Certain 2014-2016 Model Year F-250 ? F-550 and 2016 Model Year F-650 - F-750 Vehicles, With 6.7L Diesel Engine - Crankcase Ventilation Oil Separator Assembly
full bulletin at NHTSA ↗2015 Ford F-250 engine problems
severe 30 complaints filed with NHTSA · avg repair $3,100 · see engine across all vehicles →
Failure mileage
Complaints
30
Recalls
0
Avg fix
$3,100
1crash
3fires
What stands out
Owners have filed 30 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.
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.
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 ↗PICKUP - 6.7L DIESEL ENGINE - RUNS ROUGH DURING EXHAUST REGENERATION PROCESS - BUILT ON OR BEFORE 2/23/2016 ISSUE Some 2015-2016 F-Super Duty 250-450 Pickup vehicles equipped with a 6.7L diesel engine and built on or before 2/23/2016 may exhibit a runs rough/misfire condition only during the exhaust regeneration process. This condition typically occurs on light throttle tip in between 64-113 Km/h (40-70 MPH) and will not set diagnostic trouble codes (DTCs). The concern may be intermittent and a knocking noise may be present during the concern. SERVICE PROCEDURE 1. Reprogram the powertrain control module (PCM) to the latest calibration using Integrated Diagnostic System (IDS) release 99.03 or
full bulletin at NHTSA ↗Pickup - 6.7L Diesel Engine - Runs rough during exhaust regeneration process - built on or before 02/23/2016
full bulletin at NHTSA ↗Source: NHTSA manufacturer communications. Bring the bulletin number to your dealer or shop.
The failure pattern owners describe
Owners of the 2015 Ford F-250 6.7L diesel report a destructive pattern of failures spanning drivetrain control, mechanical integrity, and cooling system durability.
The most common complaint centers on violent power loss and shaking during exhaust regeneration cycles. The engine suddenly loses power, shakes violently, and produces loud knocking at speeds from 30–70 mph. Drivers must hold the throttle wide open to prevent bucking; backing off the throttle restarts the problem. This began as intermittent on hot days around 4,100 miles and escalated to occur during every regen cycle. Ford issued TSB 15-0088 and promised a software recalibration in March 2016, but owners report dealerships either did not know about it or the fix did not solve the problem.
Underneath, owners suspect valve and valve guide clearance issues. Some experienced broken valve springs and stuck exhaust valves that caused catastrophic engine damage—holes in pistons, connecting rods punching through cylinder walls—at highway speeds with zero advance warning and no check engine light.
Multiple owners reported engine compartment fires or explosions at relatively low mileage (38,000–65,000 miles), including one that destroyed the owner's residence. Radiator leaks at the plastic-to-metal joint developed around 47,000 miles; OEM replacement units also failed the same way. Ford acknowledged this is an ongoing problem but refuses warranty coverage beyond 36,000 miles.
Dealerships frequently claim ignorance of known bulletins, cannot replicate issues, or fail to diagnose and repair problems even after multiple visits.
Same Ford F-250 engine reports on nearby years: 2012 · 2013 · 2014 · 2016 · 2017
Failure modes owners describe
Power loss and violent shaking during exhaust regeneration
During DPF (diesel particulate filter) regeneration cycles, the engine loses power suddenly, shakes violently, and produces loud knocking or pinging noises. The truck can drop 15 mph instantly. Drivers must maintain throttle to the floor to prevent bucking, creating unsafe conditions since the engine cannot be controlled normally. The shaking can last 1-2 minutes or be brief (8-10 seconds). Occurs at speeds from 30–70 mph regardless of temperature or driving conditions.
When: Starts intermittently around 4,100 miles; becomes chronic by 60,000+ miles; occurs during every regen cycle once developed
Symptoms owners cite: Sudden power loss during regen; Violent engine shaking and bucking; Loud knocking and pinging; Inability to control throttle normally; Rapid speed drop (15 mph or more); Rough running
Repairs/costs cited: Ford issued TSB 15-0088 and promised a software recalibration in March 2016; owners report dealerships could not find the cause; some dealerships denied awareness of the TSB or the known issue
Recalls/TSBs owners mention: Ford acknowledged the problem to at least one owner and stated a software revision would be released April 2016; TSB 15-0088 and TSB 15-0124 reference valve and valve guide clearance issues
Valve and valve guide clearance / valve sticking
Engine exhibits hammering and valve knocking, particularly during regen cycles. Owners and dealers suspect valves sticking open or excessive valve-to-guide clearance causing mechanical noise and power loss. One owner reported a broken valve spring that dropped a valve, created a hole in the piston top, and caused immediate compression loss while driving. Another reported an exhaust valve that stuck and threw the connecting rod through the piston and cylinder wall.
When: Can occur as early as 4,000 miles; observed at 92,000 miles when valve spring broke; at 87,000 miles when exhaust valve stuck
Symptoms owners cite: Engine hammering and knocking; Valve noise; Power loss; No advance warning (no check engine light before mechanical failure); Sudden compression loss while driving
Repairs/costs cited: Broken valve spring required piston and engine work costing thousands; stuck exhaust valve required complete engine replacement ($10,000+); TSB 15-0124 references the valve-guide issue but recommends major engine work with no guarantee
Recalls/TSBs owners mention: TSB 15-0124 acknowledges valve and valve guide clearance issue as a known design flaw; no effective recall or warranty extension documented in these narratives
Check engine light / reductant heater failures and DEF sensor faults
Check engine lights illuminate with codes indicating DEF (diesel exhaust fluid) reductant heater defects (P20BA) and sensor failures. One owner received code P21B0 (reductant level sensor circuit high) without prior notification that DEF was low. Owners report dealerships either did not know of related recalls or recalls did not include their VINs. The reductant heater failure is covered under a recall for F-450/F-550 but not F-250 trucks, forcing owners to pay for repairs out-of-pocket.
When: Observed at 40,000 miles, 59,000 miles, 69,361 miles, 100,000+ miles
Symptoms owners cite: Check engine light; Low engine power message; DEF low warning (or missing warning); Vehicle limp mode
Codes mentioned: P20BA, P21B0
Repairs/costs cited: One owner paid for knock sensor replacement and DEF heater replacement; costs not specified but owner was out-of-warranty; another unable to get repairs because VIN not included in recall
Recalls/TSBs owners mention: Recall exists for some models but not F-250; owners told vehicle out of warranty; one owner referred to Customer Satisfaction Program 21N05
Engine fires and explosions
Multiple owners experienced engine compartment fires or explosions with no advance warning, resulting in total loss vehicles and property damage. One fire occurred three days after fuel filter replacement (independent mechanic work). One explosion occurred on the third engine start attempt with the driver blown out of the vehicle; the fire burned the owner's residence. Another fire started from under the hood while driving at 65 mph after "low engine power" and "low fuel" messages appeared; the owner was towing a camper at the time.
When: At 38,000 miles (explosion on startup), 50,000 miles (fire from front hood), 61,000 miles (fire while towing at 65 mph)
Symptoms owners cite: Fire under hood or in engine compartment; Engine explosion on startup; Burning odor from engine compartment; Smoke trailing vehicle; Low engine power and low fuel messages (in one case)
Repairs/costs cited: All vehicles destroyed; no repairs attempted; no diagnostic testing performed
Recalls/TSBs owners mention: Manufacturer was notified in at least one case; no recall or warranty information provided in narratives
Engine stalling and limp mode at highway speeds
Vehicle stalls suddenly without warning while driving at 70 mph or enters limp mode at various speeds. In one case, diagnosis showed exhaust system failure; repair was attempted but the stall recurred despite manual regeneration and further dealer work. In another, vehicle entered limp mode multiple times but was never properly diagnosed or repaired.
When: Occurred at 10,300 miles (stall/exhaust system), 60,000 miles (limp mode)
Symptoms owners cite: Sudden stall without warning; Loss of motive power; Vehicle enters limp/idle mode after restart; Check engine light
Repairs/costs cited: Exhaust system was replaced once and failure recurred; dealer performed manual regen but stall happened again; second vehicle not repaired
Recalls/TSBs owners mention: Manufacturer made aware; no resolution documented in these narratives
Radiator leaks at plastic-to-metal joint
Radiator develops a leak where the metal core attaches to the plastic tank/jug, typically on the driver's side. One owner replaced the radiator with an OEM Ford unit and the replacement also leaked. Dealership confirmed this is an ongoing, unresolved issue with this model year. Leak observed after use; no warning lights or advance notice.
When: At 34 months / 47,000 miles; exact mileage for others not always stated
Symptoms owners cite: Coolant leak from radiator; No warning lights before failure
Repairs/costs cited: Radiator replacement required ($500–$1,000+ range typical, exact cost not stated); OEM replacement also failed with same leak pattern
Recalls/TSBs owners mention: Dealership acknowledged it is an ongoing problem but Ford will not cover it beyond the 3-year/36,000-mile basic warranty; no TSB or recall action documented
Cylinder misfire and compression loss
Engine exhibits misfiring in cylinders (fourth and fifth cylinders noted in one case) and one owner experienced sudden total compression loss while driving 35 mph due to a broken valve spring that dropped a valve into the piston, creating a hole in the piston top. No warning lights or knocks before the failure occurred.
When: Misfire diagnosed at 3,200 miles; compression loss at 92,000 miles (valve spring break) and 87,000 miles (stuck valve)
Symptoms owners cite: Misfire (cylinders 4 and 5); Broken valve spring; Valve dropping into piston; Sudden complete compression loss; No advance warning
Repairs/costs cited: Misfire case not repaired; compression loss cases required engine replacement or major engine rebuild costing $10,000+
Recalls/TSBs owners mention: None documented in these narratives
Front-end shaking (possible death wobble)
Vehicle's front end begins shaking violently at 60 mph. Shaking ceases when brakes are depressed but resumes when accelerator is pressed. Occurs on multiple occasions. One owner suspected death wobble; dealer was unable to find the cause despite diagnostic attempt.
When: Occurred at 137,755 miles; multiple occasions
Symptoms owners cite: Violent front-end shaking at highway speed; Shaking stops with brake application; Resumes with acceleration
Repairs/costs cited: Dealer diagnosed and repaired but owner unaware of repair details
Recalls/TSBs owners mention: None documented
Excessive diesel particulate filter regeneration triggering fire risk
DEF (reductant) heater failure causes the truck to perform more frequent regeneration cycles to meet emissions specs. These frequent regen cycles cause the exhaust to heat nearby materials (straw, grass, household structures) when the vehicle is parked, creating fire hazard. One owner noted the heater failure is covered under recall for F-450/F-550 but not F-250, creating unequal safety exposure.
When: Observed at 100,000+ miles when reductant heater failed
Symptoms owners cite: More frequent regeneration cycles; Excessive exhaust heat when parked near combustible materials
Codes mentioned: P20BA
Repairs/costs cited: No repair documented; owner identified potential fire risk in high-temperature areas (straw, grass near structures)
Recalls/TSBs owners mention: Reductant heater recall only covers F-450/F-550, not F-250, leaving this model exposed
Synthesized from 30 NHTSA owner complaints — unverified consumer allegations, summarized for patterns. The verbatim filings appear below.
What owners are reporting 0 most recent
Had engine trouble with your 2015 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 2015 Ford F-250?
It's a meaningful issue. 30 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 28 complaints that reported odometer mileage, most engine failures cluster between 13,000 and 92,000 miles, with the median around 47,000. A quarter of owners report trouble before 13,000; a quarter make it past 92,000. 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/2015/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.