2019 Ford F-250 Sd Fuel system Problems

NHTSA Vehicle Safety Complain To whom it may concern, My Name is [XXX] I am submitting this complaint regarding my 2019 Ford F-250 Super Duty equipped with the 6.7L Power Stroke diesel engine (VIN: [XXX]). At approximately 137,900 miles, my vehicle suddenly lost engine power while driving and stalled without warning, creating a serious safety hazard. After stalling, the truck would not restart and had to be towed to a repair facility. The repair shop diagnosed a catastrophic failure of the diesel high-pressure fuel injection pump. According to the repair invoice, fine metallic flakes were found throughout the entire fuel system, contaminating the fuel lines, fuel tank, injectors, and related components. Because of this contamination, the shop determined that the entire fuel system required replacement, including replacement of all eight fuel injectors, cleaning of the fuel tank and fuel lines, replacement of the fuel filter, and installation of an upgraded diesel injection pump. The estimated repair cost exceeded $11,000, resulting in a significant financial burden. I understand that Ford Safety Recall 24S78 addresses a high-pressure fuel pump issue on certain 2020–2022 Ford Super Duty trucks equipped with the same 6.7L Power Stroke diesel engine. Although my 2019 model is not included in the recall, my vehicle experienced what appears to be a very similar failure that resulted in sudden loss of engine power while driving and complete contamination of the fuel system. I am not asserting that my vehicle is covered by the current recall. Rather, I respectfully request that NHTSA investigate whether the same or a substantially similar defect may also affect certain 2019 Ford F-250 Super Duty vehicles equipped with the 6.7L Power Stroke diesel engine. If the investigation determines that these vehicles are affected by the same safety defect, I ask that the recall be expanded accordingly. I have retained the repair invoice documenting the diagnosis INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA

NHTSA ID

11763171

Incident

Oct 10, 2025

The contact owns a 2019 Ford F-250 SD. The contact stated that while driving 70 MPH, there was an abnormal diesel odor on the inside of the vehicle. The contact stated that the vehicle failed to exceed 65 MPH, and there was white to gray smoke coming from under the hood. The contact pulled over with the engine still running and after opening the hood, the contact became aware of diesel fuel squirting out from the secondary fuel filter. The contact stated that the fire consumed the vehicle. The fire was coming from underneath the driver's side hood and driver’s side wheel well. The Fire Department was contacted and extinguished the fire coming from the vehicle. The vehicle was towed to an impound lot, and it was deemed a total loss by the insurance company. The manufacturer was contacted by phone and was made aware of the failure. The failure mileage was approximately 144,000.

NHTSA ID

11762856

Incident

Sep 3, 2026

Mileage

144,000 mi

While driving the truck completely just shutdown and then would not start.

NHTSA ID

11746368

Incident

Sep 20, 2024

Original Fuel pump stated intermittent long cracks about 35,000 miles. And continues to do so. It seems like FORD uses the all time favorite “ we cannot recreate the issue” in order to send the customer on their way and not take ANY responsibility whatsoever ,WOW! Its rediculous that they don’t want to acknowledge the issue after thousands of customers complain. Our whole family has been riding in this vehicle when the truck experienced the truck lag and turn off at highway speeds. Does someone have to be hurt or killed by this for this company to finally own up? I hope none does!!! Make it right FORD!!! Yet they changes and updated the newer trucks pumps after this, why? REDICULOUS

NHTSA ID

11737324

Incident

Jan 1, 2022

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.

NHTSA ID

11728201

Incident

Mar 4, 2026

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.

NHTSA ID

11726431

Incident

Mar 5, 2026

2019 Ford F-250 original fuel pump or related part connected cause hard and prolonged starting in vehicle. Prolonged starts can damage other parts if left unfixed. This is a Ford manufacturing issue and could cause a person possible harm from an unknown development from the pump and related affected parts. Dont wait until humans are injured to address this problem especially when dealing with potential combustible explosive materials. [XXX] , [XXX] [XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ID

11723532

Incident

May 1, 2025

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.

NHTSA ID

11722708

Incident

Nov 20, 2025

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.

NHTSA ID

11709622

Incident

Jan 7, 2026

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.

NHTSA ID

11697832

Incident

Oct 19, 2025

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

NHTSA ID

11688500

Incident

Sep 19, 2025

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)

NHTSA ID

11685660

Incident

Sep 4, 2025

Vehicle shuts off while traveling down the highway with no warning. I was able to not panic as this happened on interstate hwy while in middle lane was able to shift to neutral and restart vehicle shift back in drive and go on. The potential for a much worse result was huge I have to imagine a lot of drivers may not think of what I did and allowed the vehicle to come to a stop on the highway creating an obvious hazard

NHTSA ID

11680287

Incident

Aug 25, 2024

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

NHTSA ID

11680021

Incident

Aug 12, 2025

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.

NHTSA ID

11678780

Incident

Jul 28, 2025

The contact owns a 2019 Ford F-250. The contact stated that while driving approximately 75 MPH, the vehicle lost motive power and almost stalled. The contact pulled over and stopped and the vehicle stalled. The contact attempted to restart the vehicle however, the vehicle failed to restart. Several unknown warning lights were illuminated. The vehicle was towed to a dealer and diagnosed with fuel pump failure; however, due to the cost of the repair the vehicle was towed to an independent mechanic who diagnosed the vehicle and determined that the high-pressure fuel pump had failed, and the entire fuel system needed to be replaced. The vehicle was repaired. The contact researched online and related the failure to NHTSA Campaign Number: 24V957000 (Fuel System, Diesel); however, the VIN was not included. The contact called the manufacturer to request a reimbursement and it was confirmed that the VIN was not included in the recall. The manufacturer referred the contact to the NHTSA Hotline for assistance. The failure mileage was approximately 120,000.

NHTSA ID

11678761

Incident

Aug 7, 2023

Mileage

120,000 mi

The contact owns a 2019 Ford F-250. The contact stated that the passenger’s side headlight bulb was blown, and the battery was not operating as needed. The vehicle was taken to the dealer and the headlight bulb was replaced; however, the bulb failed to illuminate. The vehicle was returned to the dealer two more times and the headlight bulb was replaced; however, the failure persisted. The vehicle was taken to another certified mechanic and the headlight bulbs were replaced. Additionally, the contact stated that the vehicle intermittently failed to start. The check engine warning light was illuminated. The dealer was contacted and advised the contact to replace the battery and filters. The contact replaced the battery and filters; however, the failure persisted. The vehicle was taken to the dealer, who diagnosed that there were metal shavings inside the fuel. The filters were replaced; however, the failure persisted. The dealer informed the contact that a defective fuel pump had caused the failure and the fuel pump needed to be replaced. The vehicle was not repaired. The manufacturer was informed of the failure and opened a case. The manufacturer referred the contact to the NHTSA Hotline to report the failure. The failure mileage was approximately 190,000.

NHTSA ID

11676211

Incident

Feb 25, 2025

Mileage

190,000 mi

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

NHTSA ID

11675218

Incident

May 11, 2025

The contact owns a 2019 Ford F-250. The contact stated that the vehicle was difficult to start. The contact stated that several attempts were needed before the vehicle started. The contact stated there was no warning light illuminated. Additionally, the contact stated that the vehicle stalled while driving at a slower speed while slowing down for a traffic light. The contact stated that the vehicle restarted on the first attempt. The contact stated that there were no warning lights illuminated. The contact had taken the vehicle to a local dealer; however, the failure was not duplicated. The vehicle was not repaired. The contact researched online and related the failure to NHTSA Campaign Number: 25V455000 (Fuel System, Gasoline). The manufacturer was informed of the failure and informed the contact that the VIN was not included in the recall. The failure mileage was approximately 74,000.

NHTSA ID

11675057

Incident

Jul 8, 2024

Mileage

74,000 mi

The contact owns a 2019 Ford F-250. The contact stated while driving down a mountain at 75 MPH, the vehicle lost motive power and the vehicle decelerated to 35 MPH unintendedly. The contact stated that the reduced engine speed and power warning lights were illuminated. The contact pulled over to the right side of the road while waiting for towing assistance. An independent mechanic was contacted. The vehicle was towed to a local church where an independent mechanic where it was determined that the high-pressure fuel pump had exploded, and the fuel system needed to be replaced. The vehicle was not repaired. The manufacturer was notified of the failure, and informed the contact that the VIN was not included in the recall. The contact was referred to the NHTSA Hotline for assistance. The failure mileage was 168,187.

NHTSA ID

11673954

Incident

May 19, 2025

Mileage

168,187 mi

The contact owns a 2019 Ford F-250. The contact stated while driving at an undisclosed speed, the vehicle jerked, and the low fuel pressure warning light illuminated. The contact stated the failure occurred while driving uphill and with a tractor and trailer hitched. The vehicle lost motive power. The vehicle was restarted. The vehicle was taken to the dealer where it was diagnosed with fuel systems failure. The contact was informed that the fuel system needed to be replaced. The vehicle was not repaired. The manufacturer was made aware of the failure but provided no assistance. The contact referenced an unknown recall; however, the VIN was not included. The contact was advised to contact the NHTSA Hotline to report the failure. The failure mileage was approximately 132,000.

NHTSA ID

11668142

Incident

Jun 18, 2025

Mileage

132,000 mi

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

NHTSA ID

11667282

Incident

May 24, 2025

The contact owns a 2019 Ford F-250. The contact stated while driving approximately 65 MPH, the vehicle lost motive power. The contact was able to pull over to the side of the road where the vehicle stalled. The vehicle was not able to be restarted. The vehicle was towed to a dealer where it was diagnosed and determined that the fuel pump had exploded, sending metal fragments throughout the system. The contact was informed that the fuel system needed to be replaced. The vehicle was in the process of being repaired. The manufacturer was not notified of the failure. The failure mileage was approximately 104,000.

NHTSA ID

11663051

Incident

May 14, 2025

Mileage

104,000 mi

The contact owns a 2019 Ford F-250. The contact stated that while driving at approximately 70 MPH, the vehicle lost motive power and stalled. The contact stated that there were no warning lights illuminated. The contact had the vehicle towed to a local dealer, where it was diagnosed and determined that the high-pressure diesel fuel pump had failed, and the entire fuel system and fuel pump needed to be replaced. The vehicle was repaired. The manufacturer was informed of the failure, and the contact was referred to the NHTSA Hotline to report the failure. The failure mileage was approximately 133,000.

NHTSA ID

11660671

Incident

Apr 17, 2025

Mileage

133,000 mi

•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.

NHTSA ID

11659161

Incident

Apr 25, 2025