2021 Ford F-350 SD engine problems

Filed Oct 7, 2026 · Engine, Fuel system · MI

Failed Component & Availability for Inspection: The Bosch CP4 high-pressure fuel pump (HPFP) failed internally, shedding metallic debris throughout the entire fuel system. This matches the exact defect in the federal safety agency Recall 24V‑957 and Ford Safety Recalls 24S78 and 26S17. The failing CP4 pump and eight injectors were replaced on 03/14/2026 (Eastpointe Invoice #5997) due to contamination. The truck is located at Bob Maxey Ford in Detroit, MI, and is available for inspection alongside work orders from an authorized Ford dealership and two independent facilities. Safety Risk: The failure caused an abrupt, total loss of motive power on an active highway off-ramp, followed by an immediate no-start stall. Coasting without motive power across traffic lanes created an imminent collision hazard before the truck was towed by Troy’s Towing on 06/05/2026 (Invoice #34647). Problem Confirmation: •03/14/2026: Eastpointe replaced the failed CP4 pump and eight injectors (Inv #5997). •04/07/2026: Bill Brown Ford pulled DTC P228F, found debris on the regulator screen, and advised full fuel system replacement (RO #80302). •04/29/2026: Eastpointe confirmed metal contamination upon teardown (Inv #6342). •05/14/2026: Diesel’s Place found metal shavings on the regulator valve (Inv #2118). •Current: Bob Maxey Ford scanned DTC P0087 but reported no debris, contradicting prior documentation. Inspections: Bill Brown Ford inspected the vehicle on 04/07/2026 and documented debris. Bob Maxey Ford retrieved DTC P0087—a qualifying code for full fuel system replacement under Ford Recall 26S17—yet Ford Corporate denied coverage based on their claim of no metal shavings. Warning Signs & Timeline: In March 2026, the Check Engine Light illuminated with severe engine jerking (pump/injectors replaced 03/14). Bill Brown Ford confirmed DTC P228F and screen debris on 04/07. Metal shavings were reconfirmed on 05/14, leading to a highway stall/no-start on 06/05 and a stored DTC P0087 at Bob Maxey.

Filed Feb 20, 2026 · Engine · 92,567 miles · MO

The contact owns a 2021 Ford F-350. The contact stated that while operating the vehicle, the check engine warning light remained illuminated. The vehicle was taken to the local dealer who diagnosed that the DEF Pump, DEF Pump Lines needed, and DEF heater element needed to be replaced. The vehicle was not repaired. The manufacturer was not notified of the failure. The failure mileage was 92,567.

Filed Feb 19, 2026 · Engine · TX

Cold side intercooler boost tube cracked due to constant vibration impact from coolant overflow hose routed directly above and on top of it. Part and vehicle is available for inspection. The split in the boost hose caused me to loose power while attempting to merge onto a road, almost being hit by another vehicle. After research there are multiple other instances of complaints of the same thing happening to others and multiple aftermarket manufacturers producing replacement and upgraded parts with references and warnings of the same thing happening for the last 10 years. No warning lamps or symptoms prior to failure. After failure no warning lamps but could hear an audible hiss. The vehicle has not yet been inspected by the dealer or police. I was told by their parts people it is a regular failure and the part costs typically around $200 and they only sold it as a full part and not just the rubber replacement hose althought they are separate parts connected with hose clamps.

Filed Feb 16, 2026 · Engine, Fuel system · TX

Driving and abrupt transmission shifting issues.

Filed Dec 1, 2025 · Engine, Fuel system · TX · fire

On 11/19/25 , my 2021 Ford f350 burned to the ground due to engine malfunction. From what the fire department said.

Filed Jul 14, 2025 · Engine, Fuel system · TX

At this point, nothing has happened. This is a fuel pump, bio-diesel issue that can cause a lack of power which is a safety risk. This recall has been active for 7 months with no remedy listed, but according to Ford Motor Company will require a software update? The remedy is replacing the fuel pump with a DCR valve. Waiting for the truck to breakdown and potentially leading to loss of life should not be acceptable. They know about the issue, they say no remedy, yet they are continuing to manufacture these vehicles. Are they manufacturing new vehicles with a known safety risk or did they fix the problem on newer model vehicles and just stonewalling current owners?

Filed Jul 7, 2025 · Engine · UT

There is an active recall on my truck and it is affecting my ability to use my truck for work purposes. I am not allowed to used a vehicle with an open, active recall, therefore I cannot use my truck. This recall has been active for more than six months and a remedy has not yet been identified. I am posting a complaint to try and speed up the recall process, which if I understand correctly is a software update for the engine to reduce biodiesel buildup in the engine which "could" cause loss of power.

Filed May 25, 2025 · Engine, Fuel system · CA

Ongoing Fuel System Failures Related to Recall 24S78 – Request for Escalated Review To Whom It May Concern, My name is [XXX] , and I am the owner of two 2021 Ford F-350 6.7L Power Stroke Diesel trucks, both of which are affected by Recall 24S78 / the federal safety agency Campaign 24V957 concerning biodiesel deposit accumulation in the fuel system and a pending PCM software update. Vehicle Information: VIN [XXX] VIN [XXX] Both vehicles have already experienced critical failures that directly align with the described defect in the recall, including: Failure of the CP4 high-pressure fuel pump Repeated clogging of the water/fuel separator filter Loss of power, extended crank times, and intermittent no-start conditions These issues occurred prior to the recall remedy being available and have compromised vehicle performance and safety. I am requesting: A full inspection and evaluation of the fuel systems under the scope of Recall 24S78 once the software becomes available. Coverage or reimbursement for repair or replacement of the CP4 pump and related components if found to be caused by biodiesel-related damage as described in the recall. A formal service record entry acknowledging these failures for future reference and eligibility under the recall. Escalation of this issue to a Ford regional service manager, if needed. Given the significant safety risk and the known failure history of the CP4 fuel system, I ask that Ford address this matter thoroughly and beyond a software update, if necessary. Please confirm receipt of this inquiry and advise me on next steps. I can be reached at: Phone: [XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

Filed Jul 28, 2024 · Acceleration, Engine · CA · fire

On highway for 2 hours, pulling 5th wheel trailer. Diesel Particulate Filter Cleaning alert went on. Immediately truck lost power, a few other alerts flashed on the screen that couldn't read in time then alert that truck was being put in Neutral which it did. Smoke coming out of engine compartment. Barely coasted to stop on side of freeway. Quickly turned from white smoke to brown. Barely enough time to get me, wife and dog out of the cab before flames coming out of engine. Engine and cab completely burned out.

Filed Jan 25, 2024 · Engine · 85,000 miles · NH · fire

The contact owned a 2021 Ford F-350 Diesel. The contact stated that while the vehicle was parked in the contact's residential yard, the contact noticed the vehicle was on fire. The contact had just parked the vehicle and walked around to the back of the residence. The contact stated that the fire came from under the center area of the hood. The contact attempted to extinguish the fire, however the fire department arrived and extinguished the fire. A fire report was filed. No police report was filed. No injuries were sustained. The vehicle was still located at the contact's residence. The manufacturer was made aware of the failure but did not assist. The failure mileage was approximately 85,000. The VIN was not available