2020 Ford F-450

The Office of Defect Investigations (ODI) has received 27 complaints alleging diesel fuel leaks due to a fracture in the secondary fuel filter housing in model year (MY) 2015-2021 Ford Motor Company (Ford) F-250, 350, 450, and 550 Super Duty vehicles equipped with 6.7L diesel engines. Of these complaints, 12 describe an engine compartment fire. The proximity of the secondary fuel filter to high heat sources creates a potential for autoignition thermal events and fires. ODI has contacted the vehicle manufacturer, Ford, and the filter manufacturer, Allevard Sogefi USA (Sogefi), and learned that the low-pressure fuel system is capable of a maximum operating pressure of 8.5 Bar, while the secondary fuel filter is only tested to seven (7) Bar during the manufacturing process. Additionally, changes starting in 2022 by both Ford and Sogefi align with a lack of similar complaints on MY 2022 and newer vehicles. ODI is opening this Preliminary Evaluation (PE) to evaluate the severity of the potential problem and to fully assess the potential safety-related problems. To review the ODI reports cited in the Opening Resume ODI Report Identification Number document, go to NHTSA.gov.

In January 2021, the Office of Defects Investigation (ODI) opened a Recall Query (RQ21-001) to assess allegations of post-recall remedy uncommanded tailgate openings in model year (MY) 2017-2019 F-250/350/450 Ford trucks. Besides the recall remedy launched in January 2020, Ford also implemented a production update in November 2019.  At the time of the RQ opening, ODI had received eleven (11) Vehicle Owner Questionnaires (VOQs). ODI sent an Information Request (IR) to Ford in February 2021. In numerous meetings after receiving their IR response, Ford highlighted the drop in claims since the recall and production update and communicated how they were unable to verify the owners’ complaints or replicate the concern. Despite this, Ford began developing ways to prevent uncommanded tailgate openings from various human, mechanical or electrical causes. Based on testing, Ford issued a Customer Satisfaction program, 21M05-S1/S2/S3, to further address the potential of unintended tailgate openings. This work was applied to vehicles being produced as of December 20, 2021.  The program began for already delivered vehicles on July 22, 2022. The covered models include 2017-2022 F-250, 350, 450, 550, 650 and 750 Super Duty and 2020-2022 F-600 Super Duty trucks. ODI has received 39 VOQs between February 24, 2020, and December 15, 2023, alleging uncommanded tailgate openings.  In a detailed analysis, none of the vehicles in the VOQs were found to have received the Customer Satisfaction update. Since ODI has not received any complaints of post-Customer Satisfaction program tailgate openings, this office is closing this Recall Query. The closing of this investigation does not constitute a finding by NHTSA that a safety-related defect does not exist. The Agency reserves the right to take additional action if warranted by future circumstances. To review the ODI reports cited in the Closing Resume ODI Report Identification Number document, go to NHTSA.gov.

The contact owns a 2020 Ford F-450. 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 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 had not experienced a failure.

NHTSA ID

11722455

Incident

Sep 15, 2025

The contact owned a 2020 Ford F-450. The contact stated that while driving at 60 MPH, the steering wheel failed to steer in the intended direction. No warning lights were illuminated. The contact stated that the vehicle had driven independently sideways and then into a deep ditch before coming to a stop. In addition, the contact stated that the vehicle was uncontrollable. The vehicle was towed to a local tow yard. The vehicle was condemned as a total loss by the insurance company. The contact was unconscious and transferred to the local hospital. The contact sustained six broken ribs, a punctured left lung and a hematoma in the left leg. In addition, the contact had to have emergency surgery to remove the hematoma. The contact was receiving continued medical treatment due to the injuries. The contact stated a Police report was filed. The contact later received a recall notification: NHTSA Campaign Number: 25V626000 (Steering) however the parts were not available. The manufacturer was not made aware of the failure. The failure mileage was approximately 82,000.

NHTSA ID

11693264

Incident

Aug 28, 2025

Mileage

82,000 mi

The contact owns a 2020 Ford F-450 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 the manufacturer had exceeded a reasonable amount of time for the recall repair. The manufacturer was not made aware of the issue. The contact had not experienced a failure.

NHTSA ID

11682394

Incident

Jan 1, 2025

Vehicle caught fire. Fire in the engine compartment after heavy fuel smell/odor.

NHTSA ID

11681172

Incident

Aug 16, 2025

The contact owns a 2020 Ford F-450. The contact received notification of NHTSA Campaign Number: 24V957000 (Fuel System, Diesel). The contact stated that while hauling an RV at 65 MPH, with the cruise control feature activated, the message that the "Engine has Stopped - Pull Over Immediately" was displayed, and the vehicle stalled. The vehicle was steered to the side of the road, and the contact attempted to restart the vehicle. The contact stated that the engine was turning over however, the vehicle failed to start. The vehicle was towed to a dealer to be diagnosed, and the dealer retrieved DTC: P0087. Additionally, there were metal shavings found in the fuel system. The contact was informed that the fuel pump and the entire fuel system needed to be replaced. The vehicle was repaired. The manufacturer was notified of the failure. The failure mileage was 104,717.

NHTSA ID

11658406

Incident

Jan 2, 2025

Mileage

104,717 mi

The contact owns a 2020 Ford F-450. The contact stated that after starting the vehicle, the engine ran for several minutes before the vehicle independently shut off. No warning lights were illuminated. The contact attempted to restart the vehicle however, the vehicle failed to start. The vehicle was towed to the residence. The local dealer was contacted; however, the vehicle was not diagnosed or repaired. The contact referenced NHTSA Campaign Number: 24V957000 (FUEL SYSTEM, DIESEL) as probable cause for the failure. The manufacturer was not notified of the failure. The approximate failure mileage was 184,000.

NHTSA ID

11645130

Incident

Feb 18, 2025

Mileage

184,000 mi

The contact owns a 2020 Ford F-450. The contact stated that while driving 60 MPH, there was an abnormal knocking sound coming from the vehicle, with the "Reduced Engine Power" message displayed on the instrument panel. The contact pulled over to the shoulder of the highway, and the vehicle shut off. The contact stated that the vehicle failed to restart after several attempts. Due to the failure, the vehicle was towed to a dealer where a diagnostic test was performed, and it was determined that the high-pressure fuel pump had failed. The contact was informed that the entire fuel system needed to be replaced. The contact then 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 informed the contact that the remedy for the recall was a software update. The contact was informed that due to the fuel pump failure, the vehicle was no longer qualified for the recall repair. The dealer referred the contact to the manufacturer who offered to cover 50% of the cost for the repair. The contact stated that the recall repair was not a permanent repair and that the recall remedy failed to adequately address the failure. The vehicle was not repaired and remained in the possession of the dealer. The failure mileage was approximately 40,000. VIN tool confirms parts not available.

NHTSA ID

11642508

Incident

Jan 31, 2025

Mileage

40,000 mi

The contact owns a 2020 Ford F-450. 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 contact stated that while starting, the "Low Fuel Pressure" message was displayed. The contact stated that while driving at an undisclosed speed, the vehicle lost power. The vehicle was towed to an independent mechanic where it was diagnosed and determined that the fuel filter had exploded and needed to be replaced. The vehicle was then towed to a dealer where it was diagnosed and determined that the fuel system was contaminated with metal and that the entire fuel system needed to be flushed and replaced. The vehicle was not repaired. The manufacturer was not notified of the failure. The failure mileage was approximately 103,000. VIN tool confirms parts not available.

NHTSA ID

11640346

Incident

Jan 23, 2025

Mileage

103,000 mi

Certain 2017-2025 F-450 – F-600 Chassis Cab Upfitted with an Aerial Bucket Frame Rail Crack

The Service Awareness Newsletter is an informal communication that contains information that may not be presently available in a TSB, SSM, GSB, or other electronic communication. This article includes information on warranty, technical service tips and other service information.

Certain 2020 Model Year Super Duty F250-F600 Vehicles Equipped with a 10R140 Transmission - Number One Planetary and Ring Gear Assembly- Ref Cust Sat Program 21B03 dated March 3, 2021 In all of the affected vehicles, a distressed No. 1 planetary needle bearing inside the ring gear assembly will generate contamination that may produce rough shifts. A wrench light is likely to come on, and the transmission may go into safe mode and only operate in seventh gear. As damage progresses, the transmission may only be capable of limited vehicle speed or may not engage in forward or reverse

Some 2015-2019 Transit vehicles equipped with a 3.2L engine, 2018-2020 F-150 vehicles equipped with a 3.0L engine, 2017-2020 Super Duty vehicles equipped with a 6.7L engine built on or after 13-May-2017 may exhibit an illuminated malfunction indicator lamp (MIL) with diagnostic trouble code (DTC) P2002 stored in the powertrain control module (PCM). This may be due to a crack in the diesel particulate filter (DPF) substrate. To correct the condition, follow the Service Procedure steps to replace the DPF.

In some of the affected vehicles , a piston oil cooler bracket may have been damaged during engine assembly. A damaged piston oil cooler bracket may allow the piston oil cooler to detach. This can lead to low engine oil pressure and may result in intermittent engine noises and/or illumination of the check engine light due to diagnostic trouble code(s).

Some 2013-2020 vehicles equipped with an EVDC air conditioning (A/C) compressor may exhibit poor A/C performance/improper climate function. To support the proper diagnosis of this compressor, the EVDC control valve tester has been provided to each U.S. dealership (339-EVDC100). Ensure the A/C system has a full charge prior to any compressor diagnostics. To support the proper diagnosis of this compressor, the EVDC compressor tool must be used, and the results recorded in the Technician comments field with the warranty claim. This tester will help reduce the potential for misdiagnosis and unnecessary compressor replacement. Refer to the Rotunda catalog for a video and user manual which provide detailed operating instructions.