The Powertrain Control/Emissions Diagnosis (PC/ED) manual has been revised for diagnosing electronic throttle bodies (ETBs). The ETC_ACT and ETC_DSD PIDs should not used to diagnose possible ETB concerns. The IDS has a limited refresh rate when reading these PIDs and cannot display quickly enough to validate a concern. The PCM automatically monitors these inputs more accurately and will set diagnostic trouble codes (DTCs) when appropriate. Using these PIDs for diagnostics will lead to inaccurate results and improper ETB replacements. If a concern is intermittent and no DTCs are present, refer to historical DTCs and the PC/ED, Section 3 No DTCs Present Index chart for further information.
full bulletin at NHTSA ↗2011 Ford F-250 engine problems
severe 50 complaints filed with NHTSA · avg repair $3,100 · see engine across all vehicles →
Failure mileage
Complaints
50
Recalls
0
Avg fix
$3,100
2crashes
3fires
What stands out
Owners have filed 50 engine complaints with NHTSA against this vehicle, but no formal recall covers the issue — the federal record reflects what manufacturers have admitted, not everything owners are reporting.
Among the 19 model years of Ford F-250 in our records for engine problems, this one ranks #2 by owner-complaint volume.
Is there a fix? Manufacturer service bulletins
The manufacturer has issued service bulletins covering engine 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.
FORD: 2011-2014 F-SUPER DUTY VEHICLES EQUIPPED WITH 6.7L DIESEL ENGINE MAY EXPERIENCE A RUNNING ROUGH OR MISFIRE DURING EXHAUST REGENERATION PROCESS
full bulletin at NHTSA ↗FORD: DUE TO LOOSE, MISSING, MODIFIED OR DAMAGED GROUND G400, VARIOUS MALFUNCTION INDICATOR LIGHT (MIL) DTC'S, RELATED TO GLOW PLUG CONTROL MODULE (GPCM), MAY BE EXHIBIT ON SOME DIESEL EQUIPPED TRUCKS. MODEL YEARS 2011-2013. NO MODELS LISTED.
full bulletin at NHTSA ↗FORD: SOME SUPER DUTY TRUCKS, WITH A STEADY THROTTLE, WILL EXPERIENCE, WITH OR WITHOUT, AN ENGINE SHUDDER OR TURBO FLUTTER NOISE, IN THE ENGINE, AROUND 900-1400 RPM. MODELS 2011-2012 F-250, F-350, F-450.
full bulletin at NHTSA ↗FORD: AFTER REFUELING VEHICLE, WOULD BE HARD TO START, RUNS ROUGH AND AN AUDIBLE CLICKING NOISE CAN BE HEARD.
full bulletin at NHTSA ↗Source: NHTSA manufacturer communications. Bring the bulletin number to your dealer or shop.
The failure pattern owners describe
The 2011 Ford F-250 6.7L diesel engine exhibits multiple chronic failures across the fleet. EGT sensor shutdown is the most dangerous: sensors fail with little warning, causing the engine to cut out mid-drive while the "Stop Safely Now" message gives drivers only seconds to reach safety. This has stranded owners in intersections, on highways without shoulders, and in remote areas with no cell service. Dealers confirm the problem is common but won't cover sensors under warranty until they actually fail.
Engine catastrophic failure—spun rod bearings, crankshaft breaks, metal in oil—occurs at moderate mileage (79,000–146,000 miles) during normal driving or light towing, requiring $15,000–$24,000 replacement engines. Owners following Ford's maintenance schedule report no abuse. Sudden loss of acceleration, especially in tow-haul mode, happens intermittently; restarting the engine for 90 seconds is the only temporary fix. DEF heater assemblies fail repeatedly; one owner endured five dealer service visits for the same component.
Radiators leak at the plastic-to-aluminum junction below 50,000 miles on many units. Engine vibrations and shuddering occur at highway speeds and during regen cycles. Two reported cases of engine fire while parked. Owners describe dealership responses as dismissive—technicians claim no knowledge of widespread problems despite hundreds of similar complaints online.
Same Ford F-250 engine reports on nearby years: 2008 · 2010 · 2012 · 2013 · 2014
Failure modes owners describe
EGT (Exhaust Gas Temperature) Sensor Failure with Unplanned Engine Shutdown
Defective exhaust gas temperature sensors trigger immediate engine shutdown with little to no warning. The system displays 'Stop Safely Now' or similar message seconds before stalling, leaving drivers without power steering or brakes. Owners report multiple instances across their ownership. Dealers confirm this is a known issue but indicate sensors must actually fail before replacement is covered under warranty. Multiple sensors (typically 4) are fitted on these engines, increasing failure likelihood.
When: Occurs at various mileages (29,000–150,000+ miles) and random intervals; some instances documented at highway speeds (35–75 MPH), parking lots, intersections, and during towing
Symptoms owners cite: Dashboard message 'Stop Safely Now' or 'Pull Over Safely Now'; Sudden engine shutdown with no prior warning light; Loss of power steering and power brakes upon shutdown; Vehicle becomes immobile in traffic or intersection; Recurring failures even after sensor replacement
Codes mentioned: EGT sensor fault, P242A (DPF pressure sensor circuit low)
Repairs/costs cited: Sensor replacement; costs cited range $100–$900+ depending on whether one or all four sensors are replaced. Dealer labor $100–$120/hour. Owners report repeated replacements required.
Recalls/TSBs owners mention: Ford acknowledges the problem is 'common' per dealer personnel; partial recall exists for 2011–2012 F-250 ambulance packages with 6.7L diesel, but non-ambulance F-250 owners report being excluded. Some sensors covered under warranty only after failure occurs.
Diesel Exhaust Fluid (DEF) Heater Assembly Chronic Failure
DEF heater, pump, sending unit, and associated injectors experience repeated failures. Vehicles require multiple rounds of repair for the same components. One owner reports five separate repair attempts for the DEF heater alone before requiring full subsystem replacement (heater, pump, injector, sending unit). Problem is intermittent, especially below 30°F, and can trigger limp-mode operation or power loss during towing.
When: Low mileage through 150,000+ miles; failures occur intermittently, particularly in cold temperatures below 30°F
Symptoms owners cite: Check engine warning light illumination; DEF system warning light; Repeated failures after repair for same component; Loss of acceleration while towing; Engine power reduction or limp-mode activation; Intermittent cold-weather issues
Codes mentioned: DEF heater fault, DEF pump fault, DEF sending unit fault
Repairs/costs cited: Individual component replacement ($50–$500+ per part) or full subsystem replacement; one owner reports five service visits for recurring DEF heater failure at independent mechanic and dealership without resolution.
Recalls/TSBs owners mention: No specific recalls or TSBs cited in narratives for non-ambulance F-250 DEF failures. Owners report manufacturer has not been formally notified.
Loss of Power and Acceleration at Load (Turbo Lag / Fuel System)
Vehicles experience sudden, severe loss of acceleration and power when pulling from a stop or under load, especially in tow-haul mode. Drivers report the pedal has no response even when depressed fully. Problem occurs intermittently; the only temporary fix is stopping the vehicle, turning off the ignition, and waiting 60–90 seconds. Dealership replaced fuel injectors without resolution. Suspected root causes cited by owners include faulty engine computer or fuel system pump issues.
When: Random intermittent episodes; occurs 60–70% of the time in tow-haul mode pulling 11,500–14,000 lbs, sometimes triggered by highway on-ramps or uphill grades
Symptoms owners cite: Near-total loss of acceleration from stop; Unresponsive throttle pedal despite full depression; Rough idle and engine vibration when disabled on shoulder; Temporary fix: engine shutdown for 60–90 seconds resets problem; Occur frequently during towing; Vehicle disabled in roadway with family aboard in dangerous locations
Codes mentioned: Fuel injector fault (suspected)
Repairs/costs cited: Dealership replaced all fuel injectors; problem recurred 6+ times after service. No permanent resolution identified.
Catastrophic Engine Bearing and Internal Failure (Rod Knock / Metal Debris)
Engines suffer catastrophic internal mechanical failure—spun rod bearings, crankshaft breakage, metal debris in oil, piston damage from stuck fuel injectors, or cylinder head/valve damage. Failures occur at moderate mileages (79,000–146,000 miles) during normal operation (highway cruise, pulling trailer on incline). Engine produces loud banging, shuddering, and ground-level oil spill. Vehicles require complete engine replacement ($15,000–$24,000). Some owners suspect heat damage from regeneration (DPF regen) cycles degrades internal valve integrity. No warning lamps activate before failure.
When: 79,000 to 146,000 miles; occurs during normal highway driving or moderate towing on inclines
Symptoms owners cite: Loud banging or knocking noise from engine; Violent engine shuddering; Sudden loss of power; vehicle decelerates to stop; Metal shavings visible in oil sample; Oil spill visible on ground; Engine will not restart or will not run; Smoke from engine compartment; Rough idle if engine restarts
Codes mentioned: Engine valve failure code (detected in at least one case), No diagnostic codes present in multiple cases before failure
Repairs/costs cited: Complete engine replacement required; costs $15,000–$24,233.67. One owner received replacement engine with 2-year warranty only, then experienced three recurrent check engine light faults within days of pickup.
Recalls/TSBs owners mention: Ford refuses to stand behind product despite advertising 250,000-mile durability testing. One owner notes Ford allegedly fixed this design issue in 2012 model year but did not remedy 2011 vehicles already sold.
Fuel Injector Clamp / Hold-Down Failure
Fuel injector hold-down clamps are breaking or coming loose, allowing injectors to shift position. This creates gaps allowing combustion gases to escape the cylinder, damaging adjacent injectors and risking engine fire. Problem recurred at least twice on one owner's truck despite dealer repair. Injectors are buried under engine covers, making visual inspection impossible for owners. Ford technicians acknowledge this should not happen; Ford refuses to warranty the defect and makes owner pay for repairs.
When: Multiple instances on same vehicle (March 2021, May 2021); unspecified mileage
Symptoms owners cite: Check engine light illumination; Combustion gas leakage from cylinder; Potential risk of engine fire; Recurring problem after dealer repair
Codes mentioned: Check engine light (unspecified code)
Repairs/costs cited: Injector clamp and injector replacement; Ford technicians state this is not a normal failure but vehicle warranty does not cover it.
Recalls/TSBs owners mention: Ford refuses to warranty the defect. Owner reports Ford technician references internal memo discussing this issue.
Radiator Cooling System Failure (Plastic Tank Aluminum Coil Separation)
Radiators develop leaks at the junction where aluminum cooling coils attach to plastic tanks. Leaks begin slowly then accelerate. Failures occur at relatively low mileages (45,000–88,000 miles). Owners report this is a widespread, common occurrence affecting this year and model; many instances occur before 50,000 miles. Ford has not issued a recall despite owner assertions that public occurrence rates are high and testing was inadequate.
When: 45,000 to 88,000 miles, though owners report failures below 50,000 are not uncommon
Symptoms owners cite: Coolant leakage from radiator; Coolant smell from radiator area; Slow leak that progressively worsens; Potential engine overheating if not caught early
Repairs/costs cited: Radiator replacement required. Owners report this is a high-frequency problem within the user community.
Recalls/TSBs owners mention: No recall issued. Ford will not publish failure rate data absent external pressure. Owners assert inadequate product testing and specification design.
Engine Vibration / Shuddering (Cold Start, Acceleration, Regen Cycle)
Trucks exhibit violent full-vehicle shuddering and vibration, occurring at low mileage and repeatedly. Episodes happen during cold-weather engine starts, at highway speeds (35–85 MPH), and during or shortly after DPF regeneration cycles. Shuddering sometimes accompanied by loss of throttle response ('lugging' sensation) and can last 5–15 seconds. Dealership cannot identify cause; Ford engineering is investigating but advises dealers not to attempt repairs. Problem reported by hundreds of owners online but dealership claims no knowledge of issue.
When: As early as 15,000 miles; occurs at 35–85 MPH during regen cycles and cold starts; at least weekly in one case
Symptoms owners cite: Violent full-truck shuddering and vibration; Knocking or rapping sounds from engine during cold starts; Temporary loss of throttle response during shudder; 'Lugging' sensation; Shudder lasts 5–15 seconds; Occurs during or shortly after regen/exhaust filter cleaning cycle
Repairs/costs cited: No repairs performed; Ford's response to dealers was 'Do Not Attempt Repairs At This Time—Engineering Is Investigating.'
Recalls/TSBs owners mention: Ford is investigating via engineering. Dealers advised not to perform repairs pending investigation.
Engine Fire in Parked Vehicle
Two separate accounts of 2011 F-250 engines catching fire while parked with engine running. One fire originated in engine compartment at or near master cylinder and wiring harness area where it enters firewall. Both vehicles were completely destroyed; one owner reports vehicle engaged in uncontrolled acceleration (WOT) before impact, then continued running until ignition was manually turned off. No injuries reported in documented cases.
When: One at 62,500 miles while parked with engine on; second unspecified mileage
Symptoms owners cite: Flames visible in engine compartment; Complete vehicle destruction from fire; One case: uncontrolled full-throttle acceleration (WOT) at engine start, vehicle ran into tree, engine remained at WOT until ignition turned off
Repairs/costs cited: Total loss; vehicles destroyed.
Recalls/TSBs owners mention: One fire report noted neither dealer nor manufacturer was notified at time of submission.
Exhaust Fumes in Cabin
Exhaust fumes drawn into the vehicle cabin through the air handling system during stationary operation. One case involved obstructed exhaust gas recirculation cooler cord requiring replacement at 9,900 miles. Another ongoing complaint of fumes entering the cabin when parked.
When: As early as 9,900 miles (EGR cooler cord case); ongoing complaint in another case
Symptoms owners cite: Exhaust odor inside cabin; Fumes drawn into cab via air handling system when vehicle stationary; Check engine light illumination
Codes mentioned: EGR cooler cord obstruction
Repairs/costs cited: EGR cooler cord replacement; other cases not repaired.
Valve Cover Bolt Failure
Valve cover bolts repeatedly break, causing oil leaks over the motor and transmission. Multiple bolts (reported as 32) fail, indicating a systemic design or fastener issue.
When: Unspecified mileage
Symptoms owners cite: Oil leakage over engine block and transmission; Multiple valve cover bolt failures; Visual oil dripping
Repairs/costs cited: Valve cover bolt replacement required; recurring failures suggest design flaw.
Synthesized from 50 NHTSA owner complaints — unverified consumer allegations, summarized for patterns. The verbatim filings appear below.
What owners are reporting 1 most recent
While driving at a speed of 50 miles per hour the truck started losing power, was able to get to side of the highway as it lost all power and shut down was unable to restart truck. Got truck towed home and went checking the motor and the antifreeze was completely dry but no leaking under motor and no warnings of lights flashed when truck shut down.. Truck is serviced every 3 months and checked…
Had engine trouble with your 2011 Ford F-250?
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 engine problem on the 2011 Ford F-250?
It's a meaningful issue. 50 complaints have been filed and the failure mode causes operational problems for owners. Repairs average $3,100.
At what mileage does the engine typically fail?
Across the 45 complaints that reported odometer mileage, most engine failures cluster between 29,000 and 103,034 miles, with the median around 70,000. A quarter of owners report trouble before 29,000; a quarter make it past 103,034. 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 $3,100 for engine 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 engine?
No active recalls currently cover engine 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/2011/Ford/F-250.
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.