2015 Ford F-250 SD Fuel System Problems

Which parts fail

• Pneumatic › Regulator
  1
• Fuel filter
  1

Components named in complaints (fuel pump, injectors, fuel tank, hybrid and EV propulsion).

Mileage when the problem started

• Under 25k
  415%
• 25k–50k
  27%
• 50k–75k
  726%
• 75k–100k
  27%
• 100k–150k
  1037%
• 150k+
  27%

Owner reports

Selected complaints filed with NHTSA by 2015 Ford F-250 SD owners, lightly cleaned up (personal details are redacted by NHTSA).

The contact owns a 2015 Ford F-250. The contact stated while driving 55 MPH, the vehicle went into "Reduced Engine Power" mode and decelerated to 20 MPH. The contact pulled over to the side of the road. The vehicle was towed to a certified mechanic who diagnosed that the fuel system had failed. The fuel pressure regulator was replaced however, the vehicle remained in "Reduced Engine Power" mode. The vehicle was taken to the dealer who diagnosed that the fuel pressure regulator failed again and needed to be replaced. The contact informed the dealer that the fuel pressure regulator had been previously replaced. The dealer re-inspected the vehicle and informed the contact that the fuel tank was rusted, and the fuel pump, injector pump, and fuel system needed to be replaced. The vehicle had not been repaired. …

The contact owns a 2015 Ford F-250. The contact was exiting a highway ramp at approximately 60 MPH when the check engine and reduced engine power warning lights illuminated. The contact pulled over, stopped the vehicle, turned off, and restarted the vehicle to reset the warning lights. The contact stated that the warning lights again became illuminated, and the vehicle started to lose motive power. The contact was able to safely reach his destination and later the vehicle was taken to an independent mechanic where the vehicle was diagnosed, and it was determined that the fuel pressure sensor needed to be replaced. The vehicle was test-driven and several unknown warning lights were illuminated. The vehicle was driven back to the mechanic who drained a fuel line and discovered metal shavings in the line. The vehicle had not been repaired. The manufacturer had been informed of the failure. …

The contact owns a 2015 Ford F-250. The contact stated that while driving at 65 MPH, there was an abnormal sound coming from the engine compartment, with the check engine warning light illuminated. The contact stated that there was white smoke coming from the rear of the vehicle. The vehicle lost motive power and the contact pulled over to the side of the road and turned off the vehicle. The vehicle was unable to be restarted. The vehicle was towed to a dealer where it was diagnosed and determined that the engine needed to be replaced. The vehicle was not repaired. The vehicle was then taken to another dealer where it was diagnosed and determined that the fuel system and the engine was damaged. The contact was informed that the fuel system and the engine needed to be replaced. The vehicle was not repaired. The manufacturer was notified of the failure. …

The contact owns a 2015 Ford F-250. The contact stated that while driving at an undisclosed speed, there was smoke coming from underneath the hood with an unknown fluid splattering onto the front windshield. Additionally, an abnormally strong diesel odor was detected while the vehicle was parked and while driving. Upon inspection, the contact noticed there was fluid leaking underneath the hood and dripping down to the fender. The vehicle was taken to an independent mechanic who diagnosed that the engine block was cracked. The vehicle was then towed to the dealer where it was diagnosed with a faulty fuel filter housing and that the fuel filter assembly needed to be replaced. The dealer replaced the fuel filter assembly. The manufacturer was made aware of the failure and advised the contact to file a complaint with the NHTSA Hotline. The failure mileage was approximately 50,000.

The contact owned a 2015 Ford F-250. The contact stated while the driver was driving 70 MPH, the vehicle shut off inadvertently. The contact's fianc was able to pull to the side of the road. There was no warning light illuminated. The vehicle failed to restart and was towed to an independent mechanic, where it was diagnosed that the Bosch CP4 high pressure fuel injector pump failure caused metal shavings to enter the fuel filter, causing the vehicle to stall. The mechanic replaced the fuel system assembly. The contact stated that the transmission later failed, and the vehicle was sold. The vehicle was not repaired. An unknown dealer was notified of the failure. The manufacturer was notified of the failure and referred the contact to the NHTSA Hotline for assistance. The failure mileage was approximately 189,000.

The contact owns a 2015 Ford F-250. The contact stated that while driving at various speeds, there was an abnormal ticking sound coming from the engine while depressing the accelerator pedal. The contact stated that after accelerating from a stop light, the vehicle started to sputter with the check engine warning illuminated. The contact pulled over and had the vehicle towed to the dealer. While at the dealer, a fault code for the fuel pump failure was retrieved. The contact was informed that shards of metal had entered the fuel system, and the contact was provided an estimate for the repair. The manufacturer was notified of the failure but offered no assistance. The contact was referred to the NHTSA Hotline to report the failure. The vehicle was not yet repaired. The failure mileage was approximately 122,000.

The contact owns a 2015 Ford F-250 SD. The contact stated while driving at an undisclosed speed, the contact noticed an odor of burning fuel inside the vehicle. The contact stopped and parked the vehicle at a relative's residence. The contact noticed smoke coming from under the hood. The contact opened the hood and inspected the engine compartment and became aware that the upper filter housing was cracked. In addition, there was fuel spraying into the engine bay. The vehicle was not diagnosed or repaired by an independent mechanic or the dealer. The dealer was made aware of the failure. The manufacturer was not made aware of the failure. The failure mileage was approximately 112,000. The VIN was unavailable.

The contact owns a 2015 Ford F-250. The contact stated that while operating the vehicle, the odor of fuel was present inside the cabin of the vehicle. The contact stated that a second motorist alerted the contact that fuel was leaking from underneath the vehicle. The contact stopped to inspect the vehicle and after raising the hood, it was discovered that diesel fuel was leaking from the top fuel filter. The contact later purchased and replaced the fuel filter, and the vehicle was repaired. The cause of the failure was not yet determined. The manufacturer was notified of the failure, but no assistance was offered. The local dealer was not contacted. The failure mileage was 105,000.

The contact owns a 2015 Ford F-250 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 with a failed diesel particulate filter. The contact was informed that the diesel particulate filter needed to be replaced. The dealer advised the contact that there was a Customer Satisfaction Program for the repair, but the vehicle was not eligible. The vehicle was not repaired. The manufacturer was made aware of the failure and advised the contact to report the failure to the NHTSA Hotline. The failure mileage was approximately 85,000.

The contact owns a 2015 Ford F-250. The contact stated while pulling a trailer and driving 65 MPH, the check engine warning light and powering down warning message were illuminated. The contact stated that he continued driving for a mile before the vehicle started to decelerate. The contact parked on the side of the road. The vehicle was not drivable. The contact towed the vehicle to an independent mechanic and was informed that shards of metal were found inside the fuel line and fuel filter. The vehicle was repaired. A dealer was not contacted. The manufacturer was not made aware of the failure. The failure mileage was 82,111.

NHTSA investigations

Fuel System complaints in other F-250 SD years