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-350 fuel system problems
moderate 22 complaints filed with NHTSA · avg repair $1,200 · see fuel system across all vehicles →
Failure mileage
Complaints
22
Recalls
0
Avg fix
$1,200
When does it fail?
Of the 22 fuel system complaints filed for the 2021 Ford F-350, here's the actual mileage breakdown — failures cluster heaviest at 125,000-150,000 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
Among the 12 model years of Ford F-350 in our records for fuel system problems, this one ranks #2 by owner-complaint volume.
Fuel system accounts for 25% of all owner complaints filed against this vehicle, across 7 categories tracked.
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
Out of 21 complaints, 13 owners experienced confirmed fuel system failures; 8 reported recall notices without failures to date. The dominant issue is high-pressure diesel fuel pump failure, striking trucks between 88,000 and 280,000 miles—most frequently in the 100,000–133,000 range. Symptoms include sudden loss of power while driving, check engine lights, stalling, and refusal to restart. One owner reported the failed pump sent metal shards through the fuel system, requiring both pump and engine replacement.
Two separate cases cited fuel system contamination at 58,000 and 112,000 miles, with both dealers recommending complete fuel system replacement. A third failure involved upper fuel filter leakage linked to the recall.
The common thread: All affected owners received notification of NHTSA Campaign 24V957000 (Fuel System, Diesel), but critical recall parts remained unavailable months and even over a year after notices were mailed. One owner was told repairs wouldn't happen until Q2 2025. Several owners noted Ford exceeded a reasonable timeframe for the recall repair. Independent mechanics and Ford dealers both confirmed pump failures; repairs were largely not completed pending parts availability.
Same Ford F-350 fuel system reports on nearby years: 2020 · 2022
Failure modes owners describe
High-pressure fuel pump failure
The high-pressure diesel fuel pump fails, causing loss of engine power, stalling, and inability to restart. One owner reported the failed pump sent metal shards throughout the fuel system. Occurs across a wide mileage range.
When: Between 88,000–280,000 miles; most common 100,000–133,000 miles
Symptoms owners cite: Loss of motive power or hesitation while driving; Check engine warning light illuminated; Engine misfire; 'Decreased Engine Power' message displayed; 'Engine Protection Mode' message displayed; Vehicle stalls without warning; Vehicle fails to restart or struggles to restart; Abnormal popping and clicking sounds from engine; Loud noise from engine compartment
Repairs/costs cited: Fuel pump replacement required; one case required engine replacement due to damage from pump failure debris. Repairs not completed by owners due to recall parts unavailability.
Recalls/TSBs owners mention: NHTSA Campaign 24V957000 (Fuel System, Diesel) issued; parts unavailable as of complaint dates. One owner informed repair would not occur until Q2 2025. Campaign 22V013000 also referenced in one complaint but owner's VIN not included in that recall.
Fuel system contamination
Fuel system becomes contaminated, causing loss of power and inability to restart. Independent mechanic and dealer both diagnosed fuel contamination as the root cause in separate cases.
When: At 58,000 miles and 112,000 miles
Symptoms owners cite: Warning light illuminated indicating to pull over; Loss of motive power; Vehicle fails to restart
Repairs/costs cited: Fuel system replacement needed; repairs not completed due to recall parts unavailability.
Recalls/TSBs owners mention: NHTSA Campaign 24V957000 referenced; parts unavailable. One owner advised to contact NHTSA Hotline.
Upper fuel filter leakage
Upper fuel filter leaks diesel fuel. Dealership linked this failure to the fuel system recall.
When: At 180,000 miles
Symptoms owners cite: Diesel fuel leaking from upper fuel filter
Repairs/costs cited: Fuel pump replacement recommended by dealer; repair not completed due to parts unavailability.
Recalls/TSBs owners mention: NHTSA Campaign 24V957000 (Fuel System, Diesel); parts unavailable. Failure linked to recall by dealer.
Fuel system shutdown and loss of power
Vehicle experiences sudden loss of motive power on highway, engine stalls, and system enters shutdown. Dealer diagnosed fuel system shutdown combined with high-pressure fuel pump failure.
When: At 113,000 miles
Symptoms owners cite: Loss of motive power at highway speeds (75 MPH); Check engine warning light illuminated; Vehicle stalls and stops
Repairs/costs cited: High-pressure fuel pump failure confirmed; repairs not completed.
Recalls/TSBs owners mention: NHTSA Campaign 24V957000 (Fuel System, Diesel); parts unavailable. Manufacturer told owner repair would not occur until Q2 2025.
Synthesized from 22 NHTSA owner complaints — unverified consumer allegations, summarized for patterns. The verbatim filings appear below.
What owners are reporting 3 most recent
The contact owns a 2021 Ford F-350. The contact received a recall letter related to NHTSA Campaign Number: 24V957000 (Fuel System, Diesel). The contact was concerned about being involved in a crash. The local dealer was contacted and confirmed that the software fix was not available. The vehicle was not diagnosed or repaired. The manufacturer was contacted, but no assistance was provided. The…
The contact owns a 2021 Ford F-350. 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 contact stated that while driving at an undisclosed speed with the cruise control activated, the…
The contact owns a 2021 Ford F-350. 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 local dealer was contacted. The contact stated that the manufacturer had exceeded a reasonable amount of time for the recall repair. The manufacturer was not made aware of the issue. The contact had…
Had fuel system trouble with your 2021 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 fuel system problem on the 2021 Ford F-350?
It's a documented issue but not catastrophic. 22 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 14 complaints that reported odometer mileage, most fuel system failures cluster between 106,000 and 132,900 miles, with the median around 125,000. A quarter of owners report trouble before 106,000; a quarter make it past 132,900. 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 $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-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.