Pickup - 6.7L Diesel Engine - Runs rough during exhaust regeneration process - built on or before 02/23/2016
full bulletin at NHTSA ↗2015 Ford F-250 fuel system problems
moderate 14 complaints filed with NHTSA · avg repair $1,200 · see fuel system across all vehicles →
Failure mileage
Complaints
14
Recalls
0
Avg fix
$1,200
What stands out
No new NHTSA fuel system complaint has been filed on this vehicle in over 6 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.
Source: NHTSA manufacturer communications. Bring the bulletin number to your dealer or shop.
The failure pattern owners describe
Owners of 2015 Ford F-250s report fuel system failures across a range of mileages, starting as early as 7,000 miles and continuing beyond 280,000 miles. The most common complaint involves the Bosch CP4 high-pressure fuel injector pump shedding metal internally, sending shavings into fuel lines, filters, and the engine itself. Owners describe loss of power, check engine lights, reduced engine power warnings, and complete stalling while driving at highway speeds—typically 60-70 MPH. Several failures occur during exhaust filter cleaning cycles.
Other failures include fuel pressure regulator failures (replaced, then failed again), rusted fuel tanks, cracked fuel filter housings, and diesel fuel leaking from top fuel filter assemblies and lines. One owner found metal shavings in engine oil; another discovered white smoke from the rear and abnormal engine noise. A few vehicles suffered complete engine damage or required full fuel system and engine replacement.
Fuel system odors—both inside the cabin and in the engine bay—are reported alongside fuel spraying into the engine compartment. One vehicle lost power entirely and would not restart. Dealers and independent mechanics diagnosed metal contamination in fuel lines, failed fuel pumps, and cracked filter housings. Ford referred complainants to the NHTSA Hotline rather than offering recalls or warranty assistance for most failures.
Same Ford F-250 fuel system reports on nearby years: 2016 · 2017
Failure modes owners describe
Bosch CP4 High-Pressure Fuel Injector Pump Metal Shedding
The high-pressure fuel injector pump sheds metal internally, contaminating the fuel system with metal shavings that travel into fuel lines, filters, and the engine.
When: 7,000 miles to 189,000 miles; occurs during exhaust filter cleaning cycles in at least one case
Symptoms owners cite: Abrupt loss of engine power while driving at highway speeds; Check engine warning light and reduced engine power mode; Loud clanging and vibration noises from engine; Vehicle stalling or unable to restart; Vehicle deceleration from 60–70 MPH down to 20–45 MPH
Codes mentioned: Fuel pump failure fault code, Check engine light
Repairs/costs cited: Fuel system assembly replacement; metal shavings found in fuel line and fuel filter. One case required complete fuel and engine system replacement. Another resulted in subsequent transmission failure.
Recalls/TSBs owners mention: Referred to NHTSA Hotline; no recalls or warranty assistance noted in narratives.
Fuel Pressure Regulator Failure
Fuel pressure regulator fails, triggering reduced engine power mode and loss of power. Replacement does not always resolve the issue; regulator may fail again.
When: Around 101,000 miles
Symptoms owners cite: Reduced engine power mode; Deceleration from highway speeds to 20 MPH; Vehicle deceleration without warning lights before initial failure
Codes mentioned: Reduced engine power mode
Repairs/costs cited: Fuel pressure regulator replaced by independent mechanic; failed again within dealer's inspection. Subsequent inspection revealed rusted fuel tank and additional fuel system component failures requiring pump, injector pump, and full fuel system replacement.
Recalls/TSBs owners mention: Referred to NHTSA Hotline.
Fuel Tank Corrosion and Contamination
Fuel tank rusts internally, contaminating the fuel system and requiring replacement of the tank, fuel pump, injector pump, and related components.
When: 101,000 miles
Symptoms owners cite: Repeated fuel pressure regulator failures; Loss of engine power
Repairs/costs cited: Fuel tank, fuel pump, injector pump, and fuel system replacement required.
Fuel Pressure Sensor Failure with Metal Shaving Contamination
Fuel pressure sensor fails, accompanied by discovery of metal shavings in fuel lines indicating internal component deterioration.
When: 284,000 miles
Symptoms owners cite: Check engine light and reduced engine power warning lights; Loss of motive power; Unknown warning lights after repair attempt; Vehicle power loss during highway deceleration
Codes mentioned: Check engine code, Reduced engine power warning
Repairs/costs cited: Fuel pressure sensor replacement; mechanic found metal shavings in fuel line during inspection.
Recalls/TSBs owners mention: Manufacturer made aware; no assistance noted.
Cracked Fuel Filter Housing
Fuel filter housing cracks, allowing diesel fuel to spray or leak from the assembly into the engine bay.
When: 50,000 miles to 112,000 miles
Symptoms owners cite: Smoke coming from under hood; Unknown fluid splattering onto front windshield; Strong diesel odor while parked and driving; Fuel spraying into engine bay; Burning fuel odor inside vehicle
Repairs/costs cited: One case: fuel filter assembly replacement by dealer. Another case: upper filter housing inspection only; no repair documented.
Recalls/TSBs owners mention: One case referred to NHTSA Hotline. Manufacturer advised filing complaint with NHTSA.
Diesel Fuel Leaking from Top Fuel Filter Assembly
Diesel fuel leaks from the top fuel filter assembly, detectable inside and outside the vehicle.
When: 105,000 miles
Symptoms owners cite: Fuel odor inside vehicle cabin; Fuel leaking visible underneath vehicle; Fuel leaking from top fuel filter
Repairs/costs cited: Owner purchased and replaced fuel filter; vehicle repaired. Cause not determined.
Recalls/TSBs owners mention: Manufacturer notified; no assistance offered.
Diesel Particulate Filter (DPF) Failure
Diesel particulate filter fails prematurely, triggering check engine light. Two cases specifically noted lack of coverage under Ford Campaign Number 20M06-2.
When: 85,000 miles to 111,000 miles
Symptoms owners cite: Check engine warning light
Codes mentioned: DPF failure code
Repairs/costs cited: DPF replacement needed.
Recalls/TSBs owners mention: Ford Campaign Number 20M06-2 referenced; vehicle deemed ineligible for coverage. Referred to NHTSA Hotline.
Metal Shavings in Engine Oil
Metal shavings found in engine oil, indicating internal fuel system or engine component deterioration.
When: 61,000 miles
Symptoms owners cite: No immediate drivability symptoms noted; discovered during inspection
Repairs/costs cited: Defective fuel pump identified and replacement needed.
Recalls/TSBs owners mention: Manufacturer notified; contact referred to Ford dealer for diagnostic.
Engine Damage from Fuel System Failure
Fuel system failures lead to engine damage requiring replacement of both fuel system and engine.
When: 115,000 miles
Symptoms owners cite: Abnormal sound from engine compartment; Check engine warning light; White smoke from rear of vehicle; Loss of motive power; Unable to restart
Codes mentioned: Check engine light
Repairs/costs cited: Engine and fuel system replacement required (not completed).
Recalls/TSBs owners mention: Manufacturer notified; no assistance noted.
Fuel System Leak (General)
Fuel system develops a leak; one case involved unsafe towing conditions related to leaking fuel.
When: Unknown
Symptoms owners cite: Fuel leaking from vehicle
Synthesized from 14 NHTSA owner complaints — unverified consumer allegations, summarized for patterns. The verbatim filings appear below.
What owners are reporting 1 most recent
2015 Ford f250. Consumer writes in regards to fuel line leak, *ld the consumer no longer owns the vehicle. The consumer stated the towing company was operating an unsafe vehicle. *js
Had fuel system 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 fuel system problem on the 2015 Ford F-250?
It's a documented issue but not catastrophic. 14 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 13 complaints that reported odometer mileage, most fuel system failures cluster between 82,111 and 115,000 miles, with the median around 105,000. A quarter of owners report trouble before 82,111; a quarter make it past 115,000. 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 $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/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.