2016 Ford Transit Fuel system Problems

My 2016 Ford Transit experienced a sudden loss of engine power while I was driving on the highway. The vehicle entered limp mode, stalled, and emitted excessive black smoke from the exhaust, creating a hazardous situation for me and surrounding motorists. I was forced to pull off the roadway because the vehicle could no longer operate safely. When a warning first appeared, I promptly took the vehicle to an authorized dealer, the dealership preformed some type of update and a DPF regeneration and instructed me to drive the vehicle on the highway for 50 miles to complete the regeneration process, I followed these instructions. The light returned and the vehicle was inspected by another authorized Ford dealership, All-State Ford, which confirmed the condition covered under Ford Customer Satisfaction Program (CSP) 23M01 involving the catalytic converter system. The dealership confirmed that the required repair cannot be completed because Ford has not supplied the necessary replacement part after I called to get an update. Approximately five months have passed since the vehicle was diagnosed, and the required part remains unavailable. During this time, my vehicle has remained unusable. Ford has been unable to provide a repair date or any estimated timeline for when the part will become available. Ford’s response has been to direct me back to the dealership. However, the dealership has confirmed that it cannot obtain the part, provide a repair timeline, authorize reimbursement, or offer any alternative remedy because those decisions are controlled by Ford Motor Company. In researching this issue, I found online discussions from owners describing similar catalytic converter failures and extended delays across multiple Ford vehicle models. While I cannot independently verify those reports, they suggest this may not be an isolated incident. I respectfully request the NHTSA review whether the remedy offered under CSP 23M01 is adequately addressing the safety issue.

NHTSA ID

11746436

Incident

Feb 2, 2026

This complaint is specifically related to Ford Recall 16S32 / NHTSA Campaign 16V618000 regarding the High-Pressure Fuel Pump (HPFP) failure. ​My vehicle (VIN: [XXX] ) has experienced the exact mechanical failure described in this recall, resulting in metal debris throughout the fuel system and a sudden loss of engine power while driving. This created an immediate safety hazard on the road. ​Ford is currently denying assistance because my vehicle’s production date falls just one day (24 hours) outside the official recall window. It is mechanically impossible for a manufacturing defect present in the recalled batch to not exist in a vehicle produced only 24 hours earlier. ​I am requesting that NHTSA investigate this arbitrary 1-day exclusion. Ford should not be allowed to avoid responsibility for a known safety defect based on a marginal production date error, especially when the failure and the parts involved are identical to those covered under the recall INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ID

11719118

Incident

Feb 1, 2026

The contact owns a 2016 Ford Transit. The contact stated that while driving at various speeds, the vehicle stalled. During the failure, the warning message "Reduced Power" was displayed. The contact stated that after restarting the engine, the vehicle operated as intended; however, the failure reoccurred later. The vehicle was taken to the local mechanic who replaced the fuel injector, but the failure reoccurred. The vehicle was later towed to the local dealer, where it was diagnosed that there were metal shavings in the fuel system. The dealer determined that the entire fuel system needed to be replaced, including the fuel pump, the fuel valves and the fuel injector. The contact was informed that the VIN was not included in the NHTSA Campaign Number: 16V618000(Fuel System, Diesel, Engine and Engine Cooling), which the contact related to the failure. The vehicle was not yet repaired. The failure mileage was 165,000.

NHTSA ID

11707743

Incident

Sep 30, 2025

Mileage

165,000 mi

driveshaft coupler failed Ford refuses to fix damaged parts from coupler failure. Received notice of safety recall 10-25-2023. Recall was issued 10-25-2019 but I was never notified of a recall. (recall notices are sent by mail) once recall notice was received 10-25-2023 I tried countless times to have recall done but parts were never available. Finally took to the dealer and had them place the part on order (backorder) to be filled when available on/or around 1-2024. Failure happened 4-18-2024 with the recall part still on backorder damaging all brake lines and fuel lines all at the same time. This part should have been available when the vehicle was taken to the dealership for repair in Jan. 2024 and fixed. Not until a Failure happens that could of cost the lives of X-people on a highway due to parts not being available for a Major recall like this one.

NHTSA ID

11597015

Incident

Apr 18, 2024

Vehicle goes into "limp" mode while on highway losing the ability to control the acceleration. The van has to coast to a stop, turn off the engine, then restart. The throttle body was replaced twice (3/2/21 and 11/21/22). This causes a major safety risk for the driver, passenger and all other drivers on the road. Losing control of the vehicle mechanically without warning and in such a sporadic fashion is unacceptable at this age and mileage. 170,245 miles & 219,118 miles.

NHTSA ID

11555246

Incident

Feb 24, 2021

The contact owns a 2016 Ford Transit. The contact stated while driving approximately 65 MPH, the vehicle lost motive power and stalled. The contact was able to push the vehicle to the side shoulder. The low engine mode message was displayed. The vehicle was towed to the local dealer where it was diagnosed that the high-pressure fuel pump failed, which caused fuel, metal, and debris to enter through the fuel lines. The fuel filters were replaced but the vehicle was not repaired. The manufacturer was contacted but no additional assistance was provided. The approximate failure mileage was 169,000.

NHTSA ID

11503220

Incident

Jan 4, 2023

Mileage

169,000 mi

FUEL DOOR BROKEN AT UPPER HINGE. COMMON PART FAILURE FORD REFUSES TO ACKNOWLEDGE.

NHTSA ID

11383557

Incident

Dec 14, 2020

Mileage

96,431 mi

TL* THE CONTACT OWNS A 2016 FORD TRANSIT. THE CONTACT RECEIVED NOTIFICATION OF NHTSA CAMPAIGN NUMBER: 19V767000 (POWER TRAIN) HOWEVER THE PART TO DO THE RECALL REPAIR WAS NOT YET AVAILABLE. THE LOCAL DEALER FULLERTON FORD LOCATED AT 1044 U.S. ROUTE 22 EAST, SOMERVILLE, NJ 08876 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 VEHICLE EXPERIENCED THE FAILURE LISTED IN THE RECALL CAUSING THE VEHICLE TO STALL. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE WAS 120,000. PARTS DISTRIBUTION DISCONNECT.

NHTSA ID

11375009

Incident

Nov 10, 2020

Mileage

120,000 mi

THE DRIVELINE BROKER FROM IT'S HOLDING MOUNT WHILE DRIVING AND TANGLED UP THE FUEL LINE AND BRAKE LINES GOING TO THE REAR OF THE VAN. MAKING THE VAN LOSE POWER AND NOT BE ABLE TO BE DRIVEN ANYMORE. THIS HAPPENED WHILE DRIVING ON THE FREEWAY. THIS IS EXTREMELY DANGEROUS. ALSO THEY HAVE A RECALL ON THE REAR FLEX JOINT WHICH THE FORD DEALERSHIP HAS RECOGNIZED BUT ARE REFUSING TO PAY FOR THE TOTAL REPAIR. HOW IS THAT FAIR? IT IS FORD'S DESIGN FLAW THAT MADE THIS HAPPEN.

NHTSA ID

11374856

Incident

Sep 26, 2020

Mileage

148,000 mi

I HAVE A 2016 TRANSIT 350 WITH THE 3.2L DIESEL EMGINE AND I HAVE PROBLEMS WITH METALLIC DEBRIS IN MY FUEL LOOKING ON LINE FOED HAS A RECALL (16S32) THAT COVERS BUILD DATES JULY11/2015-APRIL14/2016 AND MY TRANSIT WAS BUILD END OF MAY 2016 AND TRANSIT IS HAVING THE SAME PROBLEMS, I THINK THE RECALL SHOULD BE EXTENED TO THE END OF MAY 2016 ALSO THE DEALER IS GOING TO CHARGE ME FOR 24 HOURS OF LABOR AND THE RECALL FOR THE SAME PROBLEM IS ONLY SAYING THAT IT SHOULD TAKE 10.2 HOURS PLEASE HELP ME

NHTSA ID

11321808

Incident

Apr 16, 2020

Mileage

100,000 mi

TL* THE CONTACT OWNS A 2016 FORD TRANSIT. WHILE DRIVING, THE VEHICLE STALLED WITHOUT WARNING. THE CONTACT WAS ABLE TO COAST THE VEHICLE TO THE SIDE OF THE ROAD. THE VEHICLE WAS TOWED TO COOPER FORD (LOCATED AT 5292 US 15 501 HWY, CARTHAGE, NC 28327, (910) 947-2244) WHERE IT WAS DIAGNOSED THAT THE HIGH AND LOW PRESSURE FUEL PUMPS DETACHED AND NEEDED TO BE REPLACED. THE VEHICLE WAS IN THE PROCESS OF BEING REPAIRED. THE CONTACT STATED THAT THE FAILURE RECURRED THREE TIMES. THE MANUFACTURER STATED THAT THE VEHICLE WAS NOT INCLUDED IN A RECALL AND REFERRED THE CONTACT TO NHTSA. THE APPROXIMATE FAILURE MILEAGE WAS 95,000. THE VIN WAS NOT AVAILABLE.

NHTSA ID

11172158

Incident

Jan 21, 2019

Mileage

95,000 mi

TL* THE CONTACT OWNS A 2016 FORD TRANSIT. THE CONTACT STATED THAT THERE WAS A FAILURE CONCERNING THE FUEL FLAP THAT WAS TO REMAIN CLOSED. THE CONTACT NOTICED THAT THE FLAP WAS STICKING OUT AND, WHEN THE DOORS WERE OPENED AND CLOSED, THE FUEL FLAP FAILED TO REMAIN CLOSED. THE DEALER (HORNE FREEDOM FORD, 2161 US-70, THATCHER, AZ 85552, (866) 862-8547) DIAGNOSED THE VEHICLE. THE SERVICE CENTER MANAGER WAS TO PROVIDE A RESPONSE TO THE CONTACT PERTAINING TO A REPAIR SOLUTION. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE AND RECOMMENDED HAVING A DEALER DIAGNOSE THE VEHICLE. THE FAILURE MILEAGE WAS NOT AVAILABLE.

NHTSA ID

11058372

Incident

Jan 1, 2018

TL* THE CONTACT OWNS A 2016 FORD TRANSIT. THE CONTACT STATED THAT THE DRIVER WAS DRIVING AT 30 MPH WHEN THE VEHICLE SUDDENLY STALLED. THE VEHICLE WAS TOWED TO A DEALER WHERE IT WAS DIAGNOSED THAT THE FUEL FILTER NEEDED TO BE REPLACED. IT WAS UNKNOWN IF THE PART WAS REPLACED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE WAS 25,000.

NHTSA ID

10966253

Incident

Mar 13, 2017

Mileage

25,000 mi

THE VEHICLE WILL STOP ACCEPTING ACCELERATOR COMMANDS RANDOMLY. IT WILL REFUSE TO ACCELERATE WHEN THE ACCELERATOR IS DEPRESSED. THERE HAVE BEEN 4 OF THESE VEHICLES IN OUR FLEET DO THIS. FORD IS AWARE OF THE PROBLEM BUT REFUSES TO DO ANYTHING ABOUT IT TO ACCOMMODATE THE DRIVERS EVEN GOING SO FAR AS TO STATE IT COULD BE WEEKS BEFORE EVEN DIAGNOSING THE PROBLEM. THIS IS TO COVER THE FACT HAT THEY HAVE THE THROTTLE BODIES NEEDED TO REPAIR THIS COMPLAINT ON BACKORDER. IF ON A FREEWAY THIS IS A DANGEROUS FAILURE THAT WOULD COMPROMISE THE SAFETY OF ALL ON BOARD. THE VEHICLE WAS IN MOTION AT THE TIME OF THE FAILURE ON A CITY STREET.

NHTSA ID

10884631

Incident

Jul 13, 2016

Mileage

6,259 mi