2015 Ford Transit fuel system problems

Filed Mar 13, 2026 · Fuel system · WA

My 2015 Ford Transit 350 equipped with the 3.2L diesel engine experienced a failure of the high-pressure fuel injection pump at approximately 72,000 miles. The pump generated metallic debris which contaminated the entire fuel system. The vehicle began experiencing drivability problems including loss of power and intermittent stalling. The vehicle was diagnosed by a Ford dealership, where metal contamination was found in the fuel system. The repair required replacement of the high-pressure fuel pump, injectors, high-pressure fuel lines, and fuel rail, along with flushing and cleaning of the fuel tank and fuel system. The total repair cost was approximately $11,500. This failure appears to match the defect described in Ford safety recall 16S32 for certain 2015–2016 Ford Transit vehicles equipped with the same 3.2L diesel engine, where scuffing in the fuel injection pump can create metallic debris that contaminates the fuel system. My vehicle was built July 16, 2015, essentially within the same production period described in the recall, but my VIN was not included in the recall population. Because this failure required replacement of most of the fuel system components and created a sudden loss of power risk while driving, I am reporting this issue so it can be investigated and considered for inclusion with similar failures.

Filed Jul 11, 2025 · Fuel system, Transmission · VA

Initially my van began with a simple engine stall and total electrical failure while driving down the highway. The check engine light came on and the van was taken to the dealer to explore the problem. Multiple codes were found and were fixed which included coils, O2 sensors, fuel pump control module and several other things. Then a few days after picking the van up from the shop it had another engine stall while driving and check engine light. After taking it to the auto shop we informed of additional codes and problems which include catalytic converters, new battery, new alternator, and other things. Picked the vehicle from dealer and a few hours later the engine light came on along with engine stall while driving. I took it back to the dealer and I report problems with poor engine performance vehicle misfiring, rough running, poor fuel performance, check engine light, several engine stalls. Dealer diagnosed the van with needing a new Powertrain Control Module. Repairs were completed and upon picking the van up from the dealer the van wouldn't start, and dealer diagnosed the van with a bad fuel pump. To date we have spent over 30K in repairs, nearly 4 vehicle accidents due to engine failures, over 4 vehicle tow's, 5 battery replacements, and the van is currently awaiting new fuel pump replacement.

Filed Feb 11, 2025 · Engine, Fuel system · 109,000 miles · CA

The contact owns a 2015 Ford Transit. The contact stated while driving at an undisclosed speed, the message "Exhaust filter overloaded, drive to clean", after which the vehicle entered LIMP Mode, and was unable to accelerate above 30 MPH. The check engine warning light was illuminated. The vehicle was taken to the dealer, who diagnosed a failure with the Diesel Particulate Filter (DPF). The vehicle was repaired under Customer Satisfaction Program: 23M01, but the failure reoccurred. The vehicle was then taken to an independent mechanic, who diagnosed a failure with the Diesel Particulate Filter (DPF). The vehicle was not repaired. The manufacturer was notified of the failure, and a case was opened. The failure mileage was 109,000.

Filed Dec 16, 2024 · Fuel system · 120,000 miles · OH

The contact owns a 2015 Ford Transit. The contact stated while driving at an undisclosed speed, the check engine warning light illuminated, and the vehicle lost motive power. The vehicle was taken to the dealer where it was diagnosed with a fractured front windshield cowl. In addition, rainwater was entering the engine compartment due to the fractured windshield cowl. The vehicle was diagnosed with a failed fuel rail. The contact was informed that the fuel rail needed to be replaced. The vehicle was repaired; however, the failure reoccurred. The vehicle was taken back to the dealer where it was diagnosed with a failed fuel system, failed fuel injector, and a failed glow plug. The contact was informed that the fuel system, fuel injector, and glow plug needed to be replaced. The vehicle was not repaired. The failure reoccurred. The vehicle was not diagnosed or repaired by an independent mechanic or the dealer. The contact researched Technical Service Bulletin: 19-2091. The manufacturer was made aware of the failure but provided no assistance. The failure mileage was approximately 120,000.

Filed Aug 29, 2024 · Brakes, Fuel system · CO

When I was driving, the driveshaft came apart and everything underneath broke including fuel lines, brake lines, and turbo lines. Ford is refusing to pay for the recall repair.

Filed Mar 29, 2024 · Fuel system · NY

The car stalled without warning while driving in heavy fast traffic which nearly caused a accident. It turns out that the recall Ford program [XXX] that addressed this issue was not performed by the dealership (even when it was serviced repeatedly at dealer) as they did not have the parts. Now Ford claims they will not fix the issue as the program expired months ago. Former ford stock owner (never again). [XXX] [XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

Filed Jan 10, 2024 · Brakes, Fuel system · IN

Vehicle has an open recall for flexible coupling from the transmission to the drive shaft. This broke and damaged the fuel line, broke the brake lines and damage some other components. Took it to the Webb Ford in Highland IN and they informed me they will cover just the flexible connector and not the other damage caused by the failure, stating they send a lot of recall notices to the previous owner. Cost for the repairs are aprox $3,100. Since the failed coupling caused the damage, why i am asked to pay for the repairs caused by the recall component. I am a new owner of the vehicle and never received any notices from Ford. Thank you

Filed Nov 20, 2023 · Electrical, Engine · FL

While driving van displayed "engine fault service now" and lost all power in the middle of the road. I was able to pull over turn it off and back on and is running. This is happened to nearly our whole fleet of Ford Transits. I have put in a claim with Ford, as this is an extremely dangerous safety issue. It is causing my employees to feel like we are providing unsafe transportation, it is causing lost revenue due to vehicles being out of service and it is a potential insurance claim/workers comp issue. Ford needs to take action.

Filed Nov 15, 2023 · Electrical, Engine · FL · crash

While driving on the highway, acceleration shuts down and I lose the ability to control speed. I had to coast to the side of the road even though the engine was still running and I was rear-ended. After I shut off the vehicle, it turned on and returned to normal operation. This has happened multiple times. The throttle body was replaced in 2021 at 117,444 miles and is having this issue again now. I have a fleet of Transit vehicles and this has happened on 4 transits from 2015-2018 a total of 6 times now. This is an ongoing issue that Ford needs to address.

Filed Mar 28, 2023 · Engine, Fuel system · MO

The 2015 Ford Transit was designed such that rainwater from the windshield drains into the engine and sometimes floods the air filter system. This issue is documented in this NTSA TSB where it's stated: To resolve this condition, install updated water management hardware and/or a revised air cleaner cover. We were driving along an interstate and were on a long viaduct while it was raining. The engine stalled and we were lucky enough that the vehicle was able to reach the end of the viaduct. I had my spouse and 7 children in the van. We received a tow but myself and 2 children were forced to walk along the interstate as the tow couldn't hold all of us. As this is a large passenger van, it's my opinion as a licensed professional engineer that it poses an substantial fatality risk to occupants because the likelihood of fatalities on interstates is tremendous due to traveling speed. Ford designed a windshield that puts water into the air system which creates a known safety and 100% preventable condition. This should be a factory safety recall repaired in all Ford Transits. Most of these vans are used by government agencies for employee or prison transport or by church/community service groups and has a high percentage of mass casualty or PDO when the system fails. There are multiple YouTube and Ford Transit auto forums highlighting this safety design flaw so it is a well known and attributable problem created by substandard Ford engineering.