What 207 owners told NHTSA about the 2015 Ford F-350 Super Crew

Failed CP4 design. $10000 to fix a known issue with a failed design that Gm had a class action lawsuit with.

NHTSA ODI 11612633

This vehicle developed a fuel leak in the area of the top of the engine which resulted in a fire that destroyed the vehicle. I spoke to the Ford Motor Company and they said that there are no recalls or Technical Service Bulletins regarding this. I just wanted to make you aware of my experience so if anyone else experienced this it may show a pattern. Thank You

NHTSA ODI 11483655

1/4/2022 – TRAVELING TO SOUTHERN OHIO IN F-350. Engine light came on. Truck info screen showed Exhaust Fluid System Fault – indicating truck would lock to 50 mph within a certain number of miles, then possibly shut down. Finally got in touch with Ford dealership in Chillicothe and took truck there. They determined it was a DEF heater and pump causing the issue, and that it would be covered by Ford as an extended warranty issue. Ford decided our truck was not covered. On 1/11, Ford added a new campaign – 21M01, Reductant Heater and Sender Assembly, covering the cost of replacement of these items. We were told we needed to pay the repair and Ford would reimburse. To this date, we have not been reimbursed - in fact have pretty much been ignored. The sensor recalibration they did caused the particulate filter to fail. Ford has said they won't replace, even though service manager has said the filter failed because Ford had them recalibrate the sensor. We could have been stranded 140 miles from home because of this design fault that Ford knows about - but is not being forced to take care of. Our truck has less than 64000 miles on it and was purchased new by me in April 2014. Will you please strongly encourage Ford to stand by this defective equipment they have installed in their vehicles, as their 'customer satisfaction campaigns' do not adequately encourage them to fix these faulty issues. Volkswagen and Audi both stand by their defective equipment. Consumer wants assistance getting Ford to pay for repairs.

NHTSA ODI 11457166

Cp4 fuel pump failure, upon failure repair was $9300.00, ford obviously knows of the problem as their is a kit that can be purchased for this catastrophic failure{fuel line replacement, fuel injection replacement, both fuel pump replacement , drop and flush fuel tank.}

NHTSA ODI 11443761

CP4 High pressure fuel injection pump blew up, causing the truck to need a 17,000$ fuel system at 93k miles. Thankfully I had warranty with Ford- however what happens when it’s over and it goes again? Pay 17,000$ out of pocket? Ford needs to recall this just like dodge / Cummins. 17,000$ out of pocket can be crippling to the average American.

NHTSA ODI 11443701

Check engine light came on in my 2015 F 3 50 super duty crew cab truck. Upon inspection at the Ford dealership I was told the Reductant Heater And Sender Assembly Need to be replaced at a cost of $1100. This is happening within 60 days of heat sensor recall being done. When I look into this topic this repair has a recall on it for F2 50s through F5 50’s including various years up to 2015, but the F3 50 is only up to 2012.

NHTSA ODI 11442414

P20BA - DEF Reductant Heater Code for a defective DEF reductant heater on a 2015 F-350 6.7L diesel with 57,500 miles NOT covered under dealer emissions warranty.

NHTSA ODI 11441227

Took truck in for smog they notified me that there is a factory recall manufacturer campaign # 21E01 , recall date 3/16/2021. Description CALIBRATION FOR NOX SENSOR AND SCR SYSTEM FAULTS

NHTSA ODI 11439137

HAVE TO REV GAS PADDLE ON VEHICLE TO TAKE OFF..VEHICLE ALSO STALLS WHILE DRIVING DOWN THE HIGHWAY..

NHTSA ODI 11396058

SAME PROBLEM W/ THE DEF HEATING UNIT AS ON EARLIER/SIMILAR F-SERIES TRUCKS THAT HAVE COMPELLED FORD TO ISSUE EXTENDED WARRANTY (SEE CUSTOMER SATISFACTION PROGRAM 18M01) -- A DTC208A ERROR COMES UP, INDICATING FAILURE IN THE DEF SENDER/HEATER. NOT CLEAR WHY FORD IS OMITTING THE 2015 F350 POWERSTROKES WHEN THEY'RE USING THE SAME PART AND BUILT IN THE SAME FACTORY AS THE MODELS THAT HAVE HAD THE WARRANTY EXTENDED.

NHTSA ODI 11270968

ON MY 2115 FORD F 350 POWERSTROKE DIESEL THE CHECK ENGINE LIGHT CAME ON AND IT DE RATED THE POWER. I READ THE CEL CODE AND ITS PB20A WHICH IS A REDACTANT HEATER PERFORMANCE FAILURE. THIS PROBLEM IS COVERED UNDER WARRANTY FOR ALL MODELS 2011-14, F250-F 550 AND 2015 F450, F550 ONLY. FORD ISN'T COVERING THE F250 OF F350 IN THE 2015 YEARS. MY TRUCK MEETS THE DATE AND MANUFACTURING PLANT CRITERIA AND IT IS NO DRIVABLE BECAUSE OF THIS EMISSIONS CONTROL PART FAILURE. THE REDACDANT HEATER KEEPS THE DIESEL EXHAUST FLUID FROM FREEZING AND RENDERS THE VEHICLE UN DRIVABLE WHEN IT FALIS.

NHTSA ODI 11265376

I WAS DRIVING OUT OF STATE (NY) WHEN AN ALERT STATED "LOW FUEL PRESSURE) AND THE VEHICLE SLOWED TO 5-10 MPH WHILE TRAVELING ON THE INTERSTATE. UPON EXITING, THE VEHICLE STOPPED RUNNING LEAVING ME AND MY FAMILY STRANDED. I HAD IT TOWED TO A LOCAL SHOP WHICH INFORMED ME THE BOSCH HIGH PRESSURE FUEL PUMP WAS NOT DELIVERING THE REQUIRED PRESSURE (/,000 PSI). UPON CONTACTING THE FORD DEALERSHIP WHERE THE VEHICLE WAS PURCHASED, I WAS INFORMED THE VEHICLE EXCEEDED WARRANTY MILES (100,000/129,239) AND THE COST OF THE PUMP WAS $1,245 WITH EXCHANGE PRIOR TO LABOR CHARGES. IN ALL, FORD DEALER WANTS NEARLY $5,000 TO REPAIR THE PUMP WHICH WAS POORLY DESIGNED.

NHTSA ODI 11254280

I OWN A 2015 FORD F-350SD WITH APPROXIMATELY 42,000 MILES THAT I BOUGHT FROM THE FORD DEALER IN SEPTEMBER OF 2018. SO, I HAVEN'T EVEN OWNED THE TRUCK A YEAR YET. ON JULY 12, 2019 I WAS DRIVING DOWN I15 HEADED TO A CAMPING TRIP. ALL OF A SUDDEN, MY CHECK ENGINE LIGHT CAME ON AND THEN A MESSAGE SAYING REDUCED ENGINE POWER AND MY TRUCK WENT FROM 70MPH TO 5MPH AND JUST BARELY GOT ME OFF THE INTERSTATE. I HAD THE TRUCK TOWED TO THE FORD DEALER WHERE I PURCHASED IT. THEY DIAGNOSED IT AND SAID THERE'S METAL THROUGHOUT THE FUEL SYSTEM, THE HPFP IS GOING BAD AND WEARING OUT, THERE IS ALSO RUST AND WATER IN THE FUEL RAIL. IN ORDER TO FIX THE PROBLEM, THE BILL WILL BE A LITTLE OVER $11,000. IN DECEMBER RIGHT AFTER I BOUGHT THE TRUCK, I TOOK IT INTO THE FORD DEALER AND HAD THEM FULLY SERVICE THE TRUCK, CHECK THE OIL, CHANGE BOTH FUEL FILTERS, ETC. I HAVE ALL RECEIPTS TO SHOW FORD THAT I HAVE MAINTAINED THE TRUCK. I HAVE FULLY MAINTAINED THE TRUCK AND HAVE DRAINED THE WATER SEPARATOR MONTHLY SINCE I PURCHASED THE TRUCK. I HAVE DONE EVERYTHING ON MY PART TO MAKE SURE THE TRUCK IS WELL CARED FOR AND MAINTAINED. I HAVE NOW BEEN FIGHTING WITH FORD CORPORATE FOR 5 WEEKS NOW AND THEY ARE SAYING THIS ISSUE ISN'T COVERED BY WARRANTY. IT'S A SHAME THAT YOU BUY A TRUCK FROM THE FORD DEALER WITH A 100,000 MILE WARRANTY AND NOW FORD IS CLAIMING THAT THIS ISSUE ISN'T COVERED BY WARRANTY. THIS IS A KNOWN FAULTY FUEL PUMP THAT WEARS OUT PREMATURELY AND IS COSTING CONSUMERS TENS OF THOUSANDS OF DOLLARS TO REPAIR AND FORD WILL NOT STAND BEHIND THEIR WARRANTY! THIS IS A SHAME AND RIDICULOUS ON FORDS END!

NHTSA ODI 11244230

HAD VEHICLE 8 MONTHS. DRIVING ON INTERSTATE 95 PULLING MY CAMPER, "LOW FUEL PRESSURE" LIGHT CAME ON, PULLED OVER IMMEDIATELY. SAW SMOKE, THEN FIRE. GOT OUT OF TRUCK WITH MY DOG AND CALLED 911. REPORT ATTACHED.

NHTSA ODI 11220464

DIESEL EXHAUST FLUID REDUCTANT HEATER FAULT, CHECK ENGINE LIGHT HAS ILLUMINATED AND IS NOT COVERED UNDER PREVIOUS RECALLS. RECURRING PROBLEM FOR FORD SUPER DUTY THAT NEEDS TO BE EXTENDED FOR THIS MODEL AS IT IS THE SAME PROBLEM THAT PREVIOUS ATTENTION WAS GIVEN TO. IT IS A EMISSIONS PROBLEM THAT FAILS ON THESE TRUCKS.

NHTSA ODI 11187014

EXHAUST FILTER CLEANING WHEN THAT WARNING COMES ON MY TRUCKS ENGINE IS REALLY ROUGH AND SHAKES. THIS IS WHEN DRIVING TO CLEAR THE EXHAUST FILTER.

NHTSA ODI 11111026

EXHAUST FLUID MESSAGE ON DASH THAT SPEED WILL BE LIMITED TO IN 50 MILES. WENT AND BOUGHT A NEW JUG OF BLUE DEF. IT TOOK 2 GALLONS TO FILL TO RUNNING OVER. THEN BEFORE I GOT TO THE KENAI, AK DEALER, IT SAYS ENGINE WILL IDLE UPON RESTART. THE KENAI, AK DEALER SAID UP AND DOWN STREAM NOX SENSORS HAD FAILED AND RESET THE CODES. 15 MILES LATER, I GET AND "EXHAUST SYSTEM FAILURE" ENGINE WILL IDLE SOON. MADE IT HOME(40 MILES AT 10PM AND RAINING) THEN IT SAYS ENGINE IDLED, CHECK OPERATOR MANUAL. BASICALLY IT THINKS MY DEF TANK IS EMPTY, BUT IT HAS ONLY 75 MILES ON A COMPLETELY FULL TANK.

NHTSA ODI 10893458

DEF TANK FILLED AT 7300 MILES. AT 9600 MILES A "EXHAUST FLUID LOW" 50 MILES TIL ENGINE IDLE. PICKED UP EXHAUST FLUID AND REFILLED-ONLY 2 GALS ADDED TO OVERFLOWING. DID NOT RESET, WENT TO STANLEY FORD KENAI, AK. COUNTDOWN WENT ON, THEN"ENGINE IDLE AT NEXT RESTART" DEALER SAYS TO BAD NOX SENSORS, REPLACED AND CODES CLEARED. 15 MILES LATER, EXHAUST SYSTEM FAILURE" ENGINE WILL IDLE SOON" FORTUNATELY I MADE IT HOME IN THE DARK AND 40 MILES IN THE RAIN. NOW IT HAS GONE INTO THE "ENGINE IDLE" MODE AND "CHECK YOUR MANUAL" DEALER CALLED, TOW TRUCK CALLED, SOON TO BE GOING BACK TO DEALER.

NHTSA ODI 10893529

DURING REGENERATION OF THE DIESEL PARTICULATE FILTER THE TRUCK LOSES POWER AND OPERATES ROUGHLY. THIS LAST OCCURRED AS I WAS MERGING INTO TRAFFIC ON THE HIGHWAY DURING SLICK ROAD CONDITIONS. THIS COULD HAVE VERY EASILY RESULTED IN LOSS OF TRACTION AND/OR COLLISION AS I WAS UNABLE TO ACCELERATE TO SPEED.

NHTSA ODI 10819844

THE VEHICLE IS A DIESEL, AND WHEN IT ENTERS REGEN MODE TO CLEAN THE EXHAUST FILTER APP. ONE MINUTES AFTERWARD THE ENGINE ROUGHS VERY ROUGH AND WILL NOT ACCELERATE AT ALL. THIS CONTINUES FOR 2-3 MINUTES. THE TRUCK REMAINS RUNNING, BUT WILL PRESSING THE GAS PEDAL AT ALL RESULTS IN BUCKING AND SHAKING UNTIL I TAKE MY FOOT OFF THE PEDAL. THE ISSUE BEGAN AT AROUND 2500-3000 MILES, AND THERE ARE CURRENTLY 8400 ON THE TRUCK. IT HAPPENS EVERY TIME THE EXHAUST FILTER IS CLEANED.

NHTSA ODI 10789072

WOULD NOT REGENERATE WHEN REQUIRED. WENT INTO FILTER FULL SERVICE NOW MODE. THEN CHECK ENGINE LIGHT CAME ON.

NHTSA ODI 10767568

BOUGHT TRUCK BRAND NEW IN DECEMBER 2014. AT APPROX. 5,000 (STILL DURING THE DIESEL ENGINE BREAK IN PERIOD) WHILE DRIVING THRU AN INTERSECTION IN TRAFFIC THE TRUCK AND MOTOR STARTED VIOLENTLY SHAKING/BUCKING WITH THE MOTOR MAKING A LOUD KNOCKING NOISE- THE TRUCK THEN HAD A TOTAL LOSS OF POWER IN WHICH I WAS UNABLE TO SAFELY ACCELERATE. THE TRUCK THEN WENT TO THE DEALER IN WHICH I WAS TOLD THEY COULD FIND NOTHING WRONG. THE TRUCK NOW BEEN IN AN OUT OF THE SHOP NUMEROUS TIMES BECAUSE THE PROBLEM KEEPS OCCURRING. FORD RELEASED A TSB STATING THAT ITS NORMAL FOR THEIR TRUCKS TO EXPERIENCE "ROUGH RUNNING" DURING THE EXHAUST REGEN CYCLE. THE EXPERIENCES THAT HAVE OCCURRED WITH MY TRUCK HAVE NO CORRELATION TO THE REGEN CYCLE AND SEEM TO HAPPEN AT RANDOM TIMES. THE TRUCK HAS BECOME DANGEROUS TO DRIVE AND PULL MY HORSES WITH AS THE SHAKING/BUCKING IS SO VIOLENT AND WITH A LOSS OF POWER AND UNABLE TO ACCELERATE ITS SCARY TO EVEN ATTEMPT TO DRIVE IN TRAFFIC.

NHTSA ODI 10746170