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 ↗2016 Ford F-350 engine problems
severe 14 complaints filed with NHTSA · avg repair $3,100 · see engine across all vehicles →
Failure mileage
Complaints
14
Recalls
0
Avg fix
$3,100
1fire
2injuries
When does it fail?
Of the 14 engine complaints filed for the 2016 Ford F-350, here's the actual mileage breakdown — failures cluster heaviest at 50,000-75,000 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 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 ↗Source: NHTSA manufacturer communications. Bring the bulletin number to your dealer or shop.
The failure pattern owners describe
Owners report multiple serious engine and fuel system failures on 2016 F-350 diesels, many occurring under 60,000 miles. The most consistent issue is DEF reductant heater malfunction (check engine code P20BA), which triggers around 50,000–60,000 miles but isn't covered by the Ford recall (18M01) extended to 2011–2015 models despite identical platform design. Repair costs run $1,200+, and dealers confirm many 2016 VINs are excluded from recall.
Fuel system contamination—metal shavings in the high-pressure fuel pump and fuel lines—causes stalling and loss of power at highway speed. One owner's truck couldn't be permanently repaired; another faces $12,000+ in damage from CP4 pump failure.
Turbocharger failure recurs even after replacement. One owner had the turbo replaced and the issue returned; Ford stated the turbo is only good for 3–4 years. DPF regeneration triggers violent backfiring and engine shaking starting around 5,000 miles; Ford issued a service bulletin but repairs (software update, cylinder head, then full engine replacement) have not permanently solved it.
One owner reports catastrophic engine failure three days after warranty expiration—connecting rod failure and crankshaft damage, allegedly from antifreeze flooding a cylinder. A separate owner's engine caught fire while driving. Stalling on interstate exits also reported.
Same Ford F-350 engine reports on nearby years: 2013 · 2015 · 2017 · 2019
Failure modes owners describe
DEF/SCR Fluid Heater Failure
Diesel Exhaust Fluid (DEF) reductant heater malfunction triggers check engine light. Owners report this issue appears related to a recall (Ford Customer Satisfaction Program 18M01) issued for 2011–2015 model years, but 2016 models are not included despite identical body/engine design. Some dealers confirm the VIN is excluded from recall coverage.
When: Around 50,000–60,000 miles
Symptoms owners cite: Check engine light illumination; Flashing check engine warning indicator
Codes mentioned: P20BA
Repairs/costs cited: Reductant heater and sender assembly replacement; owners cite ~$1,200 estimated cost. Some dealers replaced the part out of warranty.
Recalls/TSBs owners mention: Ford Customer Satisfaction Program 18M01 issued for 2011–2015; 2016 model year VINs excluded from recall despite same platform. Manufacturer referred at least one owner to NHTSA after denying repair assistance.
Coolant Loss / EGR Cooler / Cylinder Head Flooding
Chronic antifreeze loss despite multiple repair attempts. One owner reports dealer replaced EGR cooler, then engine suffered catastrophic connecting rod failure three days after warranty expiration. Owner alleges antifreeze flooded a cylinder, locking it up and causing crankshaft damage. Dealer denied warranty claim and charged for unnecessary EGR cooler repair.
When: During warranty period; failure ~3 days after warranty ended
Symptoms owners cite: Gradual antifreeze/coolant loss; Connecting rod failure, crankshaft damage; Antifreeze flood into cylinder
Repairs/costs cited: Dealer replaced EGR cooler (owner disputes necessity). Engine replacement required after connecting rod penetrated engine block.
Recalls/TSBs owners mention: Dealer refused to stand behind any repairs or warranty coverage once contract expired; offered no investigation into root cause.
Turbocharger Failure / Recurring Issues
Turbocharger requires replacement and recurs post-repair. One owner experienced repeated turbo failure at ~50,000 miles; another reports turbo replacement followed by black smoke, engine damage, and multiple other failed repair attempts (turbo again, body mounts, coolant pump). Ford stated turbocharger good for only 3–4 years and offered no further support.
When: Around 50,000 miles; recurs after replacement
Symptoms owners cite: Loss of engine power while driving 45–55 MPH; Engine enters limp mode; RPM limited to ~2,500; Black smoke from exhaust; No warning lights initially
Repairs/costs cited: Turbocharger replacement; owner replaced it once, failure recurred. Another owner had turbo, body mounts, and coolant pump replaced without permanent resolution.
Recalls/TSBs owners mention: Manufacturer stated turbocharger is only good for 3–4 years and declined further assistance. Ford dealers unable to resolve recurring issue.
Emission Regeneration DPF Backfire / Engine Vibration
During DPF regeneration cycle, engine experiences violent shaking and continuous backfiring. Ford has a service bulletin for 2016 F-350 Super Duty addressing this. Computer-controlled fuel injection imbalance (added fuel to one side of cylinder head to burn off DPF soot) triggers uncontrolled combustion. Occurs ~5,000 miles after each new engine; issue persists despite software update, cylinder head replacement, and full engine replacement.
When: ~5,000 miles into operation; recurs with each engine
Symptoms owners cite: Violent engine shaking during DPF regeneration; Continuous backfiring; Severe enough to force driver to pull over and shut down engine
Repairs/costs cited: Ford issued service bulletin (bulletin number not specified). Software update applied first, then cylinder head replaced, then entire engine replaced. Issue persists with replacement engine.
Recalls/TSBs owners mention: Ford has service bulletin on file for this issue but has pursued escalating repairs (software, head, engine) without resolving root cause.
Fuel System Contamination / Metal Shavings / High-Pressure Fuel Pump Failure
Fuel system contains metal shavings; high-pressure fuel pump suspected as source or damaged by debris. One owner's fuel tank contained metal shavings and possible water/rust; another experienced black smoke and turbocharger damage in what appears to be secondary consequence. One instance mentions fuel may have been wrong octane or contaminated. At least one case resulted in engine stall at highway speed (45,000 miles) that could not be permanently repaired.
When: 35,000–82,800 miles
Symptoms owners cite: Engine stall without warning, unable to restart; Loss of power at highway speed; Black smoke from exhaust; Multiple subsequent failures (turbo damage, body mount/coolant pump wear)
Repairs/costs cited: High-pressure fuel pump may require replacement; fuel system flushing/cleaning attempted. One owner awaiting part availability; another dealer could not provide permanent remedy.
Recalls/TSBs owners mention: Manufacturer speculated contaminated fuel but did not take responsibility. One dealer awaited part availability from manufacturer.
Exhaust Regeneration Speed Loss / Limp Mode During Heavy Towing
When pulling heavy load (18,000 lb camper) on interstate, vehicle enters exhaust cleaning mode and speed drops from 65–70 MPH to ~45 MPH in short distance, mimicking limp mode. No diagnostic codes present. Occurs when towing but not observed unloaded. Ford stated this is normal operation, but owner reports safety hazard due to sudden ~30 MPH speed drop and rear-end collision risk.
When: Occurs during loaded towing; happened twice in one month
Symptoms owners cite: Speed drop from 65–70 MPH to ~45 MPH during DPF regeneration; No diagnostic codes set; Recovery to normal speed when regeneration completes
Repairs/costs cited: None; Ford states this is normal behavior.
Recalls/TSBs owners mention: Ford informed owner this is normal operation and offered no remedy.
Engine Fire
Owner heard backfire-like noise from front of engine, then smoke and flames erupted from under hood while driving mountain highway. Truck and attached fifth-wheel trailer engulfed in flames within minutes. Both occupants treated for smoke inhalation by first responders.
When: During highway operation
Symptoms owners cite: Noise from engine compartment (backfire-like); Smoke from under hood; Rapid ignition and engine fire
Repairs/costs cited: Vehicle destroyed.
CP4 High-Pressure Fuel Pump Failure / System Destruction
CP4 (common-rail fuel injection pump) destruction caused extensive fuel system damage. Owner reports upwards of $12,000 in repairs and characterizes it as a recurring issue Ford should address.
When: <UNKNOWN>
Symptoms owners cite: CP4 pump internal failure; Fuel system damage
Repairs/costs cited: Fuel system repair/replacement; estimated cost $12,000+
Engine Stall on Interstate Exit
Vehicle stalls without warning while exiting interstate. Owner can restart after coming to complete stop, parking, and turning off ignition. Recurrence not mentioned.
When: During interstate operation / exit
Symptoms owners cite: Engine stall without warning; Requires full shutdown and restart to resume operation
Synthesized from 14 NHTSA owner complaints — unverified consumer allegations, summarized for patterns. The verbatim filings appear below.
What owners are reporting 2 most recent
The contact owns a 2016 Ford F-350. The contact stated that while driving at an undisclosed speed, the check engine warning light illuminated. The vehicle was taken to the dealer. The dealer diagnosed that the Diesel Exhaust Fluid (DEF) reductant heater needed to be replaced. The dealer informed the contact that the VIN was not included in a recall. The vehicle was not repaired and remained at…
The cp4 injection pump destructed and took out the whole fuel system with it. Cause upwards of $12,000 in repairs this is a issue ford needs to address and get took care and take some responsibility on there own
Had engine trouble with your 2016 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 2016 Ford F-350?
It's a meaningful issue. 14 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 10 complaints that reported odometer mileage, most engine failures cluster between 35,000 and 60,000 miles, with the median around 52,500. A quarter of owners report trouble before 35,000; a quarter make it past 60,000. 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/2016/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.