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 ↗2012 Ford F-250 engine problems
moderate 45 complaints filed with NHTSA · avg repair $3,100 · see engine across all vehicles →
Failure mileage
Complaints
45
Recalls
0
Avg fix
$3,100
1fire
1injury
When does it fail?
Of the 45 engine complaints filed for the 2012 Ford F-250, here's the actual mileage breakdown — failures cluster heaviest at 0-25,000 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
Owners have filed 45 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 #3 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: VEHICLE MAY EXPERIENCE EXHAUST SMOKE, ENGINE KNOCKING, LOW POWER, LONG CRANK HARD START, RUNS ROUGH OR NO CRANK START WHICH MAY BE CAUSED BY CONTAMINATED FUEL.
full bulletin at NHTSA ↗Source: NHTSA manufacturer communications. Bring the bulletin number to your dealer or shop.
The failure pattern owners describe
The 2012 F-250 diesel accumulates a pattern of engine-related failures that owners say Ford has sidestepped. EGT sensor failures dominate the complaints—when one of the four exhaust gas temperature sensors fails, the PCM triggers immediate engine shutdown with a "STOP SAFELY NOW" warning, leaving owners stranded without power steering or power brakes. Owners report being marooned mid-traffic, on highways, and in dangerous positions; some nearly collided with other vehicles. Ford issued a Technical Service Bulletin but has not recalled the sensors. Multiple owners report paying $700+ out of pocket.
High-pressure fuel pump failure is equally severe: the pump shreds internally, scattering metal filings through injectors, fuel rails, pressure regulators, and the fuel tank. Ford denies warranty, claiming fuel contamination, but conducts no fuel testing and provides no specifics. Repair estimates exceed $8,000. One owner had the fuel pump replaced four times and fuel pressure regulators replaced multiple times.
Radiator failures leak from the driver's-side lower corner at mileages as low as 29,000 miles. The defect is known since 2008 model years, yet Ford refuses to extend warranty coverage beyond earlier production runs. Repair costs exceed $2,000.
Additional failures include DEF heater units burning out around 35,000 miles on replacement units, crankcase ventilation filter oil leakage into the intake (one owner suffered eye injury when pressurized oil ejected from the cap), exhaust manifold bolt breakage (design corrected later but never recalled), and piston rod seizure. One engine fire occurred at 161,000 miles.
Same Ford F-250 engine reports on nearby years: 2010 · 2011 · 2013 · 2014 · 2015
Failure modes owners describe
EGT Exhaust Gas Temperature Sensor Failure
One or more of the four EGT sensors in the exhaust system fails, triggering immediate engine shutdown with 'STOP SAFELY NOW' warning. The PCM interprets the sensor failure as an overheating exhaust condition and enters a controlled power-reduction mode that culminates in complete engine shutdown once vehicle speed drops to approximately 4 mph. This leaves owners stranded without power steering or power brakes—a critical safety hazard in traffic.
When: Reported at 1,600 miles up to 70,000+ miles; multiple recurrences within same vehicle
Symptoms owners cite: Sudden 'STOP SAFELY NOW' or 'PULL OVER SAFELY' warning message on dashboard; Audible warning chimes (typically five chimes noted); Vehicle independently decelerates or enters limp mode; Engine shuts down completely once vehicle speed drops to ~4 mph; Complete loss of power steering and power brakes; Engine will not restart immediately; No warning prior to shutdown; Black smoke from exhaust (in some cases)
Codes mentioned: EGT Sensor code (specific code designation varies; one owner noted 'EGT 12 Sensor')
Repairs/costs cited: Sensor replacement reported by dealers; owners cite $700+ repair costs; not covered under warranty or recall as of complaint dates; owners report paying out of pocket or dealer stating 'not covered as recall or warranty'
Recalls/TSBs owners mention: Ford issued Technical Service Bulletins (TSB) for this issue per one dealer; one complaint references recall query RQ-14-005 sent February 5, 2015; manufacturer has not issued a recall; dealers confirm they have seen 'a ton of these' failures
High-Pressure Fuel Pump Failure (6.7L Diesel)
High-pressure fuel pump internal failure (often cited as shredding or breaking apart internally) introduces metal filings into the fuel system. These filings cascade damage throughout: injectors, fuel rail, pressure regulator, and even back into the fuel tank via return line. Failure is sudden with no warning and can leave engine inoperable.
When: Reported at various mileages; no consistent pattern provided; one case at approximately 120,000 miles after 4 replacements
Symptoms owners cite: Engine suddenly dies while driving with no warning; Loss of power steering and power brakes at time of shutdown; Truck will not start after failure; High-pitched whining sound from engine compartment while starting; Significant engine power reduction; Metal filings visible in fuel system components
Repairs/costs cited: Estimated repair costs $8,000+; involves complete replacement of fuel pump, injectors, fuel rail, pressure regulators, and fuel tank cleaning/potential replacement; one owner reported fuel pumps replaced 4 times and fuel pressure regulators replaced multiple times since 2012
Recalls/TSBs owners mention: Ford denies warranty coverage, claiming 'fuel contamination' despite owner maintaining fuel filters and water separator; no fuel tests conducted by Ford (diagnosis made from photograph); Ford refuses to acknowledge design flaw; no recall issued
Radiator Failure & Coolant Leaks
Primary radiator fails prematurely, typically leaking from the driver's side lower corner. Leaks occur after vehicle reaches operating temperature and is parked or shut off. Failure involves tank crimping defect. Issue is widespread across multiple model years (noted back to 2008 diesel models) but Ford has not extended warranty coverage to 2011+ models despite knowledge of defect.
When: Reported at 29,000 miles, 47,500 miles, 56,000 miles, 59,200 miles; some within warranty period but radiator excluded
Symptoms owners cite: Coolant leak from driver's side lower corner of radiator; Visible coolant spots under vehicle; No warning messages prior to leak discovery; Occurs after vehicle reaches operating temperature and cools
Repairs/costs cited: Replacement radiator cost $2,000+; warranty expired at 36,000 miles on some vehicles; repairs out of pocket for owners; Ford Service Manager confirmed multiple radiator replacements this year with leaks in same location
Recalls/TSBs owners mention: Ford previously warranted radiators on earlier production years but refuses to extend warranty to 2011 and newer; no recall issued despite known defect dating back to 2008
DEF (Diesel Exhaust Fluid) Heater Unit Failure
DEF heater unit fails prematurely. One owner reported initial failure at 115,710 miles (repaired under warranty extension 18-M-01), then second failure at 150,000 miles—only 35,000 miles on replacement unit. Repeated failures lead owners to bypass DEF system entirely, creating environmental concern.
When: Reported after ~35,000 miles on replacement unit; initial failure covered under warranty extension
Symptoms owners cite: DEF heater failure (specific symptoms of failure not detailed in narratives)
Repairs/costs cited: OEM part replacement; first repair done at owner's expense September 2015, later reimbursed by Ford; second failure expected to require another repair
Recalls/TSBs owners mention: Ford issued warranty extension 18-M-01 for reductant heater unit; owner requests additional warranty extension due to recurring failure; phenomenon noted as common on internet forums
Crankcase Ventilation (CCV) Filter Oil Leakage
CCV filter leaks oil into intake system, building extreme pressure inside crankcase. When oil cap is opened, pressurized oil is ejected forcefully. Owner reported this caused eye injury requiring medical treatment.
When: Reported at 101,000 miles
Symptoms owners cite: Oil leaking from CCV filter into intake; Extreme pressure build-up in oil system; Pressurized oil ejected from oil cap when opened; Oil discharge causing facial/eye injury
Repairs/costs cited: CCV filter is inexpensive part but labor involved; owner requests warranty coverage; owner notes 'a lot of post about this exact problem'
Recalls/TSBs owners mention: Owner states Ford is aware of problem but 'haven't figured out a solution'; no recall or warranty coverage offered
Sudden Unintended Acceleration
Truck accelerates unexpectedly immediately after being shifted into Drive from parked position. No error codes are generated. Occurs at RPM range of 2,500–4,000 during low-speed repositioning maneuvers. Brake intervention required to prevent collision. PCM reprogramming attempted but failures recur.
When: Reported at 20,064 miles (under warranty); occurred twice
Symptoms owners cite: Sudden unexpected acceleration immediately after shifting into Drive; Acceleration from parked position during low-speed maneuvers; RPM surges to 2,500–4,000 range; No error codes stored or detectable events in PCM; Requires hard brake pressure to prevent collision; Truck returns to normal operation after incidents
Repairs/costs cited: PCM reprogrammed by service center (twice, per narrative); no permanent fix achieved; vehicle still under warranty at time of report
Recalls/TSBs owners mention: Service center unable to identify root cause; PCM reprogrammed but issue persists
Engine Seizure Due to Coolant Intrusion
Coolant intrudes into engine cylinder, causing piston seizure. Engine requires complete replacement. Transmission also failed shortly after engine replacement, suggesting possible related cause or secondary damage from engine failure.
When: Discovered at approximately 27,500 miles
Symptoms owners cite: Bucking and jerking while driving at various speeds; Transmission slipping between Drive, Neutral, and Reverse; Gear shift indicator light displaying erratic behavior; Check engine light (post-replacement)
Repairs/costs cited: Engine replacement performed by dealer; transmission replacement needed (part on back order at time of report); repair status unknown
Recalls/TSBs owners mention: Manufacturer notified and referred contact to NHTSA; no assistance offered
Piston Rod Failure
Piston rod #3 snapped inside engine during normal driving, requiring complete engine replacement. Three weeks after engine replacement, exhaust gas cooling system failure occurred.
When: Discovered at approximately 42,500 miles
Symptoms owners cite: Abnormal cranking sound while driving 20 mph; Multiple unknown warning lights flashing on instrument panel; Engine immobilized
Repairs/costs cited: Complete engine replacement required; exhaust gas cooling system replacement needed post-engine swap
Recalls/TSBs owners mention: Manufacturer notified and referred contact to NHTSA Hotline; no repair completed at time of report
Exhaust Manifold Bolt Failure
Exhaust manifold bolts break, causing exhaust leaks. Issue is a known design defect in early 6.7 Powerstroke engines. Ford corrected the design in later model years but never issued a recall for defective 2011–2012 units. Exhaust is mounted on top of engine (unusual design), making failures more hazardous.
When: Known defect in early 2011–2012 models; corrected in later production
Symptoms owners cite: Exhaust leak; Loss of power / limp mode entry; Fire risk (due to exhaust location on top of engine)
Repairs/costs cited: Repair involves bolt replacement/manifold service; cost not specified
Recalls/TSBs owners mention: Ford is aware of the problem but has not issued a recall for affected 2011–2012 models despite known defect
Engine Fire
Engine compartment fire occurred while vehicle was stopped at traffic signal. Flames shot from under vehicle and engulfed engine compartment. Fire department response required.
When: Reported at 161,000 miles
Symptoms owners cite: Burning plastic smell detected; Smoke emitted from under vehicle front end; Flames shooting from engine compartment; Rapid fire spread within engine compartment
Repairs/costs cited: Vehicle towed to impound lot; fire extinguished with water
Recalls/TSBs owners mention: Manufacturer not notified at time of report; no investigation results provided
Fuel System Contamination (Disputed)
Complete fuel system failure attributed by Ford to 'fuel contamination,' though owners dispute this diagnosis. Failure involves metal shrapnel in fuel system or unknown substance in fuel tank. Ford denies warranty coverage and does not test fuel samples or specify contamination type.
When: Reported at 63,000 miles and 188,180 miles; one case at 18,877 miles
Symptoms owners cite: Engine dies while driving; Metal filings found in fuel system (in some cases); Unknown substance detected in fuel tank (in some cases); Complete fuel system failure; Warning lights illuminate
Codes mentioned: Check Engine Light
Repairs/costs cited: Estimated repair $10,500; fuel injectors and fuel pump replacement noted in one case; owner fuel testing showed no contamination
Recalls/TSBs owners mention: Ford denies warranty, claiming fuel contamination without conducting fuel tests; diagnosis made from photograph; manufacturer suggests owner insurance or third-party responsibility
Oil Pan Plastic Cracking
Plastic oil pan cracked with hairline fracture (1/8 inch) after minor impact in field conditions. Dealer confirms all oil pans on this truck are plastic. Design is questionable for a heavy-duty truck intended for off-road work.
When: Reported at unknown mileage
Symptoms owners cite: Oil leakage from hairline crack in plastic oil pan; Minimal external damage to pan (slight dent in plastic, no markings)
Repairs/costs cited: Oil pan replacement required
Recalls/TSBs owners mention: No response documented
Engine Stalling at Low Speed
Engine stalls intermittently at low speeds (1–5 seconds), posing hazard during traffic entry. Owner reports multiple service visits with dealer acknowledging problem but failing to diagnose or repair root cause.
When: Reported at unknown mileage
Symptoms owners cite: Engine stalling for 1–5 seconds at low speed; Hazardous during traffic entry attempts; Intermittent occurrence
Repairs/costs cited: Not repaired; dealer acknowledged problem but unable/unwilling to fix
Recalls/TSBs owners mention: Owner believes Ford is aware but unwilling to address
DEF Safety Switch Shutting Down Engine
DEF safety switches shut off the engine when vehicle speed drops below 10 mph, creating hazard when pulling into traffic or during parking maneuvers.
When: Reported at unknown mileage
Symptoms owners cite: Engine shut down when vehicle speed is less than 10 mph; Hazard during traffic entry
Repairs/costs cited: Not specified
Recalls/TSBs owners mention: No response documented
Synthesized from 45 NHTSA owner complaints — unverified consumer allegations, summarized for patterns. The verbatim filings appear below.
What owners are reporting 6 most recent
Ford previously issued warranty extension for this vehicle 18-M-01 related to the replacement of the reductant heater unit. I acquired the subject vehicle above and had the repair done at my expense on September 9, 2015 with 115,710 miles on the vehicle using an OEM part. Eventually, Ford would reimburse me for this expense. The truck currently has 150,000 miles and once again the DEF heater…
While driving my truck on a busy side road, the message center flashed a warning, "stop safe soon". A audible chime was heard and the truck shut off. Complete lose of power brakes, power steering. I was not able to get the truck off the road completely since it happened so fast. Traffic was stopped in both directions while we did our best to push the 7,500 pound truck to the narrow shoulder.…
This is a diesel engine f250. Egt sensor failed and engine immediately shut down in the middle of the road. CEL was on and message said " stop safely now". The failure of the egt sensor was known by dealer and he showed me 2 tsb s on the problem. Problem was fixed in 2 days but the safety aspect of this failure has not been addressed by Ford. A almost immediate shutdown of the engine…
Driving through a farm field and something hit the oil pan and cracked it with a hair line fracture, 1/8 inch, and oil leaking. No visable damage or marking until pulled from truck, even than no marks but a slight dent in plastic. No other visable damage anywere else under truck. Asked if all oil pans are plastic and I was told by dealer, yes. This is a truck designed to for off road heavy…
Tl* the contact owns a 2012 Ford f-250. The contact found metal shrapnel in the fuel system, which traveled to the engine. Multiple unknown warning indicators illuminated. The vehicle was towed to an independent mechanic where the battery was changed. The mechanic diagnosed that the fuel injectors and fuel pump needed to be replaced. The vehicle was not repaired. The manufacturer was made aware…
Tl* the contact owns a 2012 Ford f-250 sd. The contact stated that while driving approximately 63 MPH, the reduced power and the check engine warning lights illuminated. The vehicle was towed to a second dealer, who diagnosed that there was an unknown substance in the fuel tank. The vehicle was not repaired. The manufacturer was not made aware of the failure. The approximate failure mileage was…
Had engine trouble with your 2012 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 2012 Ford F-250?
It's a documented issue but not catastrophic. 45 complaints have been filed. Repairs average $3,100 and most owners catch it before it causes a breakdown.
At what mileage does the engine typically fail?
Across the 40 complaints that reported odometer mileage, most engine failures cluster between 30,000 and 72,000 miles, with the median around 51,000. A quarter of owners report trouble before 30,000; a quarter make it past 72,000. 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/2012/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.