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 ↗2016 Ford F-250 engine problems
severe 23 complaints filed with NHTSA · avg repair $3,100 · see engine across all vehicles →
Failure mileage
Complaints
23
Recalls
0
Avg fix
$3,100
1crash
1fire
3injuries
When does it fail?
Of the 23 engine complaints filed for the 2016 Ford F-250, here's the actual mileage breakdown — failures cluster heaviest at 100,000-125,000 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
No new NHTSA engine complaint has been filed on this vehicle in over 5 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.
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 describe a chain of fuel system failures starting early. The high-pressure fuel pump (Bosch CP4) degrades and sheds metal that contaminates the entire fuel system—injectors, lines, filters, tank. Check engine codes P0170, P008A, and P229F appear; one owner at 27,000 miles had to replace injectors, pump, lines, and filters, losing 15 gallons of fuel in the process. The truck went on to fail again with the same code at higher mileage despite full fuel system replacement.
Owners report sudden, complete loss of engine power while driving—sometimes at highway speed with a loaded trailer. One stall at 35 mph triggered a multi-vehicle crash and head injuries. Another happened on an interstate ramp at full turn. No warning lights precede these failures in some cases.
DEF (diesel exhaust fluid) heater failures lock trucks into 50 mph limp mode or idle, starting around 70,000 miles. Ford has a service campaign (20M01) but dealers deny coverage, citing mileage limits. The same defect was addressed for 2011–2015 models under campaign 18M01, yet recurs in 2016.
During exhaust regeneration cycles, engines shudder, sputter, stall, and produce loud jackhammer noises while losing power for 10 seconds—owners describe it as terrifying. Software reflashes don't fix it. One truck also caught fire at 137,000 miles after a loud engine pop. Another had a hole blow in the upper oil pan, dumping all oil.
A truck required three radiator replacements in 77,000 miles. Warranty denials are frequent.
Same Ford F-250 engine reports on nearby years: 2013 · 2014 · 2015 · 2017
Failure modes owners describe
High-Pressure Fuel Pump Failure & Fuel System Contamination
Bosch CP4 fuel pump fails, shedding metal debris that contaminates fuel lines, filters, tank, and injectors. Multiple check engine codes (P0170 fuel system, P008A low fuel pressure) appear. Metal found in fuel filter, lines, and tank after diagnosis. Complete fuel system replacement required: injectors, pump, lines, filters, tank flush.
When: As early as 27,000 miles; also reported at 70,000 and 137,000
Symptoms owners cite: Check engine light (P0170, P008A, P229F codes); Sudden stall while driving; Loss of power; Truck won't restart; Metal contamination in fuel system
Codes mentioned: P0170, P008A, P229F
Repairs/costs cited: Replaced fuel system kit, 8 injectors, high-pressure pump, steel lines, return line, fuel filters; flushed fuel lines and tank. Owner lost ~15 gallons fuel and paid $19.74 to restart. Parts were on backorder.
Recalls/TSBs owners mention: SSM #45737 issued for monitoring; dealer stated Ford does not know the cause or how to fix the problem permanently. Under warranty but owner charged for some repairs.
Engine Stall & Loss of Motive Power (Undiagnosed)
Vehicle loses all engine power while driving, sometimes while towing. In one case with trailer at 35 mph, warning light illuminated and vehicle stalled, causing loss of steering control and multi-vehicle crash. In another case, vehicle lost power at 50 mph on ramp, nearly hit concrete wall. No prior warning lights reported. One case involved cylinder #2 failure requiring engine replacement.
When: 35–70 mph while driving and towing; one incident at ~126,000 miles
Symptoms owners cite: Sudden total loss of engine power; Loss of steering control (power steering dependent on engine); Warning light illumination (in one case); Vehicle will not restart; Crash/collision resulting from loss of control
Repairs/costs cited: One case: cylinder #2 failure, engine replacement required. One case: fuel pump failure. Most cases: dealer diagnosis incomplete or manufacturer provided no assistance. Repairs not completed by owners.
Recalls/TSBs owners mention: Manufacturer notified but provided no assistance. One case: no recall under VIN, no further information provided. Injuries sustained; police report filed.
DEF/Reductant Heater Failure
Diesel exhaust fluid (DEF) heater assembly fails, causing check engine light and limp mode (reduced speed). In cold conditions, DEF can freeze in tank, preventing injection and increasing NOx emissions. Same failure addressed in Ford Service Campaign 18M01 (2011–2015 models) but recurring in 2016 model year.
When: 70,000–120,000 miles
Symptoms owners cite: Check engine light illumination; Vehicle decelerated and locked to 50 mph maximum; Vehicle locked in idle mode, will not move; DEF freeze in sub-freezing temperatures; Increased NOx emissions
Codes mentioned: P2002
Repairs/costs cited: DEF/reductant heater replacement required. Multiple repairs not completed because dealer refused to cover under service campaign due to mileage or because owner was out of warranty.
Recalls/TSBs owners mention: Ford Service Campaign 20M01 exists but dealer denied coverage citing mileage over limit. Related campaign 18M01 covered 2011–2015 models for same issue. Customers referred to NHTSA Hotline; no warranty coverage offered.
Knock Sensor Failure
Rear knock sensor becomes defective, triggering check engine light. Diagnostic test confirms sensor failure.
When: 71,000 miles
Symptoms owners cite: Check engine light illumination
Repairs/costs cited: Knock sensor replacement required but owner not repaired due to warranty denial.
Recalls/TSBs owners mention: Manufacturer and dealer informed owner vehicle not covered under warranty. Owner referred to NHTSA Hotline.
Diesel Exhaust Filter Clogging & Defective Fuel Filter Design
Diesel exhaust filter (DPF) becomes clogged, causing warning message on instrument panel. Separate issue: when fuel filter clogs, fuel sprays out of top of filter housing while engine still running, creating fire hazard. Not designed to shut off or safely divert fuel pressure.
When: 93,538 miles for DPF; timing unspecified for fuel filter spray issue
Symptoms owners cite: Dashboard warning message; Clogged exhaust filter; Diesel fuel spraying from fuel filter housing; Fire hazard while vehicle running and unattended
Repairs/costs cited: Exhaust filter assembly replaced. Fuel filter housing design allows pressurized fuel to spray during clogging; no known repair beyond replacement.
Recalls/TSBs owners mention: Manufacturer advised contact to file NHTSA complaint. No design fix or recall mentioned.
Engine Rough Running & Jackhammering During Regeneration
Engine shudders, sputters, and stalls sporadically during diesel particulate filter (DPF) regeneration cycle, typically at 55–65 mph. Loud jackhammer noise and sudden power loss for ~10 seconds, creating safety hazard. Vehicle loses response to throttle input. Issue persists after software reflash.
When: Timing varies; occurs during exhaust regen cycles at highway speeds
Symptoms owners cite: Rough running, shuddering, sputtering; Engine stalls during regeneration; Loud jackhammer/valve noise from engine; Sudden loss of power (10 seconds); No throttle response; Whole truck shakes
Repairs/costs cited: Software reflash attempted without resolution. Valve replacement on cylinder head and possible machine shop work planned for one case. Repairs incomplete in other cases.
Recalls/TSBs owners mention: None documented. Dealer attempted reflash; cause remains unresolved.
Engine Fire
Engine catches fire while driving at 50 mph after loud pop and smoke emission. Fire department required to extinguish.
When: 137,000 miles
Symptoms owners cite: Loud pop from engine; Smoke from engine; Fire
Repairs/costs cited: Vehicle towed to impound lot. Repairs not documented.
Recalls/TSBs owners mention: Manufacturer notified. No further information provided. Police and fire reports filed.
Catastrophic Engine Failure & Oil Pan Hole
Engine experiences sudden catastrophic failure: hole develops in upper oil pan, all oil leaks out, engine seized or destroyed. Separate reports of engine needing replacement due to internal failure (cylinder damage) or complete oil loss.
When: 77,000 miles (radiator issue with engine component); unspecified for oil pan failure
Symptoms owners cite: Total loss of oil pressure/oil leakage; Engine seizure or severe damage; Loss of power while driving; Engine noise or failure
Repairs/costs cited: Engine replacement required. Hole in upper oil pan identified as cause. Complete oil system failure.
Recalls/TSBs owners mention: Manufacturer notified. No assistance provided. Vehicle not repaired by owner.
Radiator Failure (Recurring)
Radiator develops leaks and requires replacement. Same truck experienced three radiator failures within 77,000 miles, indicating design or manufacturing defect.
When: 77,000 miles (three failures in this mileage range)
Symptoms owners cite: Coolant leak; Radiator failure
Repairs/costs cited: Radiator replaced three times. Cost not specified.
Recalls/TSBs owners mention: None documented.
Synthesized from 23 NHTSA owner complaints — unverified consumer allegations, summarized for patterns. The verbatim filings appear below.
What owners are reporting 1 most recent
The reductant heater and sender assembly failed causing the malfunction indicator to light. This is the same problem addressed for the 2011-2015 model year per customer satisfaction program 18m01. The fault was confirmed by rivertown Ford in columbus ga via diagnostic tool. Clearly the issue per customer satisfaction program 18m01 remains and is affecting 2016 model year.
Had engine trouble with your 2016 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 2016 Ford F-250?
It's a meaningful issue. 23 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 18 complaints that reported odometer mileage, most engine failures cluster between 45,240 and 110,900 miles, with the median around 77,000. A quarter of owners report trouble before 45,240; a quarter make it past 110,900. 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/2016/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.