD IT CHECKED UPON ARRIVING HOME.IF I HAD BEEN IN AN ACCIDENT THIS WOULD ALLOWED FUEL TO LEAK.

NHTSA ID

11426159

Incident

Jun 27, 2021

The DEF fluid heater has failed. This can cause failure or DEF delivery to the system at lower outdoor temperatures. This component has already been subject to a NHTSA recall in earlier year models of tge same truck, up to model year 2015.

NHTSA ID

11425302

Incident

Jul 1, 2020

FAILURE OF REDUCTANT HEATER AND SENDER UNIT FOR DIESEL EMISSION FLUID (DEF) WITH ONLY 37,000 MILES. ERROR CODES WILL EVENTUALLY FORCE VEHICLE TO IDLE AND NOT DRIVE AT HIGHWAY SPEEDS. FORD VEHICLES PRIOR TO 2016 WERE FIXED AT NO CHARGE FOR THIS DEFECT UNDER FORD'S CUSTOMER SATISFACTION RECALL

NHTSA ID

11395875

Incident

Feb 9, 2021

Mileage

37,000 mi

SERVICE ENGINE LIGHT CAME ON TWICE WHILE VEHICLE WAS UNDER WARRANTY. DEALER SERVICED BOTH TIMES AND WAS UNABLE TO RECTIFY OR UNDERSTAND THE PROBLEM. THEY ONLY CLEARED THE FAULT CODES. THE CODE IDENTIFIED WAS FOR THE REDUCTANT HEATER PUMP - LOW VOLTAGE. THE SAME CODE JUST CAME BACK ON FOR THE 3RD TIME - THIS TIME IDENTIFIED BY A DIESEL PERFORMANCE SHOP - WITH ADVICE TO REPLACE THE REDUCTANT PUMP. PREVIOUS MAKE AND MODEL SUPERDUTY TRUCKS HAVE HAD RECALLS FOR THE SAME THING. THIS IS AN OBVIOUS ISSUE, NOT SURE WHY FORD SERVICE SHOPS COULD NOT RECTIFY. TRUCK IS NOW OUT OF WARRANTY AND I AM FORCED TO PAY OUT OF POCKET. UNACCEPTABLE SERVICE AND CARE! -COLD WEATHER EACH TIME -ENGINE LIGHT COMES ON - SAME CODE EACH TIME -REDUCED SPEED AND SLUGGISH PERFORMANCE -CODE CLEARED - TRUCK PERFORMS NORMAL -OBVIOUS THAT THE REDUCTANT HEAT PUMP IS NOT DOING WHAT IT IS DESIGNED TO DO.

NHTSA ID

11309982

Incident

Feb 14, 2020

Mileage

55,000 mi

WAS DRIVING DOWN THE ROAD AND THE TRUCK STARTED LEAKING DIESEL EVERYWHERE. WE TOOK THE TRUCK TO THE DEALERSHIP WHERE THEY SAID THAT WHEN THE FILTER CLOGS THE TRUCK DOESN'T TURN OFF IT SPRAYS FUEL OUT OF THE TOP OF THE FILTER HOUSING. THIS IS DANGEROUS AS MY WIFE WAS DRIVING THE TRUCK AND SITTING IN THE TRUCK FOR SEVERAL MINUTES WITH IT RUNNING NOT REALIZING IT WAS LEAKING . IT COULD HAVE CAUGHT ON FIRE.

NHTSA ID

11228342

Incident

Jun 28, 2019

CODE P20BA, REDUCTANT HEATER IN DEF TANK. IT IS A KNOWN PROBLEM BUT FORD DID NOT INCLUDE MY YEAR MODEL IN THE WARRANTY RECALL. $1050.00 TO REPAIR. I SEE ALL OVER THE INTERNET WITH PEOPLE HAVING THE SAME PROBLEM THAT I'M HAVING.

NHTSA ID

11180846

Incident

Feb 15, 2019

Mileage

51,000 mi

DEALERSHIP REPORTS A FAILURE TO THE HIGH PRESSURE FUEL PUMP. REPAIRS ARE $7900.00. ONLY 5500 MILES ON THE DIESEL TRUCK AND IS NOT COVERED UNDER WARRANTY. NO WARNINGS LIGHTS OR ALARMS WERE GIVEN. AFTER THOROUGH RESEARCH, THIS IS A CONCERNING PROBLEM, WITH FORD/BOUSCH.

NHTSA ID

10948166

Incident

Jan 17, 2017

Mileage

5,500 mi

ENGINE RUNS ROUGH DURING EXHAUST REGEN. TYPICALLY WHEN DRIVING BETWEEN 55-65, THE DIESEL EXHAUST FLUID WARNING APPEARS. ALMOST A MINUTE LATER THE TRUCK BEGINS TO MAKE LOUD JACK HAMMER NOISE AND LOSES POWER. FEELS VERY UNSAFE AS YOU LOSE POWER FOR ABOUT 10 SECONDS.

NHTSA ID

10898625

Incident

Aug 25, 2016

Mileage

15,200 mi