Ford Recalls Nearly 300,000 Super Duty Trucks That May Contain Defective Fuel Pumps

The manufacturer has received more than 3,000 warranty claims over fuel pump problems caused by prolonged fuel storage during the COVID-19 pandemic

Federal highway safety officials have announced a recall for over 295,000 Ford Super Duty trucks, citing concerns over potential fuel pump failures that may increase the risk of an auto accident. 

The Ford Super Duty truck recall was announced by the U.S. National Highway Traffic Safety Administration (NHTSA) on December 20, warning that certain vehicles from model years 2020 through 2022 may have defective high-pressure fuel pumps prone to biodiesel deposit buildup, which could lead to pump failure and a sudden loss of engine power.

The high-pressure fuel pump plays a critical role in pressurizing fuel before it is injected into the combustion chamber, where it mixes with air and ignites to power the vehicle. 

However, officials are warning that the accumulation of biodiesel deposits on the pump can accelerate wear on its components, potentially causing a loss of engine power and increasing the likelihood of an accident.

While Ford  has not received any reported injuries or accidents related to the malfunction, the company has documented at least 3,070 warranty claims, 498 field reports, and 58 customer service complaints related to the issue.

The recall impacts 295,449 model year 2020 through 2022 Ford Super Duty F250, F350, F450, F550, F600, and 2021-2022 F650 and F750 vehicles. 

Drivers are encouraged to monitor for signs of potential fuel pump problems, such as extended cranking during startup, illuminated check engine lights, unusual noises, or reduced engine power.

Ford first became aware of the issue on September 16, 2021, after the company’s Internal Combustion Engines Propulsion and Thermal Systems Engineering team discovered an increased number of warranty reports for high pressure fuel pump failures. 

Between February and October 2022, Ford conducted an extensive investigation into the issue, analyzing warranty data, examining returned parts, interviewing customers, and reviewing connected vehicle data. The company ultimately determined that the pump failures were linked to aged biodiesel, caused by prolonged fuel storage during the COVID-19 pandemic.

The company continued to monitor and assess performance data until a field action was approved on December 13, 2024.

Customers will begin receiving notification letters on January 13, 2025, with instructions on how to schedule a free software reflash of the Powertrain Control Module (PCM), which will increase pump cooling and prevent the formation of aged biodiesel deposits. 

Any vehicle owners who have already had this remedy performed at their own expense prior to receiving the Ford recall notification may be eligible for reimbursement.

Ford’s number for this recall is 24S78. Customers may contact Ford customer service at 1-866-436-7332 or contact Ford Motor Company’s contact for this recall, Dusty Gardner, who may be reached by email at dusty.gardner@dot.gov.

Owners may also contact the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to www.nhtsa.gov.