What 286 owners told NHTSA about the 2016 Ford F-250 Supercab

On September 3, 2023, the fuel pump failed while the truck was in the corner of an on-ramp for an interstate. The truck immediately lost power while in the corner causing a loss of control of steering. This resulted in a near collision with a concrete dividing wall while attempting to maintain control of the vehicle until the vehicle came to a stop. There were no warnings, check engine lights, or other issues with the truck prior to the incident. The truck was inspected by a diesel repair company where it was determined that the Bosch CP4 fuel pump failed resulting in a catastrophic fuel system failure with metal shavings contaminating the complete fuel system. This required a complete fuel system replacement.

NHTSA ODI 11727559

The contact owns a 2016 Ford F-250. The contact stated while driving at an undisclosed speed, the check engine warning light illuminated. The vehicle was taken to the dealer but was not diagnosed or repaired. The manufacturer was made aware of the failure and referred the contact to the NHSTA Hotline for assistance. The failure mileage was approximately 16,000.

NHTSA ODI 11612413

I was attempting to access the interstate when my truck began to immediately shut down at 70 miles per hour. I received a warning as the engine shut down stating that my engine power was reduced. At the exact moment the message displayed, the truck immediately died at 70 mph leaving me to be forced to wrestle the steering wheel to maneuver the truck to the side of the interstate as I had no power steering due to the failure. I have been informed that my truck is a victim of a catastrophic engine failure as a result of a failed CP4 OEM Bosch high-pressure fuel pump. The failure has resulted in the complete contamination of the fuel system requiring a complete overhaul with parts cost at $6,600.00 and approximately $4,000.00 in labor for a total of more than $10,600.00. on a low mileage diesel.

NHTSA ODI 11547948

I recently received a warning for P20BA informing me that the truck had a failed DEF heater. The unit was not in warranty and parts estimate for this is $360.00-$400.00 with an additional $400.00 dollars in labor for a total cost at minimum of $800.00 to $1,000.00 to replace a part that Ford Motor Company knew was a high failure rate part that would not meet industry standards.

NHTSA ODI 11547951

The contact owned a Ford F-250. The contact stated that while driving at approximately 50 MPH the contact heard a loud pop from the engine. The contact stated that immediately after hearing the noise smoke started to emanate from the engine. The vehicle caught fire. The driver sustained a hand injury. Medical attention was needed. The fire department extinguished the fire. The fire and police reports were available. The vehicle was towed to an impound lot. The manufacturer was notified of the failure. The failure mileage was approximately 137,000.

NHTSA ODI 11541185

The contact owns a 2016 Ford F-250. The contact stated that the check engine warning light was illuminated. The vehicle was taken to the dealer for a diagnostic test; the diagnostic test showed that the rear knock sensor was defective and needed to be replaced. The contact was informed by the dealer and the manufacturer that the vehicle was not covered under warranty. The contact was referred to NHTSA Hotline for assistance. The vehicle was not repaired and remained in the possession of the dealer. The failure mileage was approximately 71,000.

NHTSA ODI 11522931

The contact owns a 2016 Ford F-250. The contact stated that the check engine warning light illuminated intermittently. The vehicle was taken to several independent mechanics, where the warning light was reset; however, the failure persisted. The vehicle was taken to the dealer, where it was diagnosed that the reductant heater had failed and needed to be replaced. The contact became aware that the VIN was included in Ford Service Campaign Number: 20M01; however, the dealer informed the contact that the vehicle could not be repaired under the Service Campaign due to the mileage. The dealer referred the contact to the NHTSA Hotline for assistance. The vehicle was not repaired. The manufacturer was not notified of the failure. The failure mileage was approximately 117,000.

NHTSA ODI 11517876

Maintained Truck and did all required maintenance. Truck blew up while driving. All oil leaked out. Ford found hole in upper oil pan. Truck had poor fuel Truck has exhaust issues and ford can’t correct Lost truck and a lot of money , engine needs to be replaced.

NHTSA ODI 11512492

The contact owns a 2016 Ford F-250. The contact stated that the check engine warning light illuminated on the instrument panel with error code P2002. The vehicle was taken to the dealer and the contact was informed that the diesel exhaust fluid (DEF) needed to be replaced. The vehicle was not repaired. The manufacturer was contacted and the contact was referred to the NHTSA Hotline. The failure mileage was 106,000.

NHTSA ODI 11482023

Check engine code P2002. Dealer indicated the diesel particulate filter needs replaced. Found Ford Customer Satisfaction Program 20M06 which based on the description covers the issue but Ford says 20M06 is not attached to my VIN even though it represents the exact same issue.

NHTSA ODI 11472980

My engine light has come on as a result of an emissions problem. I have taken my truck to Ford service dept. 5 times, each time, they make an adjustment and claim there is nothing else to be done. How can I resolve this problem?

NHTSA ODI 11453804

Diagnostic Trouble Code P21B0 Reductant level sensor C circuit high I know several people that have had this same issue concerning the DEF tank assembly costing close to $1000. A recall was issued for earlier models but doesnt cover my truck that now has this same issue. It's this type of failure that makes owners of diesel vehicles contemplate deleting these pollution reducing systems. Please consider an expanded recall.

NHTSA ODI 11447252

The contact owns a 2016 Ford F-250. The contact stated that an unknown recall repair was completed on the vehicle however, two hours after the repair, the check engine warning light illuminated. The vehicle was towed to the dealer who diagnosed that the DEF heater needed to be replaced and the contact would be responsible for the cost of the repair. The manufacturer was notified of the failure and referred the contact to the dealer. The vehicle was not repaired. The approximate failure mileage 120,000.

NHTSA ODI 11435919

WHILE OPERATING IN BELOW FREEZING TEMPERATURES ON THE HIGHWAY, THE DIESEL EXHAUST FLUID (DEF) TANK HEATER FAILED, ALLOWING THE DEF TO FREEZE INSIDE THE TANK. WITH THE DEF FROZEN, IT WAS NOT ABLE TO BE INJECTED INTO THE EXHAUST RESULTING IN HIGHER LEVELS OF NITROGEN OXIDES (NOX) TO BE RELEASED INTO THE ATMOSPHERE THROUGH THE VEHICLES EXHAUST.

NHTSA ODI 11396549

THE REDUCTANT HEATER AND SENDER ASSEMBLY FAILED CAUSING THE MALFUNCTION INDICATOR TO LIGHT. THIS IS THE SAME PROBLEM ADDRESSED FOR THE 2011-2015 MODEL YEAR PER CUSTOMER SATISFACTION PROGRAM 18M01. THE FAULT WAS CONFIRMED BY RIVERTOWN FORD IN COLUMBUS GA VIA DIAGNOSTIC TOOL. CLEARLY THE ISSUE PER CUSTOMER SATISFACTION PROGRAM 18M01 REMAINS AND IS AFFECTING 2016 MODEL YEAR.

NHTSA ODI 11378297

RADIATOR IS LEAKING AND NEEDS TO BE REPLACED. THIS IS THE THIRD TIME IN 77,000 MILES THE RADIATOR HAS NEEDED TO BE REPLACED.

NHTSA ODI 11321765

SERVICE ENGINE LIGHT CAME ON TWICE WHILE VEHICLE WAS UNDER WARRANTY. DEALER SERVICED BOTH TIMES AND WAS UNABLE TO RECTIFY OR UNDERSTAND THE PROBLEM. THEY ONLY CLEARED THE FAULT CODES. THE CODE IDENTIFIED WAS FOR THE REDUCTANT HEATER PUMP - LOW VOLTAGE. THE SAME CODE JUST CAME BACK ON FOR THE 3RD TIME - THIS TIME IDENTIFIED BY A DIESEL PERFORMANCE SHOP - WITH ADVICE TO REPLACE THE REDUCTANT PUMP. PREVIOUS MAKE AND MODEL SUPERDUTY TRUCKS HAVE HAD RECALLS FOR THE SAME THING. THIS IS AN OBVIOUS ISSUE, NOT SURE WHY FORD SERVICE SHOPS COULD NOT RECTIFY. TRUCK IS NOW OUT OF WARRANTY AND I AM FORCED TO PAY OUT OF POCKET. UNACCEPTABLE SERVICE AND CARE! -COLD WEATHER EACH TIME -ENGINE LIGHT COMES ON - SAME CODE EACH TIME -REDUCED SPEED AND SLUGGISH PERFORMANCE -CODE CLEARED - TRUCK PERFORMS NORMAL -OBVIOUS THAT THE REDUCTANT HEAT PUMP IS NOT DOING WHAT IT IS DESIGNED TO DO.

NHTSA ODI 11309982

TL* THE CONTACT OWNED A 2016 FORD F-250. THE CONTACT STATED THAT WHILE HER SON WAS DRIVING 35 MPH AND TOWING A TRAILER WITH HIS ATV ON, A VEHICLE IN FRONT WAS MAKING A LEFT TURN AND THE DRIVER DEPRESSED THE BRAKE PEDAL. AN UNKNOWN WARNING LIGHT ILLUMINATED AND THE VEHICLE STALLED. THE CONTACT LOST CONTROL OF THE VEHICLE AND CRASHED INTO THE VEHICLE IN FRONT THAT WAS MAKING A LEFT TURN. THE VEHICLE CONTINUED 125 FEET DOWN THE ROAD, CROSSED OVER TO THE OPPOSITE LANES, CRASHED INTO SOME TREES WHERE IT EVENTUALLY CAME TO A STOP. NO AIR BAGS DEPLOYED. THE DRIVER SUSTAINED A CONCUSSION FROM HIS FACE HITTING THE STEERING WHEEL DURING THE IMPACT, MUSCLE NECK AND SHOULDER INJURIES WHICH RECEIVED MEDICAL ATTENTION FROM THE HOSPITAL. THE OTHER DRIVER SUSTAINED UNKNOWN INJURIES AND WAS TAKEN TO THE HOSPITAL VIA AMBULANCE. A POLICE REPORT WAS FILED. THE VEHICLE WAS TOWED BY GEICO TO THE CONTACT RESIDENTS WHERE AN ADJUSTER INSPECTED THE VEHICLE AND TOWED THE VEHICLE TO A REPAIR FACILITY WHERE IT WAS DEEMED THE VEHICLE A TOTAL LOSS. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE AND INFORMED THE CONTACT THAT NO RECALL WAS UNDER THE VIN. NO FURTHER INFORMATION WAS PROVIDED BY THE MANUFACTURER. NO DEALER WAS CONTACTED. THE FAILURE MILEAGE WAS APPROXIMATELY 70,000.

NHTSA ODI 11300748

WAS DRIVING DOWN THE ROAD AND THE TRUCK STARTED LEAKING DIESEL EVERYWHERE. WE TOOK THE TRUCK TO THE DEALERSHIP WHERE THEY SAID THAT WHEN THE FILTER CLOGS THE TRUCK DOESN'T TURN OFF IT SPRAYS FUEL OUT OF THE TOP OF THE FILTER HOUSING. THIS IS DANGEROUS AS MY WIFE WAS DRIVING THE TRUCK AND SITTING IN THE TRUCK FOR SEVERAL MINUTES WITH IT RUNNING NOT REALIZING IT WAS LEAKING . IT COULD HAVE CAUGHT ON FIRE.

NHTSA ODI 11228342

VEHICLE WAS PARKED AT HOME AND NOT RUNNING. ENGINE BLOCK HEATER WAS PLUGGED IN. SOME TIME WITHIN AN HOUR OF PLUGGING THE BLOCK HEATER IN THE ENGINE CAUGHT FIRE AND WAS EXTENSIVE ENOUGH TO CALL THE FIRE DEPT. INSURANCE COMPANY DECLARED TRUCK A TOTAL LOSS WITH NO CAUSE OF THE FIRE DETERMINED

NHTSA ODI 11183454

VEHICLE HAS A HOPPING THAT OCCURS AT SPEEDS OF 40-80 MPH, HAVE TRIED SEVERAL REMEDIES, NONE OF WHICH WORK. HOPPING SENSATION IS SO SEVERE THAT I WOULD BE WORRIED TO PUT CHILDREN IN THE BACK SEAT OF THE VEHICLE. MANUFACTURER IS AWARE OF THE PROBLEM, HAS A TSB IN AN ATTEMPT TO REMEDY THE PROBLEM. THE MANUFACTURER NUMBER OF THE TSB IS 16-0087. MANUFACTURER CLAIMS ISSUE IS CAUSED BY FRAME FLEX. NO KNOWN FIX FOR THE ISSUE. ENGINE ALSO HAS A CONSISTENT ISSUE OF PUTTING DIESEL FUEL INTO THE ENGINE OIL, MANUFACTURER ALSO CLAIMS THIS ISSUE IS "NORMAL"

NHTSA ODI 11123364

DURING REGENERATION THERE IS A JACKHAMMERING EFFECT AND IT SHAKES THE WHOLE TRUCK. SOUNDS LIKE THE VALVES ARE GOING TO COME OUT OF THE ENGINE

NHTSA ODI 11021334

TL* THE CONTACT OWNS A 2016 FORD F-250. WHILE DRIVING 40 MPH, THE VEHICLE BEGAN TO BOUNCE UP AND DOWN. AT 70 MPH, THE VEHICLE SHOOK VIOLENTLY. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS MADE AWARE OF THE ISSUE. THE FAILURE MILEAGE WAS 17,000. UPDATE 01/05/2017*CT

NHTSA ODI 10916472

ENGINE RUNS ROUGH DURING EXHAUST REGEN. TYPICALLY WHEN DRIVING BETWEEN 55-65, THE DIESEL EXHAUST FLUID WARNING APPEARS. ALMOST A MINUTE LATER THE TRUCK BEGINS TO MAKE LOUD JACK HAMMER NOISE AND LOSES POWER. FEELS VERY UNSAFE AS YOU LOSE POWER FOR ABOUT 10 SECONDS.

NHTSA ODI 10898625

THE TRUCKS DIESEL ENGINE SPORADICALLY SHUDDERS/SPUTTERS/STALLS CREATING A LOSS OF POWER AND DOESN'T RESPOND TO THROTTLE INPUT. THE ISSUE OCCURS SPORADICALLY WHILE CLEANING THE EXHAUST FILTER. THE VEHICLE IS IN MOTION WHEN THIS OCCURS. THIS HAS OCCURRED 4 TIMES AND IT HAS OCCURRED ON CITY STREETS AND HIGHWAYS. THIS HAS OCCURRED 4 TIMES. THE DEALER HAS REFLASHED THE SOFTWARE ONCE. IT IS CURRENTLY AT A FORD DEALERSHIP FOR THE PAST 30 DAYS. THEY STATED THEY ARE REPLACING THE VALVES ON THE LEFT SIDE( HEAD) AND MAY SEND THE HEAD TO A MACHINE SHOP.

NHTSA ODI 10896264