SLOW FUEL FILL--MIL ON WITH DTC P0191.
full bulletin at NHTSA ↗2006 Ford F-350 fuel system problems
moderate 16 complaints filed with NHTSA · avg repair $1,200 · see fuel system across all vehicles →
Failure mileage
Complaints
16
Recalls
0
Avg fix
$1,200
When does it fail?
Of the 16 fuel system complaints filed for the 2006 Ford F-350, here's the actual mileage breakdown — failures cluster heaviest at 100,000-125,000 mi.
0-25k
25-50k
50-75k
75-100k
100-125k
125-150k
150k+
Each bar shows the share of total complaints filed at that mileage range. Peak failure window highlighted. Some owners report problems earlier; some make it well past 150,000 miles symptom-free. Maintenance habits and driving conditions shift the curve as much as mileage alone.
What stands out
No new NHTSA fuel system complaint has been filed on this vehicle in over 16 years — the issue may be aging out of the active population.
Is there a fix? Manufacturer service bulletins
The manufacturer has issued service bulletins covering fuel system on this vehicle — documented repair instructions, service campaigns, or warranty extensions sent to dealers. A TSB isn't a recall (it's not a free safety remedy), but it's the manufacturer acknowledging the issue and how to fix it.
WATER IN THE FUEL TANK BEHIND REAR AXLE - 6.0L, 6.4L AND 7.3L DIESEL ENGINE. UPDATED 2/29/08.
full bulletin at NHTSA ↗SLOW FUEL FILL.
full bulletin at NHTSA ↗Source: NHTSA manufacturer communications. Bring the bulletin number to your dealer or shop.
The failure pattern owners describe
The 2006 F-350 fuel system cluster centers on internal fuel tank failure. Owners report that the tank's interior coating delaminates and corrodes, shedding debris into the fuel system. This happens even on low-mileage vehicles with careful maintenance; most failures cluster around 52,000–66,000 miles, though one occurred at 21,000 and another at 190,000 miles.
The debris clogs fuel filters and damages fuel injectors, leading to loss of engine power, stalling without warning, and refusal to start. Some vehicles cannot exceed 25 mph. One ambulance lost power during an emergency response. Technicians find rust and corrosion inside tanks that appear new from outside.
Repair costs are steep. Parts alone run $1,300–$2,500 for tank replacement, with total bills reaching $7,000+ when injectors, filters, pumps, and EGR components require replacement too. One truck needed all 8 fuel injectors and a fuel injector control module replaced.
Ford dealers acknowledge the defective tanks but refuse warranty coverage, even for vehicles only six weeks past warranty. Ford tells owners to file NHTSA complaints instead. Secondary failures include EGR cooler issues causing white smoke from the exhaust. Owners find no TSBs or recalls addressing the problem.
Same Ford F-350 fuel system reports on nearby years: 2005 · 2008
Failure modes owners describe
Fuel tank internal delamination/corrosion
Fuel tank interior coating fails and delaminates, shedding debris into the fuel system. Tank liner corrodes and deteriorates from inside despite new appearance externally. Owners report corrosion, rust, and delaminating material clogging fuel filters and injectors.
When: Occurs between 21,000 and 190,000 miles; most failures reported between 52,000–65,000 miles
Symptoms owners cite: Loss of engine power or inability to exceed 25 mph; Engine stalls or shuts down without warning while driving or idling; Vehicle will not restart after stalling; Hard starting or refusal to start after refueling; Foreign debris visible in fuel system during service
Repairs/costs cited: Tank replacement cost $1,300–$2,500+ in parts; total repair bills often exceeded $7,000 when fuel injectors, filters, pump, and EGR valve also required replacement. Independent mechanic replaced fuel pump block-off plate and plug at one vehicle.
Recalls/TSBs owners mention: Ford refused warranty coverage despite vehicles being within or near warranty period. Dealers diagnosed defective or rusted tanks and recommended replacement. Ford advised owners to file NHTSA complaints rather than provide assistance.
Fuel injector failure (secondary to tank contamination)
Fuel injectors lose power or fail to function. Appears to be caused by corrosion debris from delaminating fuel tank coating clogging and damaging injectors.
When: Typically occurs in conjunction with fuel tank liner failure, 52,000–66,000 miles
Symptoms owners cite: Loss of engine power; 5 of 8 fuel injectors showing no power in one truck; Multiple injectors requiring replacement
Repairs/costs cited: Fuel injector replacement cited in multiple repairs; cost not separately specified but included in overall $7,000+ repair estimates
Fuel system clogging (secondary to tank contamination)
Debris from delaminating tank liner clogs fuel filters and fuel pump, restricting fuel flow and causing loss of engine power.
When: Correlates with fuel tank failure around 52,000–66,000 miles
Symptoms owners cite: Restricted fuel flow; Engine loses power; Vehicle unable to accelerate
Repairs/costs cited: Fuel pump and multiple fuel filters replaced; tank fuel system required relining in at least one case
EGR cooler failure (associated with fuel system issues)
EGR cooler develops fault, causing engine overheating and excessive white/thick smoke from exhaust. One narrative mentions EGR valve replacement alongside fuel filter; another reports EGR cooler replacement for overheating. May be related to fuel system contamination or independent defect.
When: Around 65,000 miles; also noted at lower mileages
Symptoms owners cite: Engine overheating; Thick white smoke from exhaust (fog-like density); White smoke visible from tailpipe
Repairs/costs cited: EGR cooler and EGR valve replacement; repair persisted on multiple occasions in one case
Recalls/TSBs owners mention: Ford acknowledged the problem but did not recall; owners were directed to file NHTSA complaints
Fuel pump failure (secondary to tank contamination)
Fuel pump compromised or fails, likely due to corrosion debris from internal tank coating failure. One case involved fuel pump block-off plate corrosion.
When: 52,000–190,000 miles; cluster around 60,000 miles
Symptoms owners cite: Loss of engine power; Inability to start vehicle
Repairs/costs cited: Fuel pump replacement cost included in larger repair estimates; one independent mechanic replaced fuel pump block-off plate and plug
Fuel leakage (fuel pump block-off area)
Fuel leaking from front driver's side of vehicle, traced to fuel pump block-off plate and plug corrosion at 190,000 miles.
When: 190,000 miles
Symptoms owners cite: Fuel visible leaking underneath vehicle on driver's side
Repairs/costs cited: Fuel pump block-off plate and plug replaced by independent mechanic
Synthesized from 16 NHTSA owner complaints — unverified consumer allegations, summarized for patterns. The verbatim filings appear below.
What owners are reporting 2 most recent
F-350 EGR cooler went bad and smoked up entire neighborhood. Other motorists could not see as the smoke emitted from my f-350 was like a very very thick fog. I contacted Ford, who knows about the ongoing and extensive problem, but they refuse to do anything but "document" the problem and want NHTSA to make it a recall. Apparently there are a lot of other f-350 owners with the same problem.…
Fuel tank liner is delaminating causing fuel system to clog up and truck to lose power. Ford refuses to cover this problem under warranty saying it is not their fault. *tr
Had fuel system trouble with your 2006 Ford F-350?
File a complaint with NHTSA → It's free, official, and how every report above got here — owner filings are the federal safety record this page is built on.
Common questions
How serious is the fuel system problem on the 2006 Ford F-350?
It's a documented issue but not catastrophic. 16 complaints have been filed. Repairs average $1,200 and most owners catch it before it causes a breakdown.
At what mileage does the fuel system typically fail?
Across the 15 complaints that reported odometer mileage, most fuel system failures cluster between 40,000 and 119,583 miles, with the median around 60,000. A quarter of owners report trouble before 40,000; a quarter make it past 119,583. Maintenance history matters more than the odometer alone — this is the reported failure window, not a guarantee.
What does it cost to fix?
Independent shops typically charge around $1,200 for fuel system repairs on this vehicle. Dealer pricing tends to run 20-40% higher. The exact figure depends on the specific failure mode, parts availability, and your local labor rates. If you're outside factory warranty, an extended service contract often covers this category.
Are there any recalls related to fuel system?
No active recalls currently cover fuel system issues on this vehicle. The complaints filed represent owner-reported failures that haven't risen to the level of a manufacturer-issued recall — but they're still worth knowing about before you buy or budget for repairs.
Related
Complaint and recall data sourced from the National Highway Traffic Safety Administration (NHTSA)
public records database. Verify the raw federal record at
nhtsa.gov/vehicle/2006/Ford/F-350.
Severity ratings are derived from reported crashes, fires, injuries, and fatalities. Repair cost estimates are
independent-shop national averages and may differ in your area. Some links on this page are affiliate links.