Ford F-250 SD fuel leak problems

Filed Oct 25, 2026 · Fuel system · TX · fire

Fuel leak from plastic fuel filter housing caused fire

Filed Oct 15, 2026 · Engine, Fuel system · TX

On October 9, 2026 at approximately 8:30 AM, my 2019 Ford F-250 6.7L Power Stroke diesel, with 76,512 miles, suffered a catastrophic high-pressure fuel injection pump failure while traveling approximately 55 mph on FM 3351 near Camp Stanley, Texas. The vehicle displayed “Speed Limited” and “Reduced Engine Power” warnings, then lost throttle response and propulsion and the engine shut down while moving. Steering and braking effort increased substantially after the engine stopped. The truck would crank but would not restart. Alamo Diesel Service, an independent diesel repair facility, confirmed no fuel-rail pressure, fuel leaking in the engine valley, and that the injection pump had “blown and cracked the head.” Inspection revealed metallic debris and extensive fuel-system contamination requiring replacement/repair of the pump, injectors, rails, fuel lines, return lines and filters, plus cleaning of the tank and cooler. The estimate is $11,193.97. Diagnostic codes included P0087 (Fuel Rail/System Pressure Too Low) and P2291. P0087 freeze-frame data recorded the vehicle at 54.68 mph and 1,300 RPM, confirming the fuel-pressure failure occurred while driving. There were no prior fuel-system problems and the fuel filters were recently replaced. I am concerned because there is a long, documented history of failures involving this type of high-pressure diesel fuel pump, including failures that can introduce metal into the fuel system and cause loss of propulsion. Ford has also recalled certain later-model 6.7L Super Duty trucks for high-pressure fuel pump failures that can cause loss of drive power. I am requesting the federal safety agency evaluate whether my 2019 failure may be related to a broader safety defect. Ford has been notified under case CXH-09644112-L1W2N0 but has not inspected the vehicle. The vehicle and failed components are currently available for inspection.

Filed Feb 18, 2026 · Fuel system · SC

The fuel tank is leaking fuel from the top where hose connects, it is cracked where the hose barb is connected to the tank

Filed Aug 8, 2025 · Fuel system · KS

Fuel leaking from above fuel filter housing located on undercarriage of truck. Fuel leak is considerable and was a sudden failure versus developing over time.

Filed Apr 29, 2025 · Fuel system · 105,000 miles · PA

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.

Filed Mar 5, 2025 · Electrical, Engine · CA · fire

On Tuesday, [XXX], at approximately [XXX] PM, I was driving southbound on [XXX] near Coalinga, CA, when my truck suddenly experienced a failure. I noticed smoke in the side mirror and asked my passenger to confirm. Moments later, a "Low Fuel Pressure" message appeared on the dashboard, and smoke began coming from the hood. I immediately pulled over and attempted to pop the hood, at which point flames erupted from the engine bay. The fire quickly spread, fully engulfing the vehicle within minutes. Emergency responders, including Cal-Fire and CHP, arrived on the scene. The truck was towed by Cal-State Towing Service in Huron, CA. The Fire Captain on site provided an incident card, but the full fire report is expected to take at least a week to obtain. There were no prior indications of mechanical issues before this incident, and no recent repairs or modifications to the fuel system or engine. However, I recently became aware of an ongoing the federal safety agency investigation into fuel leaks and fire risks in Ford Super Duty trucks equipped with the 6.7L diesel engine (TFL Truck Report). The investigation highlights a potential issue with fractures in the secondary fuel filter housing, which could lead to fuel leaks and fire hazards. Given that my truck displayed a Low Fuel Pressure warning immediately before catching fire, I strongly suspect this failure may be related to the issue under investigation. The truck is currently in tow yard storage and is available for inspection upon request. This incident posed a serious safety risk to myself, my father and others on the roadway, and I believe it warrants further examination by the federal safety agency. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

Filed Jan 15, 2025 · Fuel system · CA

While driving on freeway, engine started to miss/hesitate. No check engine light. Miss/hesitation started to get more frequency and started smelling gas. No check engine light. Took offramp and truck died at stop sign. Pushed truck to gas station. Once out of truck, the smell of gas was prominent. Checked under hood and saw nothing unusual. Looked under truck on driver side and saw gas dripping from the transmission to the bumper under the truck. Looked under passenger side and saw more gas. Walked around to driver side, opened the driver door (which turns the fuel pump on) and saw gas spraying from under the truck. Got under the truck and determined that the supply connector on front side of fuel tank was disconnected. I reconnected the connector, clipped it locked, checked for leaks and restarted engine. There have been no further problems. Determined that approximately 10 plus gallons of gas sprayed under the truck. Approximate milage at time of incident was 6500 miles, current mileage is 6900 miles. I have purchased and plan to replace the following Ford part numbers per the Ford workshop manual which contains the connector and downstream fuel line: PC3Z 9J280, LC3Z 9S278.

Filed Jan 8, 2025 · Fuel system · VA

The upper fuel filter plastic housing cracks and leaks fuel on hot parts and has produced fires on other vehicles, not this one. I have had this replaced twice in the past, this will be the third time. There are no warning lamps or other warnings. Only the smell of fuel.

Filed Jul 8, 2024 · Fuel system · 136,942 miles · NE

The contact owns a 2017 Ford F-250. The contact stated that after driving approximately 50-65 MPH and pulling into a business parking lot, the contact became aware that there was a trail of fuel on the ground. The contact inspected the vehicle and became aware of fuel leaking underneath the front of the vehicle between the tires. The contact drove to the nearest independent mechanic, where it was diagnosed that the upper fuel filter had fractured and was leaking. The mechanic replaced the fuel filters, and the vehicle was repaired. The dealer was not contacted. The manufacturer was notified of the failure and referred the contact to the federal safety agency Hotline to report the failure. The failure mileage was approximately 136,942.

Filed Apr 5, 2024 · Fuel system · NJ

The contact owns a 2018 Ford F-250. The contact stated while driving at an undisclosed speed, he smelled a gasoline odor on the interior of the vehicle. After a visual inspection of the engine compartment, the contact observed a fuel leak. No warning lights were illuminated. The vehicle was taken to the dealer, who diagnosed a failure with the fuel filter cap. The vehicle was repaired, but the failure reoccurred. The contact also stated that the failure reoccurred two additional times. The manufacturer was notified of the failure, a case was opened, and the contact was referred to the federal safety agency Hotline for assistance. The failure mileage was unknown.