Which parts fail
Components named in complaints (fuel pump, injectors, fuel tank, hybrid and EV propulsion).
Mileage when the problem started
Owner reports
Selected complaints filed with NHTSA by 2015 Ford F-350 SD owners, lightly cleaned up (personal details are redacted by NHTSA).
The contact owns a 2015 Ford F-350. The contact stated that a certified mechanic had installed a disaster kit on the vehicle to prevent a fuel system failure. The independent mechanic later found metal shavings inside the filter going into the manifold. The independent mechanic recommended that the fuel pump be replaced. The contact was concerned that the replacement of the fuel pump with the same part would be a temporary fix. The vehicle was not yet repaired. The dealer was contacted and advised the contact to take the vehicle in for a diagnostic test. The manufacturer was not contacted. The failure mileage was approximately 81,000.
The contact owns a 2015 Ford F-350. The contact stated that an unknown warning code was illuminated on the screen display. The vehicle was towed to the dealer where it was diagnosed that the cold side charge tube, power stroke oil filter, and outlet tube assembly needed to be replaced. The manufacturer was notified of the failure and the contact was advised to call the NHTSA Hotline. The failure mileage was approximately 36,000.
This vehicle developed a fuel leak in the area of the top of the engine which resulted in a fire that destroyed the vehicle. I spoke to the Ford Motor Company and they said that there are no recalls or Technical Service Bulletins regarding this. I just wanted to make you aware of my experience so if anyone else experienced this it may show a pattern. Thank You
1/4/2022 - TRAVELING TO SOUTHERN OHIO IN F-350. Engine light came on. Truck info screen showed Exhaust Fluid System Fault - indicating truck would lock to 50 mph within a certain number of miles, then possibly shut down. Finally got in touch with Ford dealership in Chillicothe and took truck there. They determined it was a DEF heater and pump causing the issue, and that it would be covered by Ford as an extended warranty issue. Ford decided our truck was not covered. On 1/11, Ford added a new campaign - 21M01, Reductant Heater and Sender Assembly, covering the cost of replacement of these items. We were told we needed to pay the repair and Ford would reimburse. To this date, we have not been reimbursed - in fact have pretty much been ignored. The sensor recalibration they did caused the particulate filter to fail. …
Check engine light came on in my 2015 F 3 50 super duty crew cab truck. Upon inspection at the Ford dealership I was told the Reductant Heater And Sender Assembly Need to be replaced at a cost of $1100. This is happening within 60 days of heat sensor recall being done. When I look into this topic this repair has a recall on it for F2 50s through F5 50's including various years up to 2015, but the F3 50 is only up to 2012.
CP4 High pressure fuel injection pump blew up, causing the truck to need a 17,000$ fuel system at 93k miles. Thankfully I had warranty with Ford- however what happens when it's over and it goes again? Pay 17,000$ out of pocket? Ford needs to recall this just like dodge / Cummins. 17,000$ out of pocket can be crippling to the average American.
Cp4 fuel pump failure, upon failure repair was $9300.00, ford obviously knows of the problem as their is a kit that can be purchased for this catastrophic failure{fuel line replacement, fuel injection replacement, both fuel pump replacement , drop and flush fuel tank.}
Had vehicle 8 months. Driving on interstate 95 pulling my camper, "low fuel pressure" light came on, pulled over immediately. Saw smoke, then fire. Got out of truck with my dog and called 911. Report attached.
2015 f350 6.7 diesel with 46,000 miles that is down because hpop is defective and spreading medal through system. Ford has inspected and said it is because of water in fuel, even though no warning lights or codes are available. Ford pulled sensors out of engine and rejected repair because of tarnish on sensors. The only codes were for (low fuel pressure & reduced power). No other codes. Initial inspection revealed about 3/4 inch of water in water separator but no light or code. The warnings occurred when truck was started and it ran about 100 ft before being shutdown and towed to dealership. This appears to be a common problem since Ford offers a repair kit for this issue. Total cost of repair is between $9500,00 & $12,500 dollars and this on a truck which is still under warranty that Ford will not honor. …
Bought truck brand new in December 2014. At approx. 5,000 (still during the diesel engine break in period) while driving thru an intersection in traffic the truck and motor started violently shaking/bucking with the motor making a loud knocking noise- the truck then had a total loss of power in which I was unable to safely accelerate. The truck then went to the dealer in which I was told they could find nothing wrong. The truck now been in an out of the shop numerous times because the problem keeps occurring. Ford released a TSB stating that its normal for their trucks to experience "rough running" during the exhaust regen cycle. The experiences that have occurred with my truck have no correlation to the regen cycle and seem to happen at random times. …
NHTSA investigations
Sogefi Secondary Diesel Fuel Filter Leak
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.
Fuel System complaints in other F-350 SD years
Frequently asked questions
How common are fuel system problems on the 2015 Ford F-350 SD?
NHTSA has 26 complaints about the fuel & propulsion system of the 2015 Ford F-350 SD, 13% of the model year's 208 complaints. The component named most often is delivery › fuel pump (2 mentions).
Is there a recall for 2015 Ford F-350 SD fuel system problems?
No. NHTSA lists no fuel & propulsion system recall for the 2015 Ford F-350 SD, though it has 3 recalls for other components. If the problem is widespread, a repair may still be covered by an extended warranty or a manufacturer service bulletin — ask a dealer.
At what mileage do 2015 Ford F-350 SD fuel system problems start?
Half of the complaints with a recorded mileage happened before about 46,000 miles, and 35% before 25,000 miles.
Is it dangerous?
Owners linked 0 crashes, 2 fires and 0 injuries to fuel & propulsion system problems on this model year. If you notice symptoms, have the car checked before driving further.
Source: U.S. National Highway Traffic Safety Administration (NHTSA) — owner complaints through October 20, 2026, recalls and defect investigations; fuel economy from the EPA. Complaints are unverified reports and are not proof of a defect. How we rate model years.