2022 Ford F-350 Engine Problems

NHTSA Complaint Draft Vehicle Information: Year/Make/Model: 2022 Ford F-350 VIN: [XXX] Recall Campaign: 25S75 / 25V455 Mileage: 38606 Problem Description: My 2022 Ford F-350 is subject to recall 25S75/25V455 (low-pressure fuel pump failure). Ford notified me on July 8, 2025, that no remedy is currently available. The recall states the fuel pump can fail, resulting in a loss of fuel pressure and engine stall while driving. This creates a serious safety risk of crash or injury. Despite acknowledging the defect, Ford has not provided a remedy, a timeline for repair, or safe alternative transportation. I feel unsafe driving this vehicle, and I am still financially responsible for it. Safety Concern: The risk of the engine stalling while driving, especially at highway speeds, creates an immediate danger to myself, passengers, and other motorists. Resolution Sought: Require Ford to provide a safe loaner or rental vehicle until a remedy is available, OR Require Ford to buy back or pay off the balance of this unsafe vehicle until the defect is resolved. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

The contact owns a 2022 Ford F-350. The contact stated that while driving at an undisclosed speed, the vehicle stalled. There was no warning light illuminated. The vehicle was towed to the dealer, where it was diagnosed that the engine had failed and needed to be replaced. The vehicle was not repaired. The dealer referred the contact to the NHTSA Hotline for further assistance. The manufacturer was not made aware of the failure. The failure mileage was approximately 84,000.

The contact owns a 2022 Ford F-350 SD. The contact stated that while driving approximately 40 MPH and pulling a trailer, the parking warning alert suddenly displayed on the dashboard, and moments later, a flashing check engine light was activated. While driving to the side of the road to park, smoke and flames began to come from under the passenger side of the front hood of the vehicle. The occupants immediately exited the vehicle, and the vehicle was engulfed in flames. The fire department was called to the scene and extinguished the flames. During the incident, the vehicle was completely destroyed, and the trailer had sustained severe fire damage to the front end. A police report was taken at the scene, and both the vehicle and trailer were towed away. No injuries were reported, but both the driver and passenger were severely stressed mentally from the incident. The cause of the failure has not yet been determined. The manufacturer and local dealer were notified of the incident. The failure mileage was 30,051.

The contact owns a 2022 Ford F-350. The contact stated the check engine warning would illuminate on cold starts and would remain illuminated while driving. The vehicle was taken to an independent mechanic, where it was diagnosed and determined that the Reductant Heater and Sender Assembly on the 6.7L diesel engine needed to be replaced. The mechanic related the failure to Ford Customer Satisfaction Program Number: 18M01(Reductant Heater and Sender Assembly Repair). The vehicle was not repaired. The manufacturer was notified of the failure and advised the contact that the VIN was not included, and the contact was referred to the NHTSA Hotline for assistance. The failure mileage was approximately 66,000.

Sudden loss of acceleration at highway speed. Engine sputtered and died as I coasted to a stop on a two lane bridge. Very dangerous location. Was able to restart engine. Ford dealer at next exit. Checked out and no codes thrown. Advised to keep driving until recurrence. Took to hometown Ford dealership and after three days reported no codes, no recurrence, and no problems detected. Advised to keep driving until recurrence.

The contact owns a 2022 Ford F-350 SD. The contact stated while driving at approximately 45 MPH, the temperature gauge started rising quickly. The engine overheated message was displayed. The vehicle had been taken to the dealer who diagnosed and determined that there was coolant leaking into the cylinders and might have been caused by a defective head gasket. The dealer was unable to identify the exact location of the leak. The contact was informed that the engine needed to be replaced. The vehicle had not been repaired. The manufacturer was made aware of the failure. The approximate failure mileage was 317.

I purchased this truck brand new in August 2022. I have performed routine preventive maintenance on it as prescribed by the manufacturer. (FORD) At just over 96,000 miles and just days after a professional oil change service, the truck began to misfire and the check engine light came on. I took it to the dealer that i purchased it from and they diagnosed a lifter and cam shaft failure. (A delamination problem.) I've researched it online and have discovered that it is a pretty common issue with this relatively new engine. I've contacted Ford consumer affairs and filed a complaint and as of yesterday Dec 14, 2023 they finally got an answer for me. They are offering to pay $5400.00 of a almost $15,000 repair. I cannot afford this! I take their offer as an admission of liabilty and that they know of the problem. As common as this is becoming I believe there should be a recall on this 7.3 litre gas engine. One blogger on the internet estimates that about 20,000 of these engines have had this same issue already. (So far) I believe it to be a defect in the parts and not a lubrication issue because its happening in different cylinders. Mine is cylinder #2. I know for a fact that this engine is being used in motor homes and RVs that won't have the 30 to 50 thousand miles on them to make this problem show itself for probably several years. Google; "Ford 7.3L problems" or "Ford 7.3L lifter and cam issues" and see for yourself what I have read. I use this truck to make a living, I paid $60,000.00 for it and expected it to last over 300,000 miles. I tried to upload photos and emails but it wouldn't allow me to. Please help!

I purchased the vehicle in 2022 and in January of 2023 my engine gave a malfunction indicator light flashing with only 45000 miles in it. They claimed that the hydraulic lifter and pushrod and camshaft were broken and damaged causing metal to spread throughout the engine. It took about a month to get my vehicle back. In May of 2023 the second engine gave out again with about 38000 miles on it. I was informed the same exact parts failed in the same cylinder causing metal debris to spread throughout the engine again. Ford is knowingly selling vehicles with these defective parts that could potentially put me and my family in danger. There are many videos and forums with ford technicians putting images of these parts online. I’m now on engine number three in less than a year and at two different dealerships in different states was informed that they are seeing this trend. It’s been six weeks now that my vehicle is at the dealer. I am an owner operator and this truck is my only livelihood. Another failure will put me out of business if not the. Potentially in harms way.