2020 Ford F-250 Sd Fuel system Problems

The contact owns a 2020 Ford F-250 SD. The contact stated that the vehicle was repaired under NHTSA Campaign Number: 24V957000 (Fuel System, Diesel); however, while driving 40 MPH approximately two months later, the vehicle was running rough and stalled. The check engine warning light was illuminated. The contact pulled over to the side of the road. The vehicle was towed to a dealer, where it was diagnosed with a high-pressure fuel pump failure, causing the fuel system to become contaminated. The dealer determined that the fuel system needed to be replaced. The dealer submitted a diagnostic report to the manufacturer. The contact notified the manufacturer of the failure, and a case was filed. The vehicle was not repaired and was pending the manufacturer's decision regarding the coverage of the repair. The failure mileage was approximately 103,000.

NHTSA ID

11756201

Incident

Jul 15, 2026

Mileage

103,000 mi

The contact owns a 2020 Ford F-250. 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 not made aware of the issue. The contact stated that the vehicle had become inoperable due to a transmission failure. The contact associated the transmission failure with the recall; however, the dealer advised that the transmission repair would be at the owner's expense. The approximate failure mileage was 60,000.

NHTSA ID

11743767

Incident

Jun 25, 2025

Mileage

60,000 mi

The contact owns a 2020 Ford F-250. The contact stated that he received NHTSA Campaign Number: 24V957000 (Fuel System, Diesel). The local dealer was contact who confirmed there were metal shaving in the fuel injectors. The vehilce was not repaired. The manufacture was not contacted. The failure mileage was approximately 30,000.

NHTSA ID

11737777

Incident

May 14, 2026

Mileage

30,000 mi

Vehicle experienced loss of power while in travel down a mountain. After inspection by a mechanic, CP4 pump had a catastrophic failure sending metal shards throughout the fuel system. This was less than a month after Fords SAFETY RECALL 24S78 that failed to remedy the problem, but before recall Number26V158 was issued.

NHTSA ID

11728380

Incident

Mar 11, 2026

02/04/2026 69k miles. I brought my vehicle in because I got a check engine light on the dash and had loss of power. Was informed that my fuel pump had failed and sent metal shards through the whole fuel system. The damage was covered by the recall, which also included reprogramming of the tcm and pcm. Was then told that the reflash of those systems was a failure, and that the Ford Motor Company was working on a remedy. My dealership has since completed a full fuel system replacement, and there still isn't a fix for the programming issue. This is a revenue generating vehicle, and the only one, for my small business. I lost many clients due to inability to perform the work I was contracted to do. My dealership did offer me a loaner vehicle, but it's not one that can perform the work that my truck was able to do, and was told not to use the vehicle for any commercial work or towing, as thats not allowed. Ive reached out to customer relations to get updates, and have had no help from them, save for telling me they're working on it, and will hope to have a remedy soon.

NHTSA ID

11727660

Incident

Feb 3, 2026

The contact owns a 2020 Ford F-250. The contact received notification of NHTSA Campaign Number: 24V957000 (Fuel System, Diesel); however, while attempting to schedule an appointment, the contact was informed that the recall repair had been placed on hold. The contact stated that recently, while driving approximately 60 MPH, the vehicle started to lose motive power. The contact stated that the vehicle stalled and was towed to the same local dealer. There was no warning light illuminated. The vehicle was diagnosed, and it was determined that the high-pressure fuel pump had failed, and the pump and the diesel fuel system needed to be replaced. The contact was provided and estimate for the repair. The vehicle was not repaired. The contact stated that the manufacturer had exceeded a reasonable amount of time for the recall repair. The manufacturer was informed of the failure. The failure mileage was approximately 164,000.

NHTSA ID

11722208

Incident

Feb 28, 2026

Mileage

164,000 mi

The contact owns a 2020 Ford F-250. The contact received notifications of NHTSA Campaign Numbers: 24V957000 (Fuel System, Diesel) and 25V686000 (Back Over Prevention); however, the parts to do the recall repairs were unavailable. The contact stated that the manufacturer had exceeded a reasonable amount of time for the recall repairs. The contact stated that the check engine warning light was intermittently illuminated. The contact stated that while driving at various speeds, the vehicle unintendedly decelerated and lost power. The vehicle was coasted to the side of the road, turned off, restarted, and the vehicle regained power and drove as intended. The message "Power Reduced” was displayed. The failure occurred approximately every 5 miles driven. The vehicle was taken to the dealer and was diagnosed with low fuel pressure, and it was determined that the fuel pump had failed and needed to be replaced. The vehicle had not been repaired because parts were not available. The manufacturer was not made aware of the issue. The failure mileage was approximately 95,000.

NHTSA ID

11721446

Incident

Dec 20, 2024

Mileage

95,000 mi

The fuel tank is leaking fuel from the top where hose connects, it is cracked where the hose barb is connected to the tank

NHTSA ID

11718728

Incident

Feb 12, 2026

My cp4 fuel pump failed on my 2020 ford f250 and died while towing my 7000lb trailer for my business and had to get towed to shop to find out the entire fuel system needs replaced and ford dealer has it and says because recall 24s78 for my vehicle is on pause that there is nothing they can do about it and I’m stuck without my truck which I need for my business and believe ford is responsible to replace the fuel system with no charge to me when the cp4 pump is such a common failure in my trucks!

NHTSA ID

11717342

Incident

Feb 4, 2026

NHTSA Complaint Text (Copy/Paste) Vehicle: 2020 Ford F-250 Super Duty 6.7L Power Stroke Recall: 24S78 – Powertrain Control Module (PCM) Software Update Complaint: Ford has issued Recall 24S78 for the high-pressure fuel pump defect on my 2020 F-250, but the company has not provided an actual remedy. The recall shows as open on my VIN, and Ford’s documentation says a PCM software update is the fix, but Ford released the software and then pulled it back within a week. My dealership confirmed Ford removed the remedy from their system, so they cannot perform the recall at all. This leaves my truck exposed to a known safety defect with no available repair. The high-pressure fuel pump failure this recall addresses can cause sudden loss of power, engine stall, or complete shutdown while driving. Until a working remedy is released, I’m driving a truck that Ford has admitted has a serious safety defect, but they have not provided any fix or timeline. I am requesting NHTSA investigate why the remedy was withdrawn, why no replacement remedy has been provided, and why Ford is leaving owners with a known safety risk for an extended period. This is an expensive vehicle, and the defect can cause catastrophic engine damage and create a hazardous situation on the road. Owners deserve an effective recall remedy that is actually available. Not exactly sure when the recall was first brought to light but I do know it has been months now.

NHTSA ID

11717279

Incident

Oct 1, 2025

The contact owns a 2020 Ford F-250. The contact stated that while driving at an undisclosed speed, the check engine and loss of power warning lights were illuminated. In addition, the vehicle sputtered. The vehicle was driven to the shoulder of the road. The vehicle was then towed to an independent mechanic, where it was diagnosed with fuel systems failure. The contact was informed that the fuel system needed to be replaced. In addition, the contact was informed that a complete fuel system and maintenance needed to be performed to fix the vehicle. The vehicle was repaired. The contact received notification of NHTSA Campaign Number: 24V957000 (Fuel System, Diesel); however, the part was not yet available. The dealer was made aware of the failure. The contact was informed that the recall was not associated with the VIN. The manufacturer was not made aware of the failure. The failure mileage was approximately 120,050.

NHTSA ID

11717257

Incident

Jan 26, 2026

Mileage

120,050 mi

While driving cross country, my dash warning light came on and said " In 50 miles your vehicle will lose power and you won't be able to drive more than 5 mph. DEF problem". I spent $70,000 on this vehicle used with 50K miles on it. Recall from 2024, this is unacceptable. Now another recall for steering. The steering column disengagement. I am afraid to drive it. The dealer keeps telling me no fix yet. FORD has no email to complain. I am not sure what can be done. This is my first FORD, never again.

NHTSA ID

11716649

Incident

Oct 30, 2025

Bosch high pressure fuel pump failure at 76K miles. Resulted in being stranded out of state. Dealer could not repair the fuel pump after having the vehicle for over 1 month. Dealer stated fuel pump under warranty. Dealer claimed contaminated fuel was the cause but could not prove it. Warranty denied.

NHTSA ID

11715244

Incident

Jul 16, 2024

The contact owns a 2020 Ford F-250. The contact received notification of NHTSA Campaign Number: 24V957000 (FUEL SYSTEM, DIESEL); however, the part to do the recall repair was unavailable. The local dealer was contacted, and it was confirmed that the part was not yet available. 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 stated that while driving, there was a ticking sound coming from the engine compartment. The cause of the failure was not yet determined. The failure mileage was 76,000.

NHTSA ID

11709331

Incident

Nov 1, 2025

Mileage

76,000 mi

The contact owns a 2020 Ford F-250. The contact received notifications of NHTSA Campaign Numbers: 24V957000 (Fuel System, Diesel), 25V626000 (Steering), and 25V686000 (Back Over Prevention); however, parts to do the recall repairs were 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 stated that the vehicle had experienced PCM failure. The vehicle was not repaired. The failure mileage was unknown.

NHTSA ID

11708820

Incident

Sep 10, 2025

The contact owns a 2020 Ford F-250 SD. The contact stated while driving at an undisclosed speed, the accelerator pedal was depressed, however, the vehicle failed to accelerate as intended. The vehicle lost motive power and the engine seized. The contact stated that the vehicle failed to restart, and a Police Officer assisted the contact in moving the vehicle to the shoulder of the road. The contact stated that the failure occurred while driving on a busy highway, which could have caused someone to be seriously injured. The contact stated that the incident was significantly scary, and the Police Officer arrived after 21 minutes. The contact stated that there were no warning lights illuminated prior to the failure. The contact stated that the check engine warning light illuminated after the failure occurred. The vehicle was towed to the dealer, where it was diagnosed that the fuel pump had failed, causing metal intrusion in the entire fuel system. The contact was informed that the fuel system needed to be replaced. The contact had received a recall notification of NHTSA Campaign Number: 24V957000 (Fuel system, Diesel), which the contact related to the failure; however the recall remedy parts were not available. The contact stated that the dealer had charged a fee for the repair even though the VIN was included in the recall. The vehicle was being repaired. The manufacturer was made aware of the failure, and a case was filed. The failure mileage was approximately 120,000.

NHTSA ID

11707750

Incident

Nov 22, 2025

Mileage

120,000 mi

The contact owns a 2020 Ford F-250. The contact stated that while driving 75 MPH, the vehicle made an abnormal knocking sound, and there was excessive smoke coming from the exhaust pipes, before the vehicle shut off. 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 an independent mechanic, where the entire fuel system was replaced due to metal shavings contamination from the high-pressure fuel pump(HPFP). The vehicle was repaired at the owner’s expense. The contact later received notification of NHTSA Campaign Number: 24V957000 (Fuel System, Diesel), which the contact related to the failure. The manufacturer was contacted for reimbursement; however, the manufacturer informed the contact that reimbursement could only be provided once the recall remedy was available. The contact stated that the manufacturer had exceeded a reasonable amount of time for the recall repair. The failure mileage was approximately 45,000.

NHTSA ID

11706463

Incident

Dec 3, 2025

Mileage

45,000 mi

The contact owns a 2020 Ford F-250. 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 soon after starting the vehicle, the vehicle shut off without warning. The contact made several attempts to restart the vehicle, but the vehicle failed to start. Due to the failure, the vehicle was towed to the dealer where a diagnostic test was performed. The diagnostic test determined that the high-pressure fuel pump had failed and destroyed the entire fuel system. In addition, the contact received notification of NHTSA Campaign Number: 25V686000 (Back Over Prevention); however, the part for the recall repair was unavailable. The manufacturer was notified of the failure and informed the contact that the vehicle was no longer covered under warranty. The contact inquired about the recalls on the vehicle but the manufacturer offered no assistance. The contact stated that the manufacturer had exceeded a reasonable amount of time for the recall repair. The vehicle was not repaired. The failure mileage was approximately 144,000.

NHTSA ID

11703198

Incident

Oct 8, 2025

Mileage

144,000 mi

The contact owns a 2020 Ford F-250 SD. The contact received notifications of NHTSA Campaign Numbers: 24V957000 (Fuel System, Diesel) and 25V626000 (Steering); however, the parts to do the recall repairs were not yet available. The local dealer was contacted. The contact stated that the manufacturer had exceeded a reasonable amount of time for the recall repairs. The manufacturer was made aware of the issue. The contact had not experienced a failure.

NHTSA ID

11701438

Incident

Nov 25, 2025

I am filing a complaint regarding a safety defect on my 2020 Ford F-250 (VIN: [XXX] ), which is included in NHTSA Recall 24V-957 (Ford Recall 24S78). I received Ford’s recall notice prior to the failure of the high-pressure fuel pump. When I contacted Ford at that time, I was informed that the recall remedy was not yet available. In March 2025, the high-pressure fuel pump failed suddenly while I was transporting livestock in a towed trailer with my three children in the truck. The vehicle experienced an abrupt loss of power in traffic and became unable to move. We had to remain stopped until a tow truck arrived, creating a significant safety hazard for my family and other drivers. The Ford dealer documented the failure as “high pressure pump froze up and cracked high pressure pump,” which caused metal contamination throughout the fuel system and required complete replacement of the pump, injectors, rails, lines, and a fuel tank flush. The total repair cost was $16,574.44, which I paid out of pocket. Ford has stated they cannot process reimbursement until the recall remedy becomes available, despite federal regulations allowing reimbursement for repairs completed after notification of a safety defect. I am requesting NHTSA’s assistance in ensuring Ford complies with the recall reimbursement requirements and continues to monitor this defect due to the sudden and dangerous nature of these failures. Thank you for your attention. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ID

11700558

Incident

Mar 7, 2025

The contact owns a 2020 Ford F-250. The contact received notifications of NHTSA Campaign Numbers: 24V957000 (Fuel System, Diesel) and 25V626000 (Steering); however, the parts to do the recall repairs were unavailable. The contact stated that the manufacturer had exceeded a reasonable amount of time for the recall repairs. While the contact’s husband was driving approximately 45-50MPH, the vehicle suddenly lost motive power and power steering functionality. The driver coasted to the side of the road, and the vehicle became inoperable. The vehicle was towed to the dealer, who determined that the high-pressure fuel pump (CP4 pump) had failed and there were metal fragments inside the fuel line. The CP4 pump was replaced. The dealer confirmed that the recall repairs were not completed. The manufacturer was made aware of the failure. The failure mileage was approximately 97,000.

NHTSA ID

11699233

Incident

Jul 13, 2025

Mileage

97,000 mi

We have had this truck a total of two months. The dealer told us that there were not recalls on it, come to find out there are two. The recalled part froze up and shattered that shot metal shavings all through the fuel system. This caused the truck to lose all power and shut down on a busy road which could have led to a major accident had it not been after rush hour. After towing the truck to a repair shop, we found out about the recalls. Come to find out, the warranty company nor Ford will pay to fix the vehicle due to nothing available. How are we the consumer liable for this when it is under recall and Ford has been working on a fix for a year? We have been told a fix would be around $10,000.

NHTSA ID

11696207

Incident

Oct 21, 2025

On October 3, 2025 our 2020 Ford F250 King Ranch 6.7 diesel broke down with no start and check engine light. We contacted Ford. We towed the vehicle, at our expense to the dealership we purchased it from approximately one year ago on October 6, 2025. I contacted Ford on October 3, 2025 and received a claim number. On October 7, 2025 the Ford dealership contacted us to inform us the high pressure fuel pump catastrophically failed. It cracked the pump housing. It is a 12,000.00 repair. It is a safety recall. The pickup on has approximately 56,000 miles. The 5 year power train warranty ended September 15, 2025. I have contacted Ford twice sense January 0f 2025 to see if there was a resolution to this recall and they stated there is no fix as of this time. The dealership and I have contacted Ford Customer Service several times. I have left several messages for the representative handling our case and was promised call backs but never did. On October 10, 2025 there was a new case generated due to the lack of communication. Both the dealership and I were promised a call back and we did not receive one. We use this pickup for work and we are losing income. I asked for a loaner and I was told that was not possible. I pulled a Carfax on this pickup and found that possibility this vehicle was bought back twice. When we purchased it, the service record give to us did not show that information. We would like for the repairs to be completed in a timely manner. The dealership stated on October 8, 2025 that the entire fuel system would need to be replaced and could have it completed in three business days. I am not feeling comfortable knowing the pickup has been bought back from Ford two other times and not informing us. Also I am worried it may have caused engine damage.

NHTSA ID

11692966

Incident

Oct 3, 2025

The contact owns a 2020 Ford F-250. The contact had received notifications of NHTSA Campaign Numbers: 24V957000(Fuel System, Diesel) and 25V626000(Steering); however, the parts to do the recall repairs were not yet available. The contact had contacted an unknown local dealer several times and had been advised that the recall parts were not yet available. The contact stated that the manufacturer had exceeded a reasonable amount of time for the recall repairs. The manufacturer was not contacted. The contact had not experienced a failure.

NHTSA ID

11692421

Incident

Dec 20, 2022

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 is: 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.

NHTSA ID

11688169

Incident

Aug 7, 2025