Dive Brief:
- Ford Motor Co. has recalled over 295,000 Super Duty F-series trucks for a condition where biodiesel deposits may form on the roller components of the high-pressure fuel pump and lead to pump failure, according to the National Highway Traffic Safety Administration.
- The recalled models include certain 2020-2022 F-Super Duty F250, F350, F450, F550, F600, and 2021-2022 F-650, F750 vehicles equipped with 6.7 liter diesel engines. Drivers may also experience extended engine cranking, noise or reduced power.
- Ford dealers will update the powertrain control module software on the vehicles free of charge to better prevent the buildup of deposits in the fuel pump assembly. Owner notification letters are expected to be mailed between Jan. 13-17.
Dive Insight:
Ford discovered the problem in September 2021 after its internal combustion engines propulsion and thermal systems engineering team raised a concern after noting an uptick in warranty claims related to high pressure fuel pump failures on 2020-2021 Super Duty and medium trucks equipped with diesel engines. The fuel pumps were supplied by Bosch.
The issue was then escalated to Ford’s critical concern review group for further analysis.
From February 2022 through December 2023, Ford continued to investigate warranty claims from Super Duty truck customers, which included the inspection of returned parts, customer interviews and an analysis of connected vehicle data to determine the root cause, according to the NHTSA report. But at the time, the automaker did not identify an unreasonable risk to motor vehicle safety due to engine stalling and determined the problem to be a “no start condition.”
However, as Ford’s investigation continued through late 2024 and more returned fuel pumps were disassembled for inspection, the automaker’s engineers concluded that the problem was deposits caused by “aged biodiesel.” Ford determined that the biodiesel deposits were a result of the COVID pandemic shutdowns, in which some trucks were parked for extended time periods before delivery.
According to the NHTSA report, these biodiesel deposits can cause increased wear of the fuel pump components and introduce metal debris in the fuel system. As a result of these findings, the decision to recall the trucks was made by Ford's Field Review Committee on Dec. 13, 2024.
The diesel-powered trucks suspected of having the condition were produced between Feb. 19, 2019 through Aug. 23, 2021. An estimated 4% of the 295,449 recalled trucks are suspected of having the condition.
Ford introduced a redesigned fuel pump into production on Aug. 23, 2021, which has a larger roller shoe and tappet body clearances for improved flow and better cooling performance to prevent fuel deposit buildup, according the NHTSA.
As of Nov. 13, 2024, Ford is aware of 3,070 warranty reports, 498 field reports and 58 customer service reports associated with the condition.
Biodiesel is registered with the Environmental Protection Agency as a legal fuel and fuel additive. It’s manufactured from vegetable oils, animal fats, or recycled restaurant cooking oil and is classified as a renewable and biodegradable fuel by the Department of Energy.
But high-level biodiesel fuel blends also act as a solvent, according to the DOE, which can clean a vehicle's fuel system and release deposits that may clog filters and require frequent fuel filter replacement.
