Some 2017-2020 Super Duty vehicles equipped with a 6.7L engine built on or after 13-May-2017, 2015-2019 Transit vehicles equipped with a 3.2L engine and 2018-2020 F-150 vehicles equipped with a 3.0L engine may exhibit an illuminated malfunction indicator lamp (MIL) with diagnostic trouble code (DTC) P2002 stored in the powertrain control module (PCM). This may be due to a crack in the diesel particulate filter (DPF) substrate. To correct the condition, follow the Service Procedure steps to replace the DPF and then reprogram the PCM.
full bulletin at NHTSA ↗2020 Ford F-250 engine problems
moderate 15 complaints filed with NHTSA · avg repair $3,100 · see engine across all vehicles →
Complaints
15
Recalls
0
Avg fix
$3,100
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.
In some of the affected vehicles , a piston oil cooler bracket may have been damaged during engine assembly. A damaged piston oil cooler bracket may allow the piston oil cooler to detach. This can lead to low engine oil pressure and may result in intermittent engine noises and/or illumination of the check engine light due to diagnostic trouble code(s).
full bulletin at NHTSA ↗Source: NHTSA manufacturer communications. Bring the bulletin number to your dealer or shop.
The failure pattern owners describe
The 2020 F-250 shows a cluster of serious engine failures. High-pressure fuel pump catastrophic failure stands out as the most severe: owners report the CP4 pump housing cracks or explodes, sending metal shards throughout the fuel system and into the engine cylinders. One owner's pump failed at 56,000 miles; another at 175,000 miles. Both resulted in no-start conditions, smoking, and engine damage requiring complete engine and fuel system replacement ($12,000+). Ford issued recalls 24S78 and 26V158, but owners report no permanent fix was available as of early 2025 and recall 24S78 failed to prevent subsequent failures.
Cooling system defects appear early in vehicle life: at 1,650 miles, a lower hose came loose (missing factory clamp or improperly installed), causing coolant loss and limp mode while towing on the interstate.
Check engine light events trigger limp mode at highway speeds, reducing power from 55 mph to 30 mph. Software updates and NOX sensor replacement did not resolve recurrence.
Additional reported issues include diesel fuel leaks, multiple simultaneous warning lights followed by shutdown, engine ticking or pinging noises (described as lifter noise), cracked oil pump gears with main seal weeping, and defective spark plug wires on the 7.3L gas engine. One owner notes Ford's Customer Satisfaction Program 24B27 software update never reached him despite the promised October 2024 availability date.
Same Ford F-250 engine reports on nearby years: 2017 · 2022
Failure modes owners describe
High-Pressure Fuel Pump (CP4/Denso) Catastrophic Failure
High-pressure fuel pump housing cracks or pump explodes, sending metal debris throughout fuel system and into engine. Results in loss of engine power, smoking from engine bay, and requires engine and fuel system replacement.
When: 56,000 miles; 175,000 miles
Symptoms owners cite: No start with check engine light; Loss of power at highway speed (70 mph); Large smoke cloud from engine bay; Abnormal knocking sound from engine; Vehicle stalls and cannot restart
Codes mentioned: Check engine light
Repairs/costs cited: $12,000 fuel pump and fuel system replacement; engine replacement needed in at least one case due to metal shards contamination
Recalls/TSBs owners mention: Ford issued Safety Recall 24S78 (did not resolve issue); Recall 26V158 issued. Owner reports no fix available as of January 2025 contact date. Manufacturer contacted but case management poor with missed callbacks.
Cooling System Hose Disconnection
Lower cooling hose comes loose or disconnects from engine bay, causing coolant loss, engine overheating, and loss of power. Factory installation defect—hose clamp missing or hose installed improperly at the factory.
When: 1,650 miles; early in vehicle life during highway driving
Symptoms owners cite: Smoking from engine bay; High engine temperature warning light; Sudden speed reduction from highway to 20 mph limp mode; Coolant pouring from disconnected hose; Loss of engine power while towing
Repairs/costs cited: Hose reconnection/replacement with proper clamp installation
Check Engine Light / Limp Mode with NOX Sensor Issue
Check engine light illuminates and vehicle enters limp mode reducing speed. Dealer performed software update but failure recurred. NOX sensor replacement attempted but problem persisted. No permanent resolution found.
When: 72,000 miles
Symptoms owners cite: Check engine warning light; Limp mode activation; Sudden speed reduction from 55 mph to 30 mph; Recurrent failure after repairs
Codes mentioned: Check engine code (NOX sensor related)
Repairs/costs cited: Software update performed; NOX sensor replaced—both failed to resolve issue. Engineer examination promised but not completed.
Recalls/TSBs owners mention: Manufacturer contacted; engineer examination planned but vehicle not yet repaired
Diesel Fuel Leak
Vehicle leaks diesel fuel with strong odor while being driven. A filter required replacement. Cause not fully stated in narrative.
When: 64,000 miles
Symptoms owners cite: Diesel fuel leak visible; Abnormally strong diesel odor; No warning lights
Repairs/costs cited: Unstated filter replacement required
Multiple Warning Lights / Shut-Off in Driveway
Vehicle shuts off while stopped in driveway and fails to restart. Multiple warning lights illuminate simultaneously and vehicle enters battery-saving mode, suggesting electrical or fuel system fault.
When: 139,000 miles
Symptoms owners cite: Vehicle shut-off while stopped; Failure to restart; Hill assist warning light; Traction control warning light; Brake warning light; Fuel empty warning light; Engine overheating warning light; Battery-saving mode engaged
Recalls/TSBs owners mention: Claim opened; referred to NHTSA hotline. No repair completed.
Missing Software Update (Customer Satisfaction Program 24B27)
Owner enrolled in Ford Customer Satisfaction Program 24B27 for a critical software update, but was never contacted by Ford to schedule the update. Software was supposed to be available October 1, 2024.
When: <UNKNOWN>
Symptoms owners cite: No contact from Ford for mandatory software update
Recalls/TSBs owners mention: Ford Customer Satisfaction Program 24B27—owner not contacted for update
Defective Spark Plug Wire (7.3L Gas Engine)
Check engine light comes on at highway speed. Vehicle sputters slightly when coming to a stop but remains drivable. Diagnosis shows defective spark plug wire. Owner reports this is a known common problem with the 7.3L gas engine.
When: <UNKNOWN>
Symptoms owners cite: Check engine light illumination at highway speed; Engine sputtering when stopping
Codes mentioned: Check engine code
Repairs/costs cited: Spark plug wire replacement
Cracked Oil Pump Gear / Front Main Seal Leak
Engine develops heavy ticking noise from front caused by cracked oil pump gear. Front main seal is weeping oil. Ford has issued a Technical Service Bulletin (TSB) acknowledging this as a known issue. Technician warns that oil pressure could drop under load (towing) and cause engine seizure.
When: <UNKNOWN>
Symptoms owners cite: Heavy ticking noise from front of engine; Oil weeping from front main seal
Repairs/costs cited: Oil pump gear and front main seal repair/replacement
Recalls/TSBs owners mention: Ford TSB issued for this known issue
Engine Ticking Noise (7.3L Gas Engine)
Multiple owners report heavy ticking or pinging noise coming from engine. Described as sounding like a loud lifter or lifters. Complaints note this is a common problem among 2020 F-250 7.3L gas owners.
When: <UNKNOWN>
Symptoms owners cite: Engine ticking noise; Engine pinging noise; Sound resembles loud lifter(s)
Synthesized from 15 NHTSA owner complaints — unverified consumer allegations, summarized for patterns. The verbatim filings appear below.
What owners are reporting 1 most recent
Ref: Ford Customer Satisfaction Program 24B27 VIN: [XXX] I own a 2020 Ford F-250 that is part of the above program. I have not been contact by Ford to have my truck software updated. I am concerned for my families safety driving this truck. The software update for my truck was to be available October 1st of 2024. What can I do to get this update done? [XXX] / [XXX] / [XXX]…
Had engine trouble with your 2020 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 2020 Ford F-250?
It's a documented issue but not catastrophic. 15 complaints have been filed. Repairs average $3,100 and most owners catch it before it causes a breakdown.
At what mileage does the engine typically fail?
Based on the 15 complaints filed, engine issues most often appear around 65,614 miles. Some report problems earlier; some make it well past 150,000 with no symptoms. Maintenance habits matter — vehicles that received timely fluid services and were not regularly overworked tend to last longer.
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/2020/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.