2016 Ford F-250 SD Fuel System Problems

Which parts fail

• Delivery › Fuel pump
  3

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

Mileage when the problem started

• Under 25k
  318%
• 25k–50k
  212%
• 50k–75k
  424%
• 75k–100k
  212%
• 100k–150k
  212%
• 150k+
  424%

Owner reports

Selected complaints filed with NHTSA by 2016 Ford F-250 SD owners, lightly cleaned up (personal details are redacted by NHTSA).

The contact owns a 2016 Ford F-250. The contact stated while driving at an undisclosed speed, the vehicle experienced reduced power and poor fuel efficiency. The messages "DPF System Overloaded" and "Exhaust System Fault - 50 Miles Until Speed Restrict" were displayed. The vehicle was taken to the dealer on four separate occasions. The dealer performed a manual regeneration three times, but the failure persisted. The vehicle was taken back to the dealer, where it was determined that the Diesel Particulate Filter (DPF) system needed to be replaced. The vehicle was not repaired. The contact related the failure to Customer Satisfaction Program Number: 20M06 (Diesel Particulate Filter Warranty Extension with Diagnostic Trouble Code P2002) and Emission Recall Number: 20E08 (Extended Idle Diesel Particulate Filter Calibration); however, the VIN was not included. …

On [redacted], I was driving westbound on [redacted], between Kerrville and Junction, Texas. I noticed a diesel fuel smell and pulled off the highway to investigate the source. Upon stopping, fire erupted from the engine compartment and quickly spread to the front dashboard and front passenger seating area. No warning lamps, no high temp or abnormal gage levels. The Mountain Home, TX volunteer fire dept arrived about 30 minutes after we called 911 and extinguished the remaining flames. They commented that a cracked / failed secondary fuel filter housing could be to blame. My insurer, State Farm, under claim #[redacted], now has possession of the vehicle remains. I told State Farm that NHTSA opened an investigation into possible fuel filter housing failures / fires. I do not know what their intentions are with the vehicle remains.

The contact owns a 2016 Ford F-250. The contact stated that while driving 10 MPH, the check engine warning light illuminated, and the vehicle stalled while driving through an intersection. The contact was able to safely coast the vehicle over to the side of the highway. The contact was able to restart the vehicle. The contact stated that several days later the failure reoccurred, and the vehicle was taken to a local dealer to be diagnosed. The contact was informed that there were metal particles inside the fuel system. The contact was informed that the fuel system needed to be replaced. The vehicle was not repaired. The contact referenced NHTSA Campaign Number: 24V957000 (FUEL SYSTEM, DIESEL) as a possible cause for the failure. The manufacturer was notified of the failure. The approximate failure mileage was 178,000.

The contact owns a 2016 Ford F-250. The contact stated while her husband was driving at an undisclosed speed, the accelerator pedal was depressed; however, the vehicle failed to accelerate as intended. The contact stated that the failure occurred while driving on a busy highway. The contact's husband drove the vehicle to the intended destination. The vehicle was taken to an independent mechanic. The contact stated that several warning lights illuminated, and the vehicle lost motive power. The vehicle was diagnosed with a clogged diesel particulate filter. The contact was informed that the diesel particulate filter needed to be replaced. The vehicle was not repaired. The manufacturer was made aware of the failure but provided no assistance. The failure mileage was approximately 140,000.

The contact owns a 2016 Ford F-250. The contact stated while driving at an unknown speed, the shifted into Limp Mode. The contact stated that the check engine warning light was illuminated. The vehicle was towed to an independent mechanic who diagnosed that the failure was due to metal chips being in the fuel. The independent mechanic advised the contact to tow the vehicle to the dealer. The vehicle was towed to the dealer where it was awaiting a final diagnostic report. The mechanic confirmed metal chips inside the fuel. The contact stated that he was informed by other mechanics that the failure was a known issue. The manufacturer was notified of the failure and advised the contact to file a complaint with the NHTSA. The approximate failure mileage was 67,000.

The contact owns a 2016 Ford F-250. The contact stated while driving approximately 25 MPH, the vehicle started losing motive power. There was no warning light illuminated. The contact was able to coast to the driveway at the residence and became aware of an oil leak underneath the vehicle. The contact stated that an unknown dealer was contacted and informed the contact that a fuel system upgrade was available; however, the vehicle was not upgraded. The vehicle was not diagnosed or repaired. The manufacturer was informed of the failure and a case was filed. The manufacturer referred the contact to the NHTSA Hotline to report the failure. The failure mileage was approximately 212,000.

The contact owns a 2016 Ford F-250. The contact stated while driving approximately 5 MPH and hauling a trailer, the vehicle suddenly lost motive power and stalled. There was no warning light illuminated. The vehicle failed to restart. The vehicle was towed to the dealer where it was diagnosed and determined that the fuel pump had failed due to metal shavings in the fuel system. The contact was informed that the fuel system kit needed to be replaced. The vehicle was repaired. The manufacturer was made aware of the failure. The manufacturer referred the contact to the NHTSA Hotline to file a complaint. The failure mileage was 237,778.

The contact owns a 2016 Ford F-250. The contact stated that while driving 20 MPH, the vehicle lost motive power and stalled. The check engine warning light was illuminated, with a message stating to check the engine. The vehicle was towed to an independent mechanic where a diagnostic test was performed. The mechanic stated that the high-pressure pump created metal debris that traveled through the fuel system and the high-pressure fuel pump needed to be replaced. The vehicle was not repaired. The manufacturer was made aware of the failure and referred the contact to the NHTSA Hotline. The approximate failure mileage was 110,000.

The contact owns a 2016 Ford F-250. The contact stated while driving 45 MPH, the vehicle lost motive power. There was no warning light illuminated. The contact was able to pull over to the side of the road. The vehicle failed to restart and was towed to the residence. The vehicle was then towed to the dealer, where it was diagnosed with an inoperable high-pressure fuel pump(HPFP). The dealer determined that the entire fuel system needed to be replaced. The vehicle was not repaired. The manufacturer was notified of the failure, but no assistance was provided. The failure mileage was approximately 91,000.

The contact owns a 2016 Ford F-250. The contact stated while driving at an undisclosed speed, the reduced power warning light illuminated, and the vehicle lost motive power. The contact drifted over to the shoulder of the roadway. The vehicle was towed to an independent mechanic where it was diagnosed with a failed high-pressure fuel pump. The contact was informed that the high-pressure fuel pump needed to be replaced. The vehicle was repaired. The manufacturer was made aware of the failure but provided no assistance. The failure mileage was approximately 240,000.

NHTSA investigations

Fuel System complaints in other F-250 SD years