2015 Ford F-350 Sd Engine Problems

2015 Ford F350 6.7 liter Diesel Turbocharger with only 58,000 miles malfunctioned while accelerating on to freeway without any prior warning indicators or symptoms. Immediately engine acceleration was reduced drastically causing freeway cars to nearly rear end my vehicle and other cars swerving to avoid accident. A message showed up simultaneously while reduced acceleration occured on vehicle’s dash display indicating something to the effect “Reducing Acceleration” and a yellow check engine icon lit up on dash display. I limped the vehicle to the side of Freeway and shut engine off. Upon restarting engine discovered engine and turbo operated properly and was able to drive vehicle to a non-Ford Service Center to be repaired. The Technician could not find anything wrong with the operation of the engine-turbocharger and cleared the trouble code. Drove vehical for approximately 500 miles and the same reduced acceleration problem re-occurred while accelerating on to freeway. Pulled vehicle over to safe area, shut engine off, re-started engine, engine and turbocharger operated properly, drove home and then to Ford Dealership (check engine icon still lit). Discovered vehicle can not be smog tested with this intermittent problem due to check engine icon. My safety, my passengers safety, and others safety while driving on the freeway were put at high risk. The reduced acceleration problem does reoccur. Ford diagnosed the vehicle problem to be a bad turbo with an estimate of $5,100 dollars for removal and replace with new Ford Turbocharger which only has a two year warranty. The repair work is currently in process. I consider this turbocharger to be pre-mature failure and a safety risk! This turbocharger intermittent failure in my opinion should be a mandatory recall and paid 100% by Ford.

NHTSA ID

11676208

Incident

Jul 9, 2025

The contact owns a 2015 Ford F-350. The contact stated that upon inspecting the oil level, the dipstick had fractured in half. In addition, the contact stated that the dipstick was rusted. The vehicle was not repaired. The local dealer was not contacted. The manufacturer was notified of the failure and referred the contact to the NHTSA Hotline for assistance. The approximate failure mileage was 93,000.

NHTSA ID

11647012

Incident

Feb 25, 2025

Mileage

93,000 mi

The contact owns a 2015 Ford F-350. The contact stated that while driving 55 MPH, the vehicle drove over a bump in the roadway and started losing motive power. There was no warning light illuminated. Despite the failure, the contact was able to drive at a reduced speed back to the residence. Upon inspection, the contact discovered that the intercooler hose had cracked, causing the vehicle to lose motive power. The contact replaced the intercooler hoses and the MAP sensor. Upon investigation, the contact stated that the failure was a known issue. Neither the dealer nor the manufacturer was notified of the failure. The vehicle was repaired however, the contact stated that the turbocharger failed to operate as needed. The failure mileage was approximately 120,000.

NHTSA ID

11639640

Incident

Jan 16, 2025

Mileage

120,000 mi

The contact owns a 2015 Ford F-350. The contact stated after a visual inspection of the engine compartment, he observed that the engine block heater core wire assembly was melted. No warning lights were illuminated. The vehicle was not taken to the dealer or an independent mechanic. The vehicle was not repaired. After investigating the failure, the contact related the failure to Safety Recall 18S45. The manufacturer was notified of the failure and referred the contact to the NHTSA Hotline for assistance. The failure mileage was 120,000.

NHTSA ID

11635105

Incident

Jan 9, 2025

Mileage

120,000 mi

While driving truck caught fire left side of engine and in a few hundred yards of getting stopped burning fuel was pouring from left side in the area of secondary fuel filter.

NHTSA ID

11628700

Incident

Nov 30, 2024

Had engine light on In 2019 .Nox sensor replaced under my 4year extended warranty. Truck had 103,000 miles 2021 had engine light on, Nox sensor fault, Calibration of Nox sensor preformed. Truck mileage 110,000 2024 engine light on. Nox sensor fault, Nox sensor replaced, My cost $1058.64 Truck mileage 113,945 So in four years and only 10,000 miles , I have had to install two of the same location , Nox sensors and one calibration. So in my vue, ford has an issue , with these parts and warranty. I would appreciate , if you would get back to me on the issue Sunrise Ford of north Hollywood seems to be on my side Technically the part in question has an issue,as do many other truck owners with same part.

NHTSA ID

11604359

Incident

Jul 15, 2024

The contact owns a 2015 Ford F-350. The contact stated that while driving at an undisclosed speed, the check engine warning light illuminated on the instrument panel. The vehicle was taken to an independent mechanic, who determined that the diesel particulate filter was cracked and required a replacement. The vehicle was not repaired. After investigating the failure, the contact related the failure to Customer Satisfaction Program: 20M06, but the VIN was not included. The manufacturer was notified of the failure but referred the contact to the NHTSA Hotline for assistance. The failure mileage was 49,000.

NHTSA ID

11568113

Incident

Jun 15, 2023

Mileage

49,000 mi

We purchased the vehicle brand new (33 miles). At 65,142 miles (07/09/18) the engine quit running and we pulled to the side of Interstate 15 barely off the freeway. It had to be towed to the dealership. At 69,345 miles (12/26/18) the engine blew up while we were traveling at 65 MPH on Interstate 10 towing a 5th wheel trailer. Just made it to the beginning of the off ramp in Indio. Towed to the dealership where a short block engine was put in under warranty. At 80,029 miles (08/14/19) the engine locked up, would not turn over. Dealership put in a long block engine also still under warranty. At 115,000 miles (09/06/23) the engine quit running and we had it towed to the dealership where they stated we needed a new engine (#4). Unfortunately, the engine is not available and is no longer under warranty. It has scared us each time there is an engine failure and do not trust the vehicle to keep us out of harms way. I have all of the service order receipts. Thank you for your time.

NHTSA ID

11550904

Incident

Jul 9, 2018

The contact owns a 2015 Ford F-350. The contact stated that while driving at 55 MPH, the vehicle message of “50 Miles until Derate Speed Limitation” was displayed. The check engine warning light was illuminated. The vehicle was diagnosed by a dealer as a failure with the DEF system and a failed NOX module. The manufacturer was made aware of the failure and confirmed that the vehicle was not under warranty. The failure mileage was approximately 29,593.

NHTSA ID

11542131

Incident

Jan 1, 2020

Mileage

29,593 mi

The contact a owns a 2015 Ford F-350. The contact stated there was oil on the floor underneath the vehicle. The vehicle was taken to the dealer and the dealer stated that the oil pan needed to be replaced and resealed. The vehicle was repaired. The manufacturer was contacted, and a case was filed. The manufacturer referred the contact to the NHTSA Hotline to file a complaint. The failure mileage was 96,956.

NHTSA ID

11514783

Incident

Sep 21, 2021

Mileage

96,956 mi

This vehicle developed a fuel leak in the area of the top of the engine which resulted in a fire that destroyed the vehicle. I spoke to the Ford Motor Company and they said that there are no recalls or Technical Service Bulletins regarding this. I just wanted to make you aware of my experience so if anyone else experienced this it may show a pattern. Thank You

NHTSA ID

11483655

Incident

Aug 29, 2022

The contact owns a 2015 Ford F-250. The contact stated while driving approximately 72 MPH going downhill, the instrument panel was failing where it would illuminate and unilluminated. There were fireballs being exhausted from the pipe. The fireballs caused a fire in the desert. The contact then lost power steering and the engine shut down, but the contact was able to pull over safely. The fire department and highway patrol arrived on the scene. The fire department extinguished the fire. The contact was unaware of any report being filed. There were no injuries or medical treatment needed. The vehicle was towed to the local mechanic who diagnosed a catalytic converter or blockage in the turbo. The vehicle was repaired. The manufacturer was not notified of the failure. The approximate failure mileage was 135,000.

NHTSA ID

11482580

Incident

Jul 28, 2021

Mileage

135,000 mi

1/4/2022 – TRAVELING TO SOUTHERN OHIO IN F-350. Engine light came on. Truck info screen showed Exhaust Fluid System Fault – indicating truck would lock to 50 mph within a certain number of miles, then possibly shut down. Finally got in touch with Ford dealership in Chillicothe and took truck there. They determined it was a DEF heater and pump causing the issue, and that it would be covered by Ford as an extended warranty issue. Ford decided our truck was not covered. On 1/11, Ford added a new campaign – 21M01, Reductant Heater and Sender Assembly, covering the cost of replacement of these items. We were told we needed to pay the repair and Ford would reimburse. To this date, we have not been reimbursed - in fact have pretty much been ignored. The sensor recalibration they did caused the particulate filter to fail. Ford has said they won't replace, even though service manager has said the filter failed because Ford had them recalibrate the sensor. We could have been stranded 140 miles from home because of this design fault that Ford knows about - but is not being forced to take care of. Our truck has less than 64000 miles on it and was purchased new by me in April 2014. Will you please strongly encourage Ford to stand by this defective equipment they have installed in their vehicles, as their 'customer satisfaction campaigns' do not adequately encourage them to fix these faulty issues. Volkswagen and Audi both stand by their defective equipment. Consumer wants assistance getting Ford to pay for repairs.

NHTSA ID

11457166

Incident

Jan 4, 2022

Cp4 fuel pump failure, upon failure repair was $9300.00, ford obviously knows of the problem as their is a kit that can be purchased for this catastrophic failure{fuel line replacement, fuel injection replacement, both fuel pump replacement , drop and flush fuel tank.}

NHTSA ID

11443761

Incident

Dec 30, 2020

P20BA - DEF Reductant Heater Code for a defective DEF reductant heater on a 2015 F-350 6.7L diesel with 57,500 miles NOT covered under dealer emissions warranty.

NHTSA ID

11441227

Incident

Nov 21, 2021

TURBOCHARGER INTERCOOLER HOSE BLEW OF WHILE DRIVING CAUSING A LOUD EXPLOSIVE NOISE AND LOST OF COMPRESSION ALMOST CAUSING A CRASH. I WAS ON A MULTI-LANE HIGHWAY AND IT CREATED A SAFETY HAZARD

NHTSA ID

11415952

Incident

Apr 5, 2021

Mileage

128,000 mi

VEHICLE WAS ATTEMPTING TO CLEAN THE EXHAUST FILTER WITH THE DEF SYSTEM. CHECK ENGINE LIGHT CAME ON. VEHICLE BEGAN SLOWING DOWN. SCANNER REVEALED CODE P20BA-00, REDUCTANT HEATER "A" CONTROL CIRCUIT PERFORMANCE, AND P0884 TCM POWER SIGNAL INTERMITTENT. VEHICLE WAS BEING DRIVEN AT HIGHWAY SPEED. FORD DEALER CONTACTED REGARDING REPAIRS. ADVISED WAS NOT UNDER WARRANTY FOR EMISSIONS CONTROL. COST PROHIBITIVE TO REPAIR.

NHTSA ID

11366998

Incident

Oct 26, 2020

Mileage

51,408 mi

DEF HEATER FAILED. FORD HAS A CUSTOMER SATISFACTION CAMPAIGN, BUT MY VEHICLE IS NOT INCLUDED.

NHTSA ID

11348416

Incident

Jul 21, 2020

Mileage

70,000 mi

TRUCK STARTED MISSING AND BACKFIRING WHEN ACCELERATING FROM A STOP, LOST POWER ASSIST TO BRAKES, LIMPED 1/2 MILE TO MY HOUSE . ENGINE WAS CLATTERING , MISSING, STALLING AND BACKFIRING. CHECK ENGINE LIGHT ON CODE P0307. BROKE #7 VALVE SPRING(INTAKE) , LOST KEEPERS, DROPPED VALVE , WHICH PISTON HIT, FORD DEALER SAY IT NEEDS AN ENGINE FOR $10,300.00 AND NO COVERAGE AT 69,000. BROKEN VALVE SPRINGS ARE A KNOWN PROBLEM . DANGEROUS WHEN YOU LOSE POWER ASSIST TO BRAKE PEDAL BECAUSE OF NO VACUUM. REQUEST FORD SERVICE TO ASSIST BECAUSE SPRINGS ARE DEFECTIVE

NHTSA ID

11267686

Incident

Sep 25, 2019

Mileage

69,000 mi

ON MY 2115 FORD F 350 POWERSTROKE DIESEL THE CHECK ENGINE LIGHT CAME ON AND IT DE RATED THE POWER. I READ THE CEL CODE AND ITS PB20A WHICH IS A REDACTANT HEATER PERFORMANCE FAILURE. THIS PROBLEM IS COVERED UNDER WARRANTY FOR ALL MODELS 2011-14, F250-F 550 AND 2015 F450, F550 ONLY. FORD ISN'T COVERING THE F250 OF F350 IN THE 2015 YEARS. MY TRUCK MEETS THE DATE AND MANUFACTURING PLANT CRITERIA AND IT IS NO DRIVABLE BECAUSE OF THIS EMISSIONS CONTROL PART FAILURE. THE REDACDANT HEATER KEEPS THE DIESEL EXHAUST FLUID FROM FREEZING AND RENDERS THE VEHICLE UN DRIVABLE WHEN IT FALIS.

NHTSA ID

11265376

Incident

Sep 28, 2019

Mileage

97,000 mi

I WAS DRIVING OUT OF STATE (NY) WHEN AN ALERT STATED "LOW FUEL PRESSURE) AND THE VEHICLE SLOWED TO 5-10 MPH WHILE TRAVELING ON THE INTERSTATE. UPON EXITING, THE VEHICLE STOPPED RUNNING LEAVING ME AND MY FAMILY STRANDED. I HAD IT TOWED TO A LOCAL SHOP WHICH INFORMED ME THE BOSCH HIGH PRESSURE FUEL PUMP WAS NOT DELIVERING THE REQUIRED PRESSURE (/,000 PSI). UPON CONTACTING THE FORD DEALERSHIP WHERE THE VEHICLE WAS PURCHASED, I WAS INFORMED THE VEHICLE EXCEEDED WARRANTY MILES (100,000/129,239) AND THE COST OF THE PUMP WAS $1,245 WITH EXCHANGE PRIOR TO LABOR CHARGES. IN ALL, FORD DEALER WANTS NEARLY $5,000 TO REPAIR THE PUMP WHICH WAS POORLY DESIGNED.

NHTSA ID

11254280

Incident

Aug 17, 2019

Mileage

129,239 mi

HAD VEHICLE 8 MONTHS. DRIVING ON INTERSTATE 95 PULLING MY CAMPER, "LOW FUEL PRESSURE" LIGHT CAME ON, PULLED OVER IMMEDIATELY. SAW SMOKE, THEN FIRE. GOT OUT OF TRUCK WITH MY DOG AND CALLED 911. REPORT ATTACHED.

NHTSA ID

11220464

Incident

Apr 9, 2019

Mileage

90,000 mi

TL* THE CONTACT STATED THAT THERE WAS A HOLE IN THE ENGINE ASSEMBLY. THERE WERE NO WARNING INDICATORS ILLUMINATED. BROADWAY FORD (1010 S MILITARY AVE, GREEN BAY, WI 54304, (920) 499-3131) WAS NOTIFIED AND STATED THAT THE VEHICLE WAS EXCLUDED FROM A WARRANTY TO PROVIDE A REMEDY. THE VEHICLE WAS TOWED TO AN INDEPENDENT REPAIR FACILITY FOR FURTHER DIAGNOSTIC TESTING. THE MANUFACTURER HAD NOT ISSUED ANY RECALL CAMPAIGNS FOR THE ENGINE AND ENGINE COOLING. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 60628. *BF $9349.20 IN REPAIRS. CONSUMER STATED THE FIRST ENGINE BLEW A HOLE ON THE SIDE AT 60,628 MILES. IT WAS NO LONGER UNDER WARRANTY. ENGINE WAS REPLACED AS WELL AS CONVERTER ASSEMBLY, DUE TO THE ENGINE OIL GETTING INTO THE CONVERTERS AT 61629 THE ENGINE WENT BAD DUE TO THE INTAKE MANIFOLD BEING REPLACED.*JB

NHTSA ID

11196412

Incident

Jan 1, 2019

Mileage

61,000 mi

DIESEL EXHAUST FLUID REDUCTANT HEATER FAULT, CHECK ENGINE LIGHT HAS ILLUMINATED AND IS NOT COVERED UNDER PREVIOUS RECALLS. RECURRING PROBLEM FOR FORD SUPER DUTY THAT NEEDS TO BE EXTENDED FOR THIS MODEL AS IT IS THE SAME PROBLEM THAT PREVIOUS ATTENTION WAS GIVEN TO. IT IS A EMISSIONS PROBLEM THAT FAILS ON THESE TRUCKS.

NHTSA ID

11187014

Incident

Mar 7, 2019

Mileage

55,250 mi

THIS VEHICLE HAS 42,188 MILES TO DATE, AND HAS BEEN DOWN FOR OVER 8 WEEKS DUE TO SENSOR PROBLEMS INVOLVING THE EGR AND DEF SYSTEM. 4 TEMPERATURE SENSORS WERE INITIALLY REPLACED, AND THEN THE PARTICULATE SENSOR SHOWED A FAULT. THAT SENSOR WAS $146.55! AS OF TODAY, THAT SENSOR IS BAD AGAIN AND FORD STATES THERE IS A UPDATED ONE FOR $200.99! THE EMISSIONS WARRANTY RUNS OUT AS SOON AS YOU DRIVE IT OFF THE LOT! I HAVE SPENT NEARLY $800.00, AND THIS VEHICLE SITS, AS THE CHECK ENGINE LIGHT KEEPS IT IN LIMP MODE. THIS VEHICLE IS MAINTAINED IN PERFECT CONDITION. IF THE EPA IS GOING TO REQUIRE THESE EMISSION STANDARDS, THEN VEHICLE MANUFACTURES SHOULD BE LIABLE FOR THESE COSTLY REPAIRS! I RECENTLY FOUND OUT THAT THERE ARE DELETE KITS TO ELIMINATE THIS ISSUE. HOWEVER THEY VOID THE WARRANTY AND IT IS UNLAWFUL TO DO SO. I CAN SEE WHY THEY ARE DOING THIS. FRANKLY, I DONT SEE THE POINT IN A "HANDFUL" OF US TRYING TO KEEP OURS RUNNING TO CODE, WHILE OTHERS ARE RIPPING THIS POLLUTION STUFF OFF. I DON;T SEE THE POINT. HOWEVER I AM TOTALLYL FRUSTRATED AT A $70,000.00 PICKUP THAT REMAINS BROKE DOWN. YOU CAN'T EVEN TRADE THEM OFF IF THEY ARE HAVING DEF ISSUES. I READ QUITE OFTEN ABOUT STATE, COUNTY AND CITY VEHICLES THAT ARE HAVING THE SAME ISSUES, AND THAT KEEPS THEM OFF THE ROAD FOR SNOW PLOWING AND A HOST OF OTHER DUTIES. THIS ISSUE NEEDS ADDRESSED AND RESOLVED. TALK ABOUT A SAFETY ISSUE: DRIVING HOME IN THE DARK AND THIS THING DECIDES TO LIMP OFF THE ROAD. ALWAYS A WEEKEND OR AFTER HOURS. AND SERVICE SHOPS ARE SO FAR BEHIND IT TAKES WEEKS TO GET IN. THIS IS OUTLANDISH THAT THE US IS TRYING TO REDUCE EMISSIONS WHILE THE REST OF THE PLANET COULD CARE LESS. WHAT IS THE POINT? I AM A REASONABLE PERSON, BUT I DO NOT SEE THE POINT. CLUE ME IN PLEASE.

NHTSA ID

11173608

Incident

Dec 20, 2018

Mileage

40,000 mi