Ford F-350 SD engine failure problems

Filed Oct 17, 2026 · Engine · VA

The vehicle is a 2022 Ford F-350 Super Duty equipped with the 7.3L Godzilla gas engine. This vehicle has experienced recurring, catastrophic internal engine component failures involving the lifters and camshaft, resulting in severe powertrain malfunctions while operating under load. The original factory engine began demonstrating progressive valvetrain symptoms and mechanical ticking at approximately 36,000 miles, which ultimately resulted in a complete engine failure and replacement under warranty at 50,000 miles. A factory replacement engine block was subsequently installed under the Ford Service Parts Warranty. At approximately 75,000 total vehicle miles, the replacement engine began demonstrating the exact same symptoms and lifter failure characteristics. The dealership has officially diagnosed this second engine failure under the manufacturer's Technical Service Bulletin (TSB). While actively hauling a trailer at highway speeds, the vehicle developed severe engine misfires and a pronounced mechanical ticking noise from the valvetrain, creating an immediate and alarming concern of imminent mechanical failure. The vehicle's onboard diagnostics generated critical powertrain malfunction alerts, which were broadcast in real-time via the FordPass application. This recurring failure represents a severe safety hazard. A high-risk valvetrain failure that threatens an immediate breakdown while a heavy-duty truck is actively trailering commercial or heavy loads creates an extreme danger of a high-speed highway collision or roadside emergency. Furthermore, the repeating nature of this failure indicates a systemic manufacturing or design defect in the 7.3L valvetrain components, which presents an ongoing safety risk even after a full engine replacement has been performed.

Filed Oct 2, 2026 · Fuel system · 89,545 miles · CA

The contact owns a 2021 Ford F-350 SD. The contact stated that while driving 50 MPH, the accelerator pedal was depressed; however, the vehicle failed to accelerate as intended. The engine seized, and the vehicle was pulled over to the shoulder of the roadway. The contact stated that while attempting to start the vehicle, the vehicle failed to start. The vehicle was towed to the dealer, where it was diagnosed with high-pressure fuel pump failure. The contact was informed that the high-pressure fuel pump needed to be replaced. In addition, the contact was informed that a repair request had been submitted to the manufacturer; however, the request was denied. The contact was informed that the failure codes displayed were not associated with an unrepaired recall. The contact received notification of the federal safety agency Campaign Number: 24V957000 (Fuel System, Diesel). The manufacturer was contacted by phone, and a case was filed. The failure mileage was approximately 89,545.

Filed Dec 4, 2025 · Fuel system · 138,527 miles · TX

The contact owns a 2020 Ford F-350. The contact stated that while driving at an undisclosed speed, the engine power failure warning light illuminated, and the engine seized. The contact stated that the failure had occurred while towing a small vehicle. The contact coasted the vehicle to the shoulder of the road, which was very unsafe. The contact stated that while attempting to restart the vehicle, the vehicle failed to restart. The vehicle was towed to an independent mechanic, where it was diagnosed with high-pressure fuel pump failure, cylinder rod and head gasket failures. The contact was informed that the high-pressure fuel pump had exploded and sent fuel all over and into the engine. The contact was informed that the engine had failed due to a high-pressure fuel pump failure. The contact was advised to tow the vehicle to the dealer. The contact received notification of the federal safety agency Campaign Number: 24V957000 (Fuel System, Diesel); however, parts for the recall repair were unavailable. The manufacturer was made aware of the failure, and a case was filed. The contact was advised to contact the dealer to schedule a diagnostic test. The failure mileage was approximately 138,527.

Filed Dec 4, 2025 · Engine · MN

I have the 7.3 gas engine. It is now sounding like a typewriter. I've been told I could have a $8,000 to $13,000 repair or total engine replacement. My truck is just under 97,000 miles and this has been a known issue for the Job 1 engines. Ford is not taking ownership of these lifter/cam issue. I was told I could have my engine lock up on me while driving. I am autistic and have an autoimmune issue that cause me to have a disabilities. It does not seem right, that a long term, multiple Ford owner now could have their engine fail or lock up while I'm driving, not to mention I may need a complete new engine from this design error. From what I've read, the Job 2 of these engines they've enlarged oil recyclers or something to correct this issue. Can you help us that have this major saftey issue?

Filed Oct 30, 2025 · Engine · 35,000 miles · WV

The contact owns a 2020 Ford F-350. The contact stated that while driving at an undisclosed speed, the vehicle inadvertently lost motive power. The vehicle returned to normal functionality, but the failure became a regular occurrence. The check engine warning light was illuminated. The vehicle was taken to the dealer, who diagnosed a failure with the lifter in cylinder #2, resulting in damage to the engine. The contact was informed that the engine needed to be replaced. The contact stated that the original engine was replaced at 39,400 miles in 2022. The vehicle was not repaired. The manufacturer was not notified of the failure. The failure mileage was 35,000. The VIN was not available.

Filed Aug 13, 2025 · Engine · 72,000 miles · WA

The contact owns a 2018 Ford F-350. The contact stated while driving 55 MPH and hauling a boat, the vehicle made abnormal banging sounds and stalled. There was no warning light illuminated. The contact was able to pull over to the side of the road. The vehicle was restarted but was undrivable. The vehicle was towed to a dealer, but the diesel mechanic was unavailable to service the vehicle. The vehicle was then towed to a certified mechanic and was diagnosed with a blown engine. The contact was informed that the engine needed to be replaced. The vehicle was being repaired. The contact stated that the failure had occurred in Vancouver Island, Canada, where the vehicle remained for the repair. The manufacturer was notified of the failure, but no assistance was provided. The failure mileage was approximately 72,000.

Filed Jul 14, 2025 · Engine, Fuel system · 172,000 miles · NC

The contact owns a 2017 Ford F-350 SD. The contact stated while driving 65 MPH, the contact drove over and object on the road and the check engine warning light and several other unknown warning lights illuminated. The contact stated that the vehicle was losing motive power. The accelerator pedal was depressed; however, the vehicle failed to respond as needed. The contact stated that the engine seized. The contact was able to coast to the side of the road. The contact attempted to restart the vehicle several times; however, the vehicle failed to restart. The vehicle was towed to the residence. A mechanic arrived at the residence and diagnosed the vehicle with high-pressure and low-pressure fuel pump failures due to the metal shavings inside the fuel rail and fuel injectors. Additionally, the EGR valve was damaged. The contact was advised that the entire fuel system needed to be replaced. The vehicle was not repaired due to the cost. In addition, the vehicle was leaking engine oil while parked. The manufacturer was not informed of the failure. The failure mileage was approximately 172,000.

Filed May 7, 2025 · Fuel system · WA

I own a 2020 Ford F-350 with the 6.7L Power Stroke diesel engine. It uses the Bosch CP4 high-pressure fuel pump, which is known to be prone to sudden, catastrophic failure. If the pump fails, it sends metal shavings through the fuel system, which can cause complete engine shutdown without warning — a dangerous situation while driving. Currently, an unresolved safety recall exists that could cause additional potential damage to this high pressure fuel pump, which only increases the odds of the pump itself failing. That said, the present unresolved recall does not solve the problem of a faulty high pressure fuel pump. Ford is aware of the issue and switched to a more reliable pump in later models, but has not issued a recall or offered repairs to affected vehicles. This is a known defect that affects safety and reliability. While mine has not failed yet, many owners have experienced engine failure due to this pump, and I believe it’s only a matter of time. I’m concerned for my safety and the cost of repair if this part fails.

Filed Mar 27, 2025 · Steering · 15,000 miles · CO · crash · 1 injury

The contact owned a 2024 Ford F-350. The contact stated that while driving at approximately 55 MPH, the steering wheel seized, causing the front passenger side to crash into the front driver side of a commercial vehicle. No warning lights were illuminated. The vehicle ricocheted and rolled over to the driver's side, and did a 180 turn where the tires came to a stop at the bottom of a hill; however, there was no property damage. The air bags deployed. The vehicle was towed to a tow lot, where the vehicle was deemed totaled due to severe front tire damage. The vehicle was then towed to a salvage lot, where it was informed that the link to the ABS unit failed and there was a connectivity issue with the steering module that could have possibly caused the failure. A police report was filed. Due to the impact, the contact's wife broke her right wrist and immediately sought medical attention; the contact's wife was seated on the front passenger side. No one outside of the vehicle was injured. The manufacturer was notified of the failure. The failure mileage was approximately 15,000.

Filed Mar 4, 2025 · Electrical · IL

After purchasing our Ford F350 in October 2024, on [XXX], the truck did not start. The starter appeared to work, but the engine would not turn over. An error message appeared about the fuel gauge on [XXX], but then disappeared by [XXX]. The fuel gauge stopped registering fuel in the tank. Fortunately, the non-starting issue occurred locally and the truck had to be towed to a local Ford dealer. Upon inspection by a Ford dealer service department, it appears as though rodents have chewed through the soy-based polymer used for electrical wiring. It is currently at Ford City in Urbana, Illinois and the dealer is taking photos of the damage. This will likely cost several thousand dollars to repair. My [XXX] daughter uses this truck to pull a horse and trailer to horse shows often several hours away. The engine failure would have put her and her horse at great risk had it happened on her way home when she stopped for gas or at a rest stop. We will likely have a Geico insurance representative examine the damage as well. However, I don't feel this should be at our expense and affect our insurance rates as it is a "defect" in the design of the Ford F350. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)