2016 Ford F-350 Sd Fuel system Problems

The CP4 is failing, this has been a know problem on these F- series trucks for sometime now. This needs to be remedied on these vehicles. This has been known for years.

NHTSA ID

11730672

Incident

Apr 10, 2026

The contact owns a 2016 Ford F-350. The contact stated while driving 60 MPH, there was an abnormal knocking sound coming from the engine compartment. The vehicle was taken to the local dealer where it was diagnosed and determined that the cylinder was not operating as needed, and there was engine damage. The vehicle was not repaired. The vehicle was previously taken to the local dealer, Summerville Ford (9700 Dorchester Rd, Summerville, SC 29485); where it was diagnosed and determined that there were metal shavings in the fuel system in the high-pressure fuel pump. The vehicle was repaired; however, the failure recurred. There was black smoke while driving and the check engine warning light was illuminated. The contact stated that the turbo charger, body mounts, and coolant pump were replaced; however, the failure persisted. The manufacturer was not yet contacted. The failure mileage was approximately 82,800.

NHTSA ID

11666336

Incident

Nov 1, 2024

Mileage

82,800 mi

P207F dtc Nox sensor issue

NHTSA ID

11663029

Incident

Apr 4, 2025

The contact owns a 2016 Ford F-350. The contact stated that the check engine warning light was illuminated. The contact stated that after adding diesel particulate filter fluid in the vehicle, the message that the vehicle was low on fluid was displayed, and the vehicle would unintendedly decelerate to under 50 MPH. The vehicle was taken to the dealer, who replaced the DPF pump and burner. Approximately 30,000 miles later, the failure recurred, and the vehicle was returned to the dealer. The dealer replaced the DPF pump and burner again. The manufacturer was informed of the failure and opened a case. The manufacturer transferred the contact to the NHTSA Hotline to report the failure. The failure mileage was 52,860.

NHTSA ID

11653421

Incident

Apr 8, 2022

Mileage

52,860 mi

The contact owns a 2016 Ford F-350. The contact stated that while driving at 55 MPH, the vehicle inadvertently lost motive power. The contact was able to pull to the shoulder of the roadway, where the vehicle failed to restart. The oil and check engine warning lights were illuminated. The vehicle was towed to the dealer who diagnosed a failure with the fuel pump. The contact was informed that the entire fuel system needed to be replaced. The vehicle was repaired. The manufacturer was notified of the failure but did not assist. The failure mileage was 88,000.

NHTSA ID

11632162

Incident

Dec 11, 2024

Mileage

88,000 mi

I keep on hand a set of fuel filters and other filters for my personal vehicle. The set I just installed (fuel filters), the upper one, made of plastic, exploded while purging the air out of the diesel system. Diesel went all over the motor, the exhaust, the turbo, and all over my garage. While looking into this more, I found more people in the listings showing the same thing to happen to them. I had to go out and spend another $103 to fix this problem, so I could get my vehicle up and running again. Now, imagine if this engine was hot, the exhaust hot, the turbo hot. This would have ignited the fuel and possibly caused a wreck and or loss of life. I use my vehicle to tow a 5.5 ton trailer, so the motor can run warm some days. This could have been extremely dangerous to myself and others around me. I have contacted Amazon about this seller, but when Amazon allows anyone to sell anything on there, there is opportunity for people to sell fake garbage. I have kept the filter that exploded, along with the packaging. Comparing the old with the one that exploded, I can now tell the fakes from the originals. [XXX] # In the uploads, the white writing on the canister is the fake one. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ID

11623307

Incident

Nov 2, 2024

The contact owns a 2016 Ford F-350. The contact stated that while driving at an undisclosed speed, the engine seized. The check engine warning light illuminated. The contact stated that the vehicle failed to restart. The vehicle was towed to an independent mechanic where it was diagnosed with a failed fuel pump and metal shavings inside the fuel system. The contact was informed that the fuel system and injectors needed to be replaced. The vehicle was not repaired. The manufacturer was made aware of the failure and a case was filed. The failure mileage was approximately 150,000.

NHTSA ID

11592147

Incident

Nov 3, 2022

Mileage

150,000 mi

THERE ARE TWO INCIDENTS ONE FORD DIESEL HIGH PRESSURE FUEL PUMP DISINTERGRATES WHILE DRIVING VEHICLE AND THE INTERCOOLER HOSE WHICH IS PLASTIC BLOWS UP WHICH IN BOTH CASES CAUSES THE VEHICLE TO LOSE POWER AND STOP RUNNING. THIS OCCURED TO ME WHILE PULLING RV ON INTERSTATE .

NHTSA ID

11583137

Incident

Apr 6, 2024

The contact owns a 2016 Ford F-350. The contact stated while driving approximately 70 MPH, the "Engine Power Reduced" message was displayed and the vehicle downshifted while running very rough before the vehicle stalled. The contact coasted to the side of the road and had the vehicle towed to the dealer. The dealer diagnosed the vehicle and determined that the high-pressure fuel pump had failed and caused metal fragments to enter the fuel system. The contact was informed that the high-pressure fuel system needed to be replaced. The vehicle had not been repaired. The manufacturer was made aware of the failure and referred the contact to the NHTSA Hotline for assistance. The approximate failure mileage was 112,000.

NHTSA ID

11558911

Incident

Nov 30, 2023

Mileage

112,000 mi

The contact owns a 2016 Ford F-350. The contact stated that while driving at an undisclosed speed, the vehicle inadvertently lost motive power. The contact was able to reach her destination but had to periodically start the vehicle and let it run to ensure that the vehicle would remain operable. No warning lights were illuminated. The vehicle was taken to the dealer, who determined that the diesel exhaust fluid tank had frozen and needed to be replaced. The vehicle was repaired. The manufacturer was not notified of the failure. The failure mileage was 100,000.

NHTSA ID

11534446

Incident

Dec 22, 2022

Mileage

100,000 mi

The contact owns a 2016 Ford F-350. The contact stated that while driving at an undisclosed speed, the check engine warning light illuminated. The vehicle was taken to the dealer where it was diagnosed that the diesel particulate filter needed to be replaced. The vehicle was not repaired. The manufacturer was notified of the failure and the contact was advised to call the NHTSA Hotline. The failure mileage was approximately 44,000.

NHTSA ID

11484822

Incident

Aug 16, 2022

Mileage

44,000 mi

The contact owns a 2016 Ford F-350. The contact stated that while driving at an undisclosed speed, the check engine warning light illuminated. The vehicle was taken to the dealer where it was diagnosed that the diesel particulate filter needed to be replaced. The vehicle was not repaired. The manufacturer was made aware of the failure and informed the contact that there was no recall associated with the VIN. The contact related the failure to Customer Satisfaction Program: 20M06 (Diesel Particulate Filter Warranty Extension) however, the VIN was not included. The failure mileage was approximately 36,000.

NHTSA ID

11481042

Incident

Aug 24, 2022

Mileage

36,000 mi

The diesel exhaust fluid system, reductant heater and sender assembly. The truck went into a -idell reduced power mode ( 5 miles an hour) 25 miles from service at 2:00 AM 300 miles from home. The dealer has the truck. They towed it in September, 2021. they have had it for seven months. I need a TRUCK !!!!!!!! What is going on, this is unacceptable.I have been renting a car since Oct, 2021. Ford didn't offer me anything. The truck has 21,000 miles on it. Sell it and get me a new truck, I need a TRUCK.

NHTSA ID

11465712

Incident

Sep 18, 2021

The cp4 injection pump destructed and took out the whole fuel system with it. Cause upwards of $12,000 in repairs this is a issue ford needs to address and get took care and take some responsibility on there own

NHTSA ID

11443813

Incident

Dec 12, 2021

A main computer communication cable failed (rubbed through) due to rubbing due from the use of the parking brake. I noticed all my gauges were not working. I happened to be very close to the Ford dealer, so I pulled in the lot and turned the truck off to see if the issue would reset. Upon trying to start the truck, everything was dead. I got the service manager and left the truck. When he called me to tell me what he found, I immediately recall reading about this same issue several times on the Ford Truck Enthusiast web site, and the fix was simply moving the communication cable so it doesn’t rub.

NHTSA ID

11443546

Incident

Dec 12, 2021

The Diesel Exhaust Fluid system is faulty. I have been informed that GMC and Chevy have recalled the system but Ford has not. I have complained to Ford with no response. My neighbor has 4 work trucks that have all needed replacing (so has mine). I have 2 friends who also have Fords, one was covered under the factory warranty and the other was not. My mechanic states it is a known issue.

NHTSA ID

11422999

Incident

Jun 30, 2021

TL* THE CONTACT OWNS A 2016 FORD F-350. THE CONTACT STATED THAT WHILE DRIVING 70 MPH, THE FUEL MODE WARNING LIGHT ILLUMINATED, WHICH CAUSED THE VEHICLE TO STALL FOR APPROXIMATELY ONE MINUTE BEFORE RESUMING NORMAL OPERATION. THE FAILURE RECURRED INTERMITTENTLY. THE VEHICLE WAS TAKEN TO TINDOL FORD (1901 E. FRANKLIN BLVD, GASTONIA, NC 28054, (704) 867-8341) WHERE IT WAS DIAGNOSED AND IT WAS DETERMINED THAT THE FUEL RAIL SYSTEM FAILED AND NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE WAS APPROXIMATELY 209,700. THE VIN WAS NOT AVAILABLE.

NHTSA ID

11385306

Incident

Nov 25, 2020

Mileage

209,700 mi

ABOUT 2018 MY 2016 F350 DIESEL GAS MILEAGE WAS GOOD AROUND 16 MPG CITY AND 19MPG HWY I TOOK MY TRUCK TO FORD FOR SERVICE BECAUSE THE REGENERATION WOULD KEEP COMING ON ALL THE TIME WELL THEY FINELY SAID IT WAS A SENSOR BUT DID NOTHING TO REPLACE ANYTHING BUT THEY TOLD ME FORD COMPANY TOLD THEM TO RE-FLASH MY COMPUTER IN MY TRUCK BECAUSE THEY HAD A UPDATE WELL MY GAS MILEAGE WENT DOWN TO 11 MPG CITY AND 9 MPG HWY AND I TRY TO TAKE IT BACK AND TELL ME IT IS NO LONGER UNDER WARRANTY.....SO THEY DID SOMETHING TO MY FUEL MILEAGE WHICH IS TOTALLY WRONG WHAT THEY DID TO ME BECAUSE WHEN I BOUGHT IT THE TRUCK THE FUEL MILEAGE WAS BETTER SO I AM LOOSING MONEY EVERY TIME I DRIVE IT BECAUSE WHAT THE DID BEHIND MY BACK OUR FIRST TRIP ABOUT OCT 2019 WE HAD POWER LOSS WHILE DRIVING AT AROUND 60 MPH WHERE NO MATTER HOW FAR I PUSH THE GAS PEDDLE TO THE FLOOR NOTHING HAPPEN OF FLAT LAND WHILE TOWING AND IN HEAVY TRAFFIC WHERE SPEED LIMIT WAS HIGHER THEN 60 MPH WHERE PEOPLE WERE RUSHING AROUND ME AND HONKING THERE HORNS AND WE COULD NOT PULL OVER WITH NO POWER TO GET OVER A CHECK ENGINE LIGHT ON WE HAVEN'T USED THIS TRUCK MUCH IF I DID WOULD HAVE MORE PROBLEMS SO I WILL NOT KNOW WHAT WILL HAPPEN THIS YEAR ON THE 2ND TRIP ALSO I HAVE CHECK ENGINE THAT COMES ON WITHOUT TOWING BUT GOES OUT AFTER AWHILE AND THE DEALER TOLD ME THEY CANT DO ANYTHING ..I DO HAVE A PICTURE OF THE CHECK ENGINE LIGHT ON AT 20,203 MILES AND NOW I ONLY HAVE 20,300 ON A 2016 F350 TRUCK RIGHT NOW AND IT IS MAY 22, 2020 THE CHECK ENGINE LIGHT WAS ON MORE THEN ONE TIME BUT THIS WAS THE FIRST TIME I TOOK A PICTURE. *TR

NHTSA ID

11325592

Incident

May 2, 2018

Mileage

18,000 mi

TRUCK WAS TAKEN TO GREEN FORD PEORIA IL. FOR RECALL ON THE CRANKCASE VENTILATION RECALL. AFTER RECEIVING MY TRUCK BACK THE NEXT DAY TRUCK THREW ANOTHER ENGINE LIGHT ON AND TRUCK WAS RETURNED THAT DAY TO FIND REDUCTANT HEATER CODE WAS SHOWING. MY TRUCK OF COURSE IS A 2016 F350 WITH THE 6.7 FOUND RECALLS FOR PREVIOUS YEARS BUT NOT THIS TRUCK YEAR, SAME EXACT ISSUE. I LEFT THE DEALERSHIP PREPARING TO ENTER THE HIGHWAY, TRUCK WAS STILL UNDER FULL POWER AS I MERGED INTO HEAVY TRAFFIC SPEEDING UP TO MERGE THE TRUCK LOST POWER. I NEARLY WAS REAR-ENDED AS THE TRAFFIC WAS MOVING AT 70 MPH. I WAS ABLE TO THROW MY FLASHERS ON AND GET TO THE SIDE OF THE ROAD. AFTER SPEAKING WITH THE ADVISOR AT GREEN FORD I WAS TOLD MY TRUCK WENT INTO LIMP MODE. I PURCHASED THE TRUCK USED WITH 92K MILES AND HAVE ONLY PUT 3K ON IT SINCE. I'M VERY DISSAPOINTED IN THIS ISSUE AS I'VE SEEN IT'S A VERY COMMON THING TO HAPPEN. THE RECALL SHOULD BE EXTENDED TO THE 2016 6.7 JUST AS THE PREVIOUS YEARS

NHTSA ID

11299472

Incident

Dec 30, 2019

Mileage

94,700 mi

THE REDUCTANT HEATER RECALL NEEDS TO EXTEND TO AT LEAST MY 2016 TRUCK. THEY HAVE HAD EXCESSIVE FAILURES. MY LAST TRUCK WAS INCLUDED IN THE RECALL (WARRANTY EXTENSION-PROGRAM 18M01). THIS RECALL WAS GIVEN IN 2018 AND THEY SHOULD HAVE INCLUDED MORE THAN JUST 2012 TO 2015.

NHTSA ID

11278223

Incident

Oct 14, 2019

Mileage

54,000 mi

WHILE DRIVING ON I-75 IN THE PASSING LANE AT BETWEEN 70-75 MPH, APPROACHING MACON,GA. OUR VEHICLE SLOWED WAY DOWN. WE WERE ABLE TO MAKE IT TO EXIT 167 BEFORE VEHICLE QUIT RUNNING. VEHICLE QUIT ON THE EXIT RAMP, LESS THAN A MILE FROM WHERE IT 1ST BEGAN SLOWING DOWN. VEHICLE WAS TOWED TO RIVERSIDE FORD IN MACON. UPON EXAMINATION BY FORD MECHANIC, WHILE THERE WAS NO WATER IN THE FUEL, THERE WAS A SLIGHT AMOUNT OF RUST AROUND RIM AND METAL IN THE FUEL FILTER. WE HAD VEHICLE TOWED HOME. ON MONDAY WE HAD THE VEHICLE TOWED TO ROBBIE ROBERSON FORD IN WAYCROSS, GA. UPON EXAMINATION OF THE FUEL SYSTEM BY ONE OF THEIR MECHANICS THE SAME DETERMINATION WAS MADE., SLIGHT RUST AROUND RIM OF FUEL FILTER AND METAL IN THE FILTER. AT NO TIME DID THE WATER SENSOR LIGHT COME ON. THE FUEL PUMP HAD EXPLODED. FORD ASSUMED NO LIABILITY ALTHOUGH THE VEHICLE IS STILL UNDER WARRANTY. THE VEHICLE FUEL SYSTEM SHOULD NOT BE SO SENSITIVE THAT THE FUEL PUMP EXPLODES JUST BECAUSE OF A LITTLE RUST PROBABLY CAUSED BY CONDENSATION. HAD WE NOT BEEN ABLE TO EXIT I-75 AND THE VEHICLE QUIT IN TRAFFIC THIS COULD HAVE RESULTED IN A MAJOR ACCIDENT WITH MULTIPLE INJURIES/DEATHS. FORD IS AWARE THEY HAVE AN ISSUE BECAUSE THEY HAVE A KIT TO FIX IT BUT REFUSE TO ACKNOWLEDGE PROBLEM.

NHTSA ID

11141819

Incident

Oct 8, 2018

Mileage

38,600 mi

TL* THE CONTACT OWNS A 2016 FORD F-350 SD. THE CONTACT STATED THAT THE VEHICLE STALLED WITHOUT WARNING. THE VEHICLE WAS TOWED TO BASIL FORD (1540 WALDEN AVE, BUFFALO, NY 14225, (716) 893-1000) WHERE IT WAS DIAGNOSED THAT THE INCORRECT FUEL WAS PLACED IN THE VEHICLE. THE VEHICLE WAS THEN TOWED TO WASHINGTON FORD (507 WASHINGTON RD, WASHINGTON, PA 15301, (724) 223-5100) WHO SPECULATED THAT THERE WAS NO OCTANE IN THE FUEL OR THERE MAY HAVE BEEN WATER OR RUST IN THE FUEL SYSTEM. THE DEALER LATER STATED THAT, WITH FUEL SAMPLES, THEY FOUND METAL SHAVINGS IN THE FUEL SYSTEM AND THE HIGH PRESSURE FUEL PUMP MAY NEED TO BE REPLACED. THE VEHICLE WAS SERVICED BY THE SECOND DEALER, BUT THEY COULD NOT PROVIDE A PERMANENT REMEDY TO REPAIR THE VEHICLE. THE CONTACT WAS AWAITING A RESPONSE FROM THE MANUFACTURER TO DETERMINE IF THE PART WAS AVAILABLE TO PROVIDE TO THE DEALER TO REPAIR THE VEHICLE. THE APPROXIMATE FAILURE MILEAGE WAS 45,222. *TT *DT UPDATED 10/19/18*JB

NHTSA ID

11104178

Incident

May 25, 2018

Mileage

45,222 mi

TL* THE CONTACT OWNS A 2016 FORD F-350. WHILE DRIVING APPROXIMATELY 70 MPH, 'LOSING POWER' DISPLAYED AND THE VEHICLE STALLED. THE VEHICLE WAS NOT ABLE TO RESTART AND WAS TOWED TO CLASSIC FORD SMITHFIELD (1698 E BOOKER DAIRY RD, SMITHFIELD, NC 27577). THE DEALER DIAGNOSED THE VEHICLE, BUT COULD NOT LOCATE THE CAUSE OF THE FAILURE. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE AND INFORMED THE CONTACT THAT THE FAILURE WAS DUE TO CONTAMINATED FUEL. THE APPROXIMATE FAILURE MILEAGE WAS 35,000. THE VIN WAS NOT PROVIDED. *TT *DT UPDATED 10/19/18*JB

NHTSA ID

11088433

Incident

Oct 14, 2017

Mileage

35,000 mi

VEHICLE HAS 30K MILES ON IT. WAS DRIVING DOWN THE ROAD, VEHICLE SHUT UP, AND WOULD NOT START BACK UP. TOOK TO DEALER, STATED IT WAS A FUEL PUMP PROBLEM, THAT THE FUEL PUMP IN THE TRUCK BLEW UP AND SENT METAL SHREDS THROUGH THE FUEL RAIL SYSTEM AND INTO THE ENGINE. FORD DENIED THE WARRANTY STATING THE FUEL WAS CONTAMINATED WITH TO MUCH WATER. UPON HAVING MY FUEL TESTED, IT WAS DETERMINED IT WAS NOT CONTAMINATED AND THEY PAID 9000 OF REPAIR COST, AND I PAID 1000. I HAVE TWO VEHICLES (THE OTHER WHICH I WILL ALSO MAKE A COMPLAINT AS WELL) AND BOTH VEHICLES HAVE UNSAFETLY SHUT OFF AND LOST POWER. AFTER DOING RESEARCH, THE FUEL PUMP IN THE TRUCKS IN NOT RATED FOR THE LUBRICITY THE DIESEL FUEL IN AMERICA OFFERS. I HAVE SPOKEN TO SEVERAL MECHANICS WHO SAID THE PUMP WILL BLOW UP IF YOU DO NOT USE A FUEL ADDITIVE. FUEL SPECIFICALLY STATES TO USE UNITED STATES ULTRA LOW DIESEL FUEL IN THEIR SYSTEM, AND DOES NOT REQUIRE THEIR CONSUMERS TO USE FUEL ADDITIVES. THE PUMP IS NOT RATED, AND FORD IS PUTTING THESE PUMPS IN THEIR TRUCKS KNOWING THEIR NOT RATED FOR ULSD IN THE UNTIED STATED.

NHTSA ID

11015417

Incident

Jul 24, 2017

Mileage

30,000 mi

VEHICLE HAS 10K MILES ON IT. WAS DRIVING DOWN THE ROAD, VEHICLE SHUT UP, AND WOULD NOT START BACK UP. TOOK TO DEALER, STATED IT WAS A FUEL PUMP PROBLEM, THAT THE FUEL PUMP IN THE TRUCK BLEW UP AND SENT METAL SHREDS THROUGH THE FUEL RAIL SYSTEM AND INTO THE ENGINE. FORD DENIED THE WARRANTY STATING THE FUEL WAS CONTAMINATED WITH TO MUCH WATER. UPON HAVING MY FUEL TESTED, IT WAS DETERMINED IT WAS NOT CONTAMINATED AND THEY PAID 9000 OF REPAIR COST, AND I PAID 1000. I HAVE TWO VEHICLES (THE OTHER WHICH I WILL ALSO MAKE A COMPLAINT AS WELL) AND BOTH VEHICLES HAVE UNSAFETLY SHUT OFF AND LOST POWER. AFTER DOING RESEARCH, THE FUEL PUMP IN THE TRUCKS IN NOT RATED FOR THE LUBRICITY THE DIESEL FUEL IN AMERICA OFFERS. I HAVE SPOKEN TO SEVERAL MECHANICS WHO SAID THE PUMP WILL BLOW UP IF YOU DO NOT USE A FUEL ADDITIVE. FUEL SPECIFICALLY STATES TO USE UNITED STATES ULTRA LOW DIESEL FUEL IN THEIR SYSTEM, AND DOES NOT REQUIRE THEIR CONSUMERS TO USE FUEL ADDITIVES. THE PUMP IS NOT RATED, AND FORD IS PUTTING THESE PUMPS IN THEIR TRUCKS KNOWING THEIR NOT RATED FOR ULSD IN THE UNTIED STATED.

NHTSA ID

11015415

Incident

Nov 25, 2016

Mileage

10,000 mi