Ford F-450 SD fuel pump problems

Filed Jan 2, 2025 · Engine, Fuel system · FL

High pressure fuel pump failed while driving towing a trailer. Was able to pull over safely, entire fuel system needs to be replaced. Unknown if anything else was damaged yet. Vehicle is still in for repairs, estimate is between 9-13k parts and labor. I hope it didn't destroy the entire engine.

Filed Jan 9, 2019 · Engine, Fuel system · 15,000 miles · GA

Fuel tank delamination leading to blown engine x2 and fuel pump replacement x2. I use no additives and buy only commercial fuel almost exclusively in northeast georgia.

Filed May 31, 2016 · Engine, Fuel system · 74,000 miles · MS

The high pressure fuel pump failed. Ford claimed that this was from contaminated fuel. Ford has two fuel filters and a water separator. I personally added two additional filters and an additional water separator, for a total of four filters and two separators. Ford also has a water in fuel light that is supposed to alert the driver to contamination. At no time did this light come on. In short, I believe ford has a defective fuel pump and a defective filtration and water alerting system. This truck shutdown, with no warning at 70 MPH on a limited access highway. Ford refuses to address the problem and continues to blame the owner. This is a safety issue and I was fortunate that there was light traffic and I was able to safely steer the powerless truck to the side of the road. In researching this issue, I've seen that there are numerous reports of the same problem on the 6.7 liter powerstroke diesel engine from 2011 on.

Filed Jun 26, 2015 · Engine, Fuel system · 124,000 miles · TX

I was making a left hand turn afyer stoping at a traffic light and loss power. The engine light came on and the turbo pressure gauge dropped. I took the truck into the dealer and the dealer told me that a manafold bolt had broken which caused a bad exhuast leak. Repair cost was $3500. I drove the truck less than 50 miles over the next two days and the problem happened again with loss of power and engine light on. I took the truck back the dealer and was informed that the high pressure fuel pump had exploded and sent metal debris through out the fuel system. I was then told the repair cost were going to $7500 ($6000 for parts and $1500 for labor). This is a bad ford engineering design problem and should be paid for by ford as well as a recall on all models using the same hpfp assembly.

Filed Jun 26, 2015 · Fuel system · 8,200 miles · OH

We are original owners.truck only used to haul drinking water. That is why the mileage is low. In march we smelled gasoline in drive but we have several cars and couldn't pinpoint problem or see gas on ground. We had filled up the truck and thought maybe some gas had spilled. After that we had several incidences of driving down road 40-60 MPH and truck slowed to 20mph. It stalled and came toa complete stop on a few occasions. We were able to restart it. Local shop ran diagnostic check and nothing was evident. Took it to ford dealer today and mechanic says the gas tank has imploded due to crack and dirt got in and fuel pump is clogged. We have never had any incidence of damage to our vehicle and no incident that would cause the fuel tank to split. We found on the internet a class action lawsuit in 2012 for the same problem and model of vehicle we have.we were never notified of a recall or potential problem. This is a safety issue as the vehicle suddenly loses power and it is difficult to steer to the berm.

Filed Dec 23, 2014 · Fuel system · 96,356 miles · VA

The vehicle involved is a horton ambulance on a ford f450 chasis. While on an emergency call the unit stopped operating and then engine would no longer start. The vehicle was towed to ted britt ford's truck repair center in chantilly. Upon examination they found that due to the fuel tank delaminating, debris had damaged the fuel pump and fuel system. Spoke with ford in regards to recall or repair assistance as this is a highly documented issue. Ford refuses to acknowledge this as an ongoing issue and will not take ownership for the defective fuel tanks. At this time we are considering having to replace all of our ford steel fuel tanks as we have no way to prevent this damage to our vehicles and ford refuses to resolve the issue.

Filed Oct 2, 2014 · Engine, Fuel system · 650 miles · IN

Tl* the contact owns a 2015 ford f-450 sd. While driving approximately 55 MPH, the engine warning indicator illuminated and the engine stalled without warning. The vehicle was towed to an independent mechanic who stated that the fuel pump and module needed to be replaced. The vehicle was repaired, but the failure recurred. The dealer was unable to determine the cause of the failure. The failure occurred on multiple occasions. The vehicle was not repaired. The manufacturer was not notified of the failure. The approximate failure mileage was 650.

Filed Apr 3, 2014 · Electrical, Engine · 64,075 miles · TN

Vehicle lost complete power while driving on interstate at cruising speed. There were absolutely no warnings, the engine just quit, disabling the vehicle in high speed traffic. The dealer repair was to replace wiring harness for high pressure fuel pump due to wires shorting the engine after the insulation was chafed by internal contact with other engine parts, which was a known issue with this engine for builds prior to august 20, 2007, according to a ford tsb: 07-26-2. This part is completely internal and not subject to inspection until failure. My family and I were extremely fortunate that we were able to get safely to the shoulder of the interstate with many semi's and cars around us when the failure occurred. Also, since engine wouldn't start at all, we were subjected to extreme cold weather conditions while waiting for tow vehicle, over 2 hours. This is a potential life-threatening defect!! Losing all power in seconds without warning in high-speed traffic is unacceptable, ford!

Filed Nov 3, 2012 · Engine, Fuel system · 59,000 miles · CA

Vehicle looses power, no acceleration, occurs most frequently under heavy load or high acceleration demand, told by ford dealer the problem is caused by de-laminating fuel tank resulting in fuel tank coating entering the fuel system and obstructing diesel fuel flow to motor when high demand for duel occurs. Near collision at freeway speeds and was very dangerous to pull over when there was no shoulder. Ford dealer states the cost to repair is over $3,500.00 and open ended depending on whether the fuel tank coating entered the motor or injectors. They want to start by replacing the harness, fuel tank and fuel pump and go from there. Ford refuses to honor this clear manufacturing defect.

Filed Oct 6, 2012 · Fuel system · 34,918 miles · CA

In 2006 34,918 miles ford had to replace the fuel pump on my 2005 f450 truck. They also replaced the injectors several times also replaced the turbo. They have found rust in the system, this is caused from the liner in the tank has fallen apart. The truck runs real bad, bucking and losing power. The mileage on the truck now is 125000. I have changed my fuel filter many times and within mins after changing the bucking starts. I live in the san francisco area and I know they regulate the fuel. The shop wants $4000.00 to change my injectors, then $2100.00 to change the tank. This is said when a fuel tank falls apart in side and they want you to pay the cost. I paid $50000 when I bought this f450. I know I will not buy another ford product if I have to pay this bill. My 3 gmc trucks are running great, and so was our dodge. I hope you can help me with on going problem. [xxx] information redacted pursuant to the freedom of information act (foia), 5 u.s.c. 552(b)(6).