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 ↗2021 Ford F-250 fuel system problems
moderate 27 complaints filed with NHTSA · avg repair $1,200 · see fuel system across all vehicles →
Failure mileage
Complaints
27
Recalls
0
Avg fix
$1,200
What stands out
Owners have filed 27 fuel system 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.
Among the 16 model years of Ford F-250 in our records for fuel system problems, this one ranks #2 by owner-complaint volume.
Is there a fix? Manufacturer service bulletins
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.
Source: NHTSA manufacturer communications. Bring the bulletin number to your dealer or shop.
The failure pattern owners describe
The 2021 F-250 diesel shows a clear pattern of CP4 high-pressure fuel pump failures. Owners report the pump fails internally or explodes, contaminating the entire fuel system with metal debris. When this happens, the truck stalls, won't restart, or loses power mid-drive with no warning. One owner at 89,000 miles had the pump explode and require fuel system decontamination; another experienced it at 8,500 miles. Failure mileage ranges from under 10,000 to 150,000 miles, and diagnostics point consistently to CP4 failure or fuel injector problems.
The manufacturer issued recall 24V957000 in response, but the recall parts have been unavailable since these complaints were filed. Owners waited beyond what they considered reasonable for parts, leaving vehicles undrivable or forcing them to pay out-of-pocket for repairs—one owner replaced the pump, rails, and decontamination kit at their own expense. One owner questioned whether the recall's software update would even prevent the problem, noting biodiesel deposits on pump rollers as the root cause. Multiple owners reported rough idle and starting difficulty early on, suggesting an underlying fuel system weakness from production.
A handful of complaints cite erratic transmission behavior, loss of power in limp mode, and one diesel injector leak, all cross-referenced with the same recall campaign. The core issue remains: the CP4 pump is not reliable, the recall fix has been delayed, and owners are stranded.
Same Ford F-250 fuel system reports on nearby years: 2020 · 2022
Failure modes owners describe
CP4 High-Pressure Fuel Pump Failure / Explosion
The CP4 pump fails internally and in severe cases explodes, contaminating the fuel system with metal debris. Owners report the pump was faulty or exploded, requiring replacement of the pump, fuel rails, and fuel system decontamination.
When: 67,994 to 150,000 miles; one case at 8,500 miles on stall event
Symptoms owners cite: Vehicle fails to start or struggles to turn over; Loss of motive power while driving; Vehicle stalls and will not restart; Loud clanking sound from engine; Check engine light illuminated (some cases); No warning light (some cases)
Codes mentioned: P0087
Repairs/costs cited: Replace high-pressure fuel pump, fuel rails, and fuel system decontamination kit; one case also replaced fuel injector. Parts not available for recall completion.
Recalls/TSBs owners mention: NHTSA Campaign Number 24V957000 (Fuel System, Diesel) issued; however, recall parts were unavailable at time of complaints. Manufacturer exceeded reasonable timeframe for parts availability.
Rough Idle and Starting Difficulty
Vehicle idles roughly or struggles to start. One owner explicitly questioned the recall remedy's adequacy, stating software update would not prevent biodiesel deposit accumulation on pump drivetrain roller components.
When: Early in ownership; one case at 7,000 miles
Symptoms owners cite: Rough idle at startup; Difficulty starting vehicle; No warning light illuminated (some cases)
Recalls/TSBs owners mention: NHTSA Campaign Number 24V957000 addresses via software update; however, owner skepticism noted regarding effectiveness.
Erratic Transmission Shifting and Engine Control Issues
Vehicle exhibits transmission shift irregularities, rough idle, and starting difficulty. Dealer refused diagnostic without check engine light, though owner reported symptoms correlating with fuel system issues.
When: 95,000 miles
Symptoms owners cite: Transmission failing to shift as intended; Erratic transmission shifting; Difficult to start; Rough idle; Intermittent failure
Recalls/TSBs owners mention: NHTSA Campaign Number 24V957000; parts unavailable. Manufacturer made aware.
Loss of Power / Limp Mode
Vehicle loses motive power while driving at various speeds or idling, sometimes accompanied by entry into limp mode before stalling. Vehicle may or may not restart.
When: 100,000 to 133,071 miles
Symptoms owners cite: Loss of motive power while driving; Loss of power while idling; Vehicle enters limp mode then stalls; Check engine light illuminated (some cases); Vehicle fails to restart or restarts intermittently
Codes mentioned: P0087
Recalls/TSBs owners mention: NHTSA Campaign Number 24V957000; parts unavailable.
Fuel Injector Leaking
Diesel fuel injector develops a leak, causing engine to enter limp mode and stall. Replacement and exhaust system repair attempted but failure reoccurred.
When: 100,000 miles
Symptoms owners cite: Check engine light illuminated; Vehicle enters limp mode; Vehicle stalls; Failure reoccurs after dealer repair
Repairs/costs cited: Diesel fluid injector replaced and exhaust system replaced by dealer; failure persisted.
Recalls/TSBs owners mention: Manufacturer made aware; no assistance provided.
Fuel System and Fuel Pump Module Failure
Fuel pump module and fuel system components fail, diagnosed at dealer but parts for recall were unavailable. Loud clanking sound accompanied the failure.
When: 115,000 miles
Symptoms owners cite: Loud clanking sound from rear of vehicle; No warning light illuminated; Vehicle enters limp mode; Loss of motive power
Repairs/costs cited: Fuel system and fuel pump module required replacement per dealer diagnosis; parts unavailable.
Recalls/TSBs owners mention: NHTSA Campaign Number 24V957000; dealer confirmed parts not yet available.
Synthesized from 27 NHTSA owner complaints — unverified consumer allegations, summarized for patterns. The verbatim filings appear below.
What owners are reporting 1 most recent
The contact owns a 2021 Ford F-250. The contact received notification of NHTSA Campaign Number: 24V957000 (Fuel System, Diesel); however, the part to do the recall repair was not yet available. The contact stated that the manufacturer had exceeded a reasonable amount of time for the recall repair. The dealer was made aware of the issue and confirmed that parts were not yet available. The…
Had fuel system trouble with your 2021 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 fuel system problem on the 2021 Ford F-250?
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.
At what mileage does the fuel system typically fail?
Across the 15 complaints that reported odometer mileage, most fuel system failures cluster between 37,000 and 124,000 miles, with the median around 100,000. A quarter of owners report trouble before 37,000; a quarter make it past 124,000. 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 $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.
Are there any recalls related to fuel system?
No active recalls currently cover fuel system 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/2021/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.