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moderate 27 complaints filed with NHTSA · avg repair $1,200 · see fuel system across all vehicles →
An improperly attached fuel tank increases the risk of a fuel leak and potential for fire.
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.
Some 2021 F-150 vehicles equipped with a 3.0L Diesel may exhibit an oil change minder in the IPC staying at 100%. This may be due to the software in the IPC. Engineering is currently investigating this concern. Inform the customer they can continue to drive the vehicle. Monitor OASIS for additional updates.
full bulletin at NHTSA ↗Some 2021-2022 F-150 Raptor vehicles built on or before 06-Jun-2022 may experience a rattle noise from the exhaust at the exhaust tailpipe actuators. This may be due to the exhaust tailpipe actuator valves rattling inside the muffler assembly. To correct the condition, follow the Service Procedure to reprogram the powertrain control module (PCM) and install new exhaust tailpipe actuator valve springs on the exhaust tailpipe actuator valves.
full bulletin at NHTSA ↗Some 2021 F-150 PowerBoost vehicles may exhibit the fuel door release tappet separated from the fuel door housing, slow fuel fill, fuel spit back during refueling, a message in the cluster that states Close Fuel Door To Avoid Check Engine Light and/or diagnostic trouble code (DTC) P04B5 stored in the powertrain control module (PCM). This may be due to opening the fuel door without pressing the fuel door release button. Prior to following normal diagnostics, first check that the fuel door release tappet is properly installed into the fuel door and that the fuel door closes properly and opens when using the fuel door release button. If the tappet has separated from the fuel door press the fuel
full bulletin at NHTSA ↗Some 2021 F-Super Duty and 2021-2022 E-Series vehicles equipped with a 6.2L or 7.3L gasoline engine may exhibit an illuminated malfunction indicator lamp (MIL) with diagnostic trouble code (DTC) P0457 stored in the powertrain control module (PCM). This may be due to a loose fuel filler cap. The fuel filler cap design has changed, requiring multiple turns to seal properly. Advise the customer to turn the fuel filler cap clockwise until there is at least one audible click to seal properly. For further diagnostics, refer to the Powertrain Control/Emissions Diagnosis (PC/ED) manual, pinpoint test HX.
full bulletin at NHTSA ↗Source: NHTSA manufacturer communications. Bring the bulletin number to your dealer or shop.
A 2021 F-150 with 26 complaints centers on fuel system behavior tied to NHTSA Campaign 25V455000. The core issue: engine stalling at highway and low speeds, happening between 26,000 and 113,000 miles. Most owners report no warning lights. One owner's truck stopped mid-road and wouldn't move even in neutral; the dealer diagnosed a defective fuel pump but couldn't source recall parts. Another stalled ascending a hill at 45 mph; two separate dealers couldn't diagnose it.
Owners also report rough idle, vehicle starting then stopping immediately, and hesitation when depressing the accelerator—sometimes with transmission shudder. One truck, after battery replacement didn't fix the problem, was diagnosed with a faulty fuel pump control module and Auto START/STOP module; those parts were replaced but the stalling continued.
The single biggest frustration across complaints: recall parts are unavailable. Owners say Ford exceeded reasonable wait times. Dealers confirm parts are still under engineering review. One owner feared driving the truck with family inside. One instance of excessive oil burning with gasoline smell through the A/C vents was reported but stands apart from the stalling cluster. Most vehicles remained unrepaired or undiagnosed at complaint filing.
Engine loses power or stalls during driving—sometimes at highway speeds, sometimes at low speeds, sometimes while ascending hills. Vehicle may restart without intervention or require restart after towing. Owners report no warning lights or check engine lights illuminated in most cases; a few report check engine light present. One owner reported vehicle failed to restart at all.
When: 26,000–113,000 miles; some instances early in ownership
Symptoms owners cite: Engine stalls while driving at various speeds; Vehicle loses motive power mid-drive; Vehicle fails to restart or remains stuck in neutral; No warning light in majority of cases; check engine light reported in some; Vehicle able to restart after delay in some cases
Codes mentioned: 25V455000
Repairs/costs cited: Complaint #9 reports vehicle diagnosed with defective fuel pump and approved estimate; parts for recall not yet available at time of complaint. Most complaints undiagnosed or not repaired.
Recalls/TSBs owners mention: NHTSA Campaign 25V455000 (Fuel System, Gasoline) parts unavailable at time of complaints. Manufacturer directed owners to NHTSA Hotline in several cases. Complaint #7 shows fuel pump control module, fuel pump assembly, and Auto START/STOP module replaced but failure persisted.
Vehicle hesitates to accelerate when pedal is depressed, shudders during acceleration, or jerks abnormally while driving. Some instances occur at complete stop; others at various highway speeds. No warning lights typically present. Transmission may shudder or vehicle may fail to accelerate at all despite pedal input.
When: 32,899–98,000 miles
Symptoms owners cite: Vehicle hesitates when accelerator pedal depressed; Transmission shudders; Vehicle jerks abnormally at various speeds; No warning light illuminated in reported cases; Failure to accelerate despite pedal input
Codes mentioned: 25V455000
Repairs/costs cited: Complaints unrepaired or undiagnosed. Complaint #8 notes parts unavailable.
Recalls/TSBs owners mention: NHTSA Campaign 25V455000; parts unavailable. Complaint #8 manufacturer filed a case and advised to contact NHTSA Hotline.
Engine idles roughly at startup, or vehicle starts then immediately stops. Vehicle may require extended waiting period (20 minutes reported) before operating normally. Owner in complaint #7 replaced battery thinking that was the cause; failure recurred after battery replacement, then diagnosed as faulty fuel pump control module.
When: 15,000–32,962 miles; early in ownership reported
Symptoms owners cite: Rough idle upon engine start; Vehicle starts then stops; Hesitation at startup; Extended delay required before vehicle operates normally
Codes mentioned: 25V455000
Repairs/costs cited: Complaint #7 battery replaced ($cost not stated), then fuel pump control module, fuel pump assembly, and Auto START/STOP eliminator module replaced; failure persisted despite repairs.
Recalls/TSBs owners mention: NHTSA Campaign 25V455000. Complaint #7 manufacturer contacted but no assistance provided.
Uncommon complaint (#16) reporting strong gasoline smell and smoke through A/C vents when A/C engaged. Simultaneously, vehicle burning oil excessively (owner changing oil every 2,500 miles) with blue smoke from exhaust—signs of internal engine wear or burning. No other complaints in cluster mention this pattern.
When: 15,000 miles
Symptoms owners cite: Strong gasoline odor through A/C vents; Smoke through A/C vents; Excessive oil consumption; Blue smoke from exhaust; Unknown warning light illuminated
Repairs/costs cited: Vehicle not diagnosed or repaired.
Synthesized from 27 NHTSA owner complaints — unverified consumer allegations, summarized for patterns. The verbatim filings appear below.
It's a documented issue but not catastrophic. 27 complaints have been filed. Repairs average $1,200 and most owners catch it before it causes a breakdown.
Across the 17 complaints that reported odometer mileage, most fuel system failures cluster between 26,000 and 60,000 miles, with the median around 35,000. A quarter of owners report trouble before 26,000; a quarter make it past 60,000. Maintenance history matters more than the odometer alone — this is the reported failure window, not a guarantee.
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.
Yes — 1 active recall(s) cover fuel system issues on this vehicle. Recall fixes are always free regardless of mileage or warranty status. Use the VIN decoder at the top of the page to check if your specific vehicle is affected.