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 ↗2015 Ford F-350 engine problems
severe 25 complaints filed with NHTSA · avg repair $3,100 · see engine across all vehicles →
Failure mileage
Complaints
25
Recalls
0
Avg fix
$3,100
3fires
What stands out
Owners have filed 25 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.
No new NHTSA engine complaint has been filed on this vehicle in over 4 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 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.
Pickup - 6.7L Diesel Engine - Runs rough during exhaust regeneration process - built on or before 02/23/2016
full bulletin at NHTSA ↗FORD: CERTAIN 2011-2015 FORD F-SUPER DUTY WITH 6.7 DIESEL ENGINES MAY EXPERIENCE A VIBRATION BUZZ NOISE FROM THE DIESEL FUEL CONDITIONING MODULE (DFCM) AND/OR MAY 10/1/1 PRESSURE FUEL LINES W/O DIAGNOSTIC TROUBLE CODE POOSA.
full bulletin at NHTSA ↗FORD: POWERTRAIN CONTROL MODULE (PCM) MEMORY HAS STORED SAMPLE ERROR BANK-1 OF PARTICULATE MATTER SENSOR EXHAUST WITH DTC P24DA, MALFUNCTION INDICATOR LAMP (MIL) ON. MODEL 2015 F-SUPER DUTY.
full bulletin at NHTSA ↗Source: NHTSA manufacturer communications. Bring the bulletin number to your dealer or shop.
The failure pattern owners describe
The 2015 F-350 6.7L diesel shows a pattern of major engine and emissions-control problems across a broad mileage range.
Engine and turbo failures appear most critical. One owner experienced catastrophic engine failure at 69,345 miles while towing at highway speed, requiring short-block replacement under warranty. Later the engine locked up again at 80,029 miles (long-block replacement), then failed entirely at 115,000 miles with no coverage. Another owner's turbo malfunctioned at 58,000 miles, cutting power suddenly on the freeway—a dangerous intermittent fault that Ford diagnosed only after the second occurrence. A third reported a hole in the engine block at 60,628 miles, out of warranty, costing $9,349 to repair.
Emissions and DEF system failures are expensive and recurrent. Owners report sensor failures (EGR, DEF, NOX, temperature, particulate) starting as early as 4,500 miles. One owner replaced the same NOX sensor twice plus one calibration within four years and 10,000 miles, paying $1,058.64 out of pocket for the second one. Another spent nearly $800 on multiple sensor replacements and was stranded for over 8 weeks. DEF heater failures trigger speed limiters (50 mph max), and Ford's coverage campaigns exclude some vehicles despite known defects.
Fuel system and fire hazards reported include complete vehicle destruction from fuel leaks at the engine top, burning fuel pouring from the secondary fuel filter area, and CP4 fuel pump failures costing $9,300 to repair. One owner's high-pressure fuel pump failed at 129,239 miles, stranding the family on an interstate.
Violent shaking during exhaust regeneration cycles occurs repeatedly. Multiple owners describe dangerous engine shuddering when the "Cleaning Exhaust Filter" message appears, beginning as early as 4,500 miles and recurring every 400–600 miles. One owner was merging onto an interstate while towing a 9,000 lb trailer when the regen cycle triggered violent shaking and power loss. Ford has told owners this is normal.
Many owners report intermittent faults that technicians cannot reproduce, leading to unresolved issues and denied warranty claims once mileage exceeds limits.
Same Ford F-350 engine reports on nearby years: 2012 · 2013 · 2016 · 2017
Failure modes owners describe
Turbocharger intermittent failure and reduced acceleration
Turbocharger malfunction causing sudden loss of engine power and acceleration capability during highway driving, with check engine light and 'Reducing Acceleration' message on dash. Issue recurs after restart even when technician cannot locate fault initially.
When: 58,000 miles; intermittent with repeated occurrences
Symptoms owners cite: Drastic reduction in engine acceleration; Check engine light illumination; 'Reducing Acceleration' message on dash display; Vehicle operated normally after shutdown and restart; Safety hazard due to sudden loss of power on freeway
Codes mentioned: Check engine code (not specified)
Repairs/costs cited: Ford diagnosed as bad turbo; replacement with new Ford turbocharger estimated at $5,100 with two-year warranty
Recalls/TSBs owners mention: Turbo replacement warranty is two years; owner believes should be recall
EGR and DEF system sensor failures
Multiple sensor failures in exhaust emissions and fluid systems causing vehicle to enter limp mode via check engine light. Repeated failures of the same sensor type within weeks of replacement.
When: 42,188 miles; over 8 weeks of downtime
Symptoms owners cite: Check engine light illumination; Vehicle in limp mode; Emissions test failure; Reduced drivability
Codes mentioned: EGR system fault, DEF system fault, Temperature sensor fault, Particulate sensor fault
Repairs/costs cited: Four temperature sensors replaced ($146.55 each initially), particulate sensor replaced twice (first $146.55, second $200.99); total owner expense nearly $800
Recalls/TSBs owners mention: Emissions warranty expires immediately after purchase; Ford has not issued a redesign or recall
DEF heater and reductant sender assembly failure
DEF system heater and sender assembly malfunction causing exhaust fluid system fault message and vehicle speed limitation to 50 mph, with threat of engine shutdown. Covers 2015 model year under Ford Campaign 21M01.
When: Less than 64,000 miles; January 2022
Symptoms owners cite: Engine light illumination; 'Exhaust Fluid System Fault' message; Vehicle limited to 50 mph; Threat of engine shutdown
Codes mentioned: Exhaust Fluid System Fault
Repairs/costs cited: DEF heater and pump replacement; owner paid out of pocket and was supposed to be reimbursed by Ford but has not received reimbursement
Recalls/TSBs owners mention: Ford Campaign 21M01 issued covering cost of reductant heater and sender assembly replacement; owner claims lack of follow-up on promised reimbursement; sensor recalibration by Ford subsequently caused particulate filter to fail but Ford declined to cover filter replacement
Catastrophic engine failure with multiple replacements
Multiple complete engine failures including sudden engine shutdown, catastrophic engine blow-up while towing, engine lock-up, and final engine failure requiring replacement. Vehicle replaced with short block engine, then long block engine under warranty, then required another engine at 115,000 miles with no warranty coverage.
When: 65,142 miles (first failure); 69,345 miles (blow-up while towing); 80,029 miles (lock-up); 115,000 miles (final failure)
Symptoms owners cite: Engine quit running without warning on Interstate; Engine catastrophic failure while traveling at 65 mph towing trailer; Engine locked up, would not turn over; Engine quit running again at 115,000 miles
Repairs/costs cited: Short block engine installed under warranty (69,345 miles); long block engine installed under warranty (80,029 miles); fourth engine required at 115,000 miles but not available and out of warranty; multiple service orders documented
Recalls/TSBs owners mention: Covered first two replacements under warranty; declined coverage for final engine replacement at 115,000 miles
Engine block structural failure with hole
Engine block developed a hole in the assembly causing catastrophic failure. Primary engine replaced and converter assembly also replaced due to oil contamination from the block failure.
When: 60,628 miles (initial hole); 61,629 miles (engine replacement due to intake manifold issue)
Symptoms owners cite: No warning lights; Engine block hole discovered during inspection
Repairs/costs cited: Engine replacement and converter assembly replacement; total repair cost $9,349.20; second engine failed at 61,629 miles due to intake manifold replacement
Recalls/TSBs owners mention: Vehicle excluded from warranty coverage; no recall issued
Turbo and exhaust system blockage with fire hazard
Catalytic converter blockage or turbo failure causing fireballs exhausted from exhaust pipe, which ignited fire in desert. Vehicle simultaneously lost power steering and engine shut down.
When: 135,000 miles
Symptoms owners cite: Instrument panel illumination/unillumination cycling; Fireballs being exhausted from pipe; Loss of power steering; Engine shut down; Fire in desert
Repairs/costs cited: Local mechanic diagnosed catalytic converter blockage or turbo issue; vehicle was repaired
Recalls/TSBs owners mention: Manufacturer was not notified of failure
Intercooler hose cracking and failure
Intercooler hose cracked while driving, causing loss of motive power. Owner reports this is a known issue. Turbocharger subsequently failed to operate as needed even after hose replacement.
When: 120,000 miles
Symptoms owners cite: Loss of motive power during highway driving; No warning light illuminated; Reduced speed drivability
Repairs/costs cited: Intercooler hoses replaced; MAP sensor replaced; turbocharger still failed to operate properly after repair
Recalls/TSBs owners mention: Owner identified this as known issue; neither dealer nor manufacturer was notified
Engine violent shaking and knocking during exhaust filter cleaning
Engine shakes violently and produces knocking noises when the 'Cleaning Exhaust Filter' message appears and regen cycle activates. Problem occurs intermittently but consistently during exhaust regeneration, starting around 4,500 miles.
When: Starting around 4,500 miles; recurring at 400-600 mile intervals; reported at 6,865 miles and 32,000 miles
Symptoms owners cite: Violent shaking and knocking during regen cycle; 'Cleaning Exhaust Filter' message displayed; Engine vibration feels like four flat tires; Loss of power during regen; Jerking backward and forward; Spiking noises from engine
Repairs/costs cited: Unable to recreate at dealership; owner reports shaking happens multiple times (4 times reported in one complaint; started at 4,500 miles in another)
Recalls/TSBs owners mention: Ford stated this is normal operation; owner disputes and expresses safety concern on mountain roads
NOX sensor repeated failures and calibration issues
NOX sensor fails repeatedly within short timeframe (two replacements and one calibration in four years and 10,000 miles). Owner incurs out-of-pocket cost for second replacement after warranty expires.
When: 2019 (103,000 miles); 2021 (110,000 miles calibration); 2024 (113,945 miles)
Symptoms owners cite: Engine light illumination; NOX sensor fault code
Codes mentioned: NOX sensor fault
Repairs/costs cited: First NOX sensor replaced under 4-year extended warranty (2019); sensor calibration performed (2021); second NOX sensor replacement cost $1,058.64 out of pocket (2024)
Recalls/TSBs owners mention: First replacement covered under extended warranty; no pattern recognition or redesign; owner reports Sunrise Ford acknowledges part has issue shared by other truck owners
High-pressure fuel pump failure
Bosch high-pressure fuel pump failed to deliver required pressure (7,000 PSI), causing sudden vehicle slowdown to 5-10 mph on interstate and eventual complete engine shutdown, leaving owner stranded.
When: 129,239 miles
Symptoms owners cite: 'Low Fuel Pressure' alert on display; Vehicle slowed to 5-10 mph on interstate; Engine stopped completely
Codes mentioned: Low fuel pressure
Repairs/costs cited: Bosch high-pressure fuel pump replacement with exchange; pump cost $1,245 plus labor totaling nearly $5,000
Recalls/TSBs owners mention: Vehicle exceeded 100,000 mile warranty; Ford declined coverage; owner characterizes pump as poorly designed
Diesel particulate filter cracking
Diesel particulate filter developed a crack requiring replacement. Related to Ford Customer Satisfaction Program 20M06 but vehicle VIN not included in program eligibility.
When: 49,000 miles
Symptoms owners cite: Check engine warning light
Codes mentioned: Check engine code related to DPF
Repairs/costs cited: Filter cracking identified by independent mechanic; vehicle not repaired; related to CSP 20M06
Recalls/TSBs owners mention: Ford CSP 20M06 exists but VIN not included; manufacturer referred owner to NHTSA; no recall issued
Engine block heater core wire assembly melting
Engine block heater core wire assembly melted with no warning lights. Issue related to Ford Safety Recall 18S45 but vehicle was not covered.
When: 120,000 miles
Symptoms owners cite: Melted wire assembly observed during visual inspection; No warning lights illuminated
Repairs/costs cited: Visual inspection only; vehicle not repaired
Recalls/TSBs owners mention: Safety Recall 18S45 issued but vehicle apparently not included; manufacturer referred owner to NHTSA
DEF system failure with speed derate warning
DEF system and NOX module failure causing '50 Miles until Derate Speed Limitation' message and check engine light, indicating imminent vehicle speed limitation.
When: 29,593 miles
Symptoms owners cite: '50 Miles until Derate Speed Limitation' message; Check engine light illumination; DEF system fault
Codes mentioned: NOX module fault
Repairs/costs cited: Dealer diagnosis only; vehicle condition unknown
Recalls/TSBs owners mention: Manufacturer confirmed vehicle not under warranty at 29,593 miles (likely emissions warranty expired)
Violent engine shaking during regeneration cycle
Engine shakes violently and loses power during diesel particulate filter regeneration cycle (regen). Problem escalated to dangerous levels during highway merging while towing heavy equipment.
When: Timing not specified; significant enough to trade in vehicle
Symptoms owners cite: Violent engine shaking during regen; Loss of power while merging onto interstate; Dangerous with loss of power while towing 9,000 lb trailer
Repairs/costs cited: Vehicle traded back to dealer; not repaired by owner
Recalls/TSBs owners mention: Ford stated violent shaking during regen is normal operation; no repair offered
Oil pan seal failure with oil leak
Oil leaking from underneath vehicle due to oil pan seal failure requiring replacement and resealing.
When: 96,956 miles
Symptoms owners cite: Oil on floor underneath vehicle
Repairs/costs cited: Oil pan replaced and resealed
Recalls/TSBs owners mention: Manufacturer contacted and case filed; referred owner to NHTSA
Oil dipstick fracture and corrosion
Engine oil dipstick fractured in half and was rusted, preventing proper oil level checking.
When: 93,000 miles
Symptoms owners cite: Dipstick fractured in half; Dipstick rusted
Repairs/costs cited: Vehicle not repaired; local dealer not contacted
Recalls/TSBs owners mention: Manufacturer notified and referred owner to NHTSA
Fuel leak and engine fire
Fuel leak developed in area of top of engine resulting in vehicle fire that destroyed the entire vehicle. No recall or technical service bulletin exists for this issue.
When: Timing not specified
Symptoms owners cite: Fuel leak at top of engine area; Vehicle fire; Complete vehicle destruction
Repairs/costs cited: Vehicle destroyed by fire; not repaired
Recalls/TSBs owners mention: Ford stated no recalls or technical service bulletins exist for fuel leak fire issue
CP4 fuel pump catastrophic failure
CP4 fuel pump catastrophic failure with owner reporting Ford is aware of the problem and offers a retrofit kit, indicating known design issue.
When: Not specified
Symptoms owners cite: Fuel pump failure
Repairs/costs cited: Repair cost $9,300; retrofit kit available (fuel line replacement, fuel injection replacement, both fuel pumps, tank drop and flush)
Recalls/TSBs owners mention: Ford has retrofit kit available but does not address root cause; no recall issued despite known issue
Secondary fuel filter area fire
Vehicle caught fire with burning fuel pouring from left side of engine in the secondary fuel filter area while driving on highway.
When: Not specified
Symptoms owners cite: Engine fire on left side; Burning fuel pouring from secondary fuel filter area
Repairs/costs cited: Vehicle not repaired (destroyed by fire)
Recalls/TSBs owners mention: Manufacturer not notified
DEF heater failure outside campaign coverage
DEF heater failed but vehicle not included in Ford's customer satisfaction campaign addressing this issue.
When: Not specified
Symptoms owners cite: DEF heater failure
Repairs/costs cited: Not repaired due to lack of campaign coverage
Recalls/TSBs owners mention: Ford has customer satisfaction campaign for DEF heater but vehicle excluded; no other remedy offered
Synthesized from 25 NHTSA owner complaints — unverified consumer allegations, summarized for patterns. The verbatim filings appear below.
What owners are reporting 2 most recent
Cp4 fuel pump failure, upon failure repair was $9300.00, ford obviously knows of the problem as their is a kit that can be purchased for this catastrophic failure{fuel line replacement, fuel injection replacement, both fuel pump replacement , drop and flush fuel tank.}
While driving truck caught fire left side of engine and in a few hundred yards of getting stopped burning fuel was pouring from left side in the area of secondary fuel filter.
Had engine trouble with your 2015 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 engine problem on the 2015 Ford F-350?
It's a meaningful issue. 25 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 16 complaints that reported odometer mileage, most engine failures cluster between 29,593 and 120,000 miles, with the median around 61,000. A quarter of owners report trouble before 29,593; a quarter make it past 120,000. 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-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.