NHTSA opens probe into 2015–2021 Ford F-250 SD and 9 other models: Sogefi Secondary Diesel Fuel Filter Leak
On May 9, 2024, the National Highway Traffic Safety Administration’s Office of Defects Investigation (ODI) opened a Preliminary Evaluation (PE24014) into 2015–2021 Ford F-250 SD and 9 other models, concerning the fuel system, diesel and fuel system, other. A Preliminary Evaluation is the first formal stage of an NHTSA defect investigation: ODI gathers information from the manufacturer and from owner reports to decide whether to close the case or take it further. As of NHTSA’s latest data it is still open.
- Action
- PE24014 (Preliminary Evaluation)
- Status
- Open
- Component
- Fuel System, Diesel; Fuel System, Other: Fuel Filter
- Listed
- 40 make/model/year entries in NHTSA’s file
Vehicles under investigation
| Make | Ford |
|---|---|
| Models | F-250 SD, F-350 SD, F-450, F-450 SD, F-550, F-550 SD, redundant F-250, redundant F-350, redundant F-250, redundant F-350 |
| Model years | 2015–2021 |
As listed in NHTSA’s investigation file. Not every vehicle of a listed model is necessarily affected.
What ODI says
The Office of Defect Investigations (ODI) has received 27 complaints alleging diesel fuel leaks due to a fracture in the secondary fuel filter housing in model year (MY) 2015-2021 Ford Motor Company (Ford) F-250, 350, 450, and 550 Super Duty vehicles equipped with 6.7L diesel engines. Of these complaints, 12 describe an engine compartment fire. The proximity of the secondary fuel filter to high heat sources creates a potential for autoignition thermal events and fires. ODI has contacted the vehicle manufacturer, Ford, and the filter manufacturer, Allevard Sogefi USA (Sogefi), and learned that the low-pressure fuel system is capable of a maximum operating pressure of 8.5 Bar, while the secondary fuel filter is only tested to seven (7) Bar during the manufacturing process. Additionally, changes starting in 2022 by both Ford and Sogefi align with a lack of similar complaints on MY 2022 and newer vehicles. ODI is opening this Preliminary Evaluation (PE) to evaluate the severity of the potential problem and to fully assess the potential safety-related problems. To review the ODI reports cited in the Opening Resume ODI Report Identification Number document, go to NHTSA.gov.
Official summary by NHTSA’s Office of Defects Investigation for PE24014, quoted in full (U.S. government work, public domain).
What owners have reported
Owners filed 5,781 complaints with NHTSA about the model years in this investigation, reporting 91 crashes, 92 fires, 84 injuries. These are all complaints on file for those vehicles, about any problem, not only this one; complaints are unverified owner reports.
| Vehicle | Complaints | Crashes | Injuries | Deaths |
|---|---|---|---|---|
| 2015 F-250 SD | 296 | 8 | 7 | 0 |
| 2016 F-250 SD | 290 | 6 | 6 | 0 |
| 2017 F-250 SD | 1,155 | 12 | 13 | 0 |
| 2018 F-250 SD | 398 | 7 | 4 | 0 |
| 2019 F-250 SD | 1,164 | 16 | 12 | 0 |
| 2020 F-250 SD | 265 | 2 | 2 | 0 |
| 2021 F-250 SD | 166 | 3 | 0 | 0 |
| 2015 F-350 SD | 208 | 3 | 1 | 0 |
| 2016 F-350 SD | 209 | 5 | 12 | 0 |
| 2017 F-350 SD | 573 | 7 | 3 | 0 |
| 2018 F-350 SD | 202 | 1 | 5 | 0 |
| 2019 F-350 SD | 467 | 9 | 9 | 0 |
| 2020 F-350 SD | 188 | 7 | 3 | 0 |
| 2021 F-350 SD | 98 | 1 | 3 | 0 |
| 2020 F-450 | 24 | 2 | 1 | 0 |
| 2015 F-450 SD | 1 | 0 | 0 | 0 |
| 2016 F-450 SD | 1 | 0 | 0 | 0 |
| 2017 F-450 SD | 1 | 0 | 0 | 0 |
| 2018 F-450 SD | 0 | 0 | 0 | 0 |
| 2019 F-450 SD | 3 | 0 | 0 | 0 |
| 2020 F-450 SD | 0 | 0 | 0 | 0 |
| 2021 F-450 SD | 18 | 0 | 0 | 0 |
| 2020 F-550 | 17 | 0 | 0 | 0 |
| 2015 F-550 SD | 11 | 1 | 3 | 0 |
| 2016 F-550 SD | 3 | 0 | 0 | 0 |
| 2017 F-550 SD | 2 | 0 | 0 | 0 |
| 2018 F-550 SD | 0 | 0 | 0 | 0 |
| 2019 F-550 SD | 4 | 0 | 0 | 0 |
| 2020 F-550 SD | 4 | 1 | 0 | 0 |
| 2021 F-550 SD | 12 | 0 | 0 | 0 |
| 2015 Redundant F-250 | 1 | 0 | 0 | 0 |
| 2016 Redundant F-250 | 0 | 0 | 0 | 0 |
| 2017 Redundant F-250 | 0 | 0 | 0 | 0 |
| 2018 Redundant F-250 | 0 | 0 | 0 | 0 |
| 2019 Redundant F-250 | 0 | 0 | 0 | 0 |
| 2020 Redundant F-250 | 0 | 0 | 0 | 0 |
| 2016 Redundant F-350 | 0 | 0 | 0 | 0 |
| 2017 Redundant F-350 | 0 | 0 | 0 | 0 |
| 2018 Redundant F-350 | 0 | 0 | 0 | 0 |
| 2019 Redundant F-350 | 0 | 0 | 0 | 0 |
Recalls and problems for these vehicles
Timeline
- ODI opens preliminary evaluation PE24014
- OpenNo closing date yet
What this means for owners
- An investigation is not a recall. NHTSA has not made a defect finding here, and owners are not asked to do anything yet. If a safety defect is confirmed, the manufacturer recalls the vehicles and the repair is free.
- Check your vehicle for open recalls with a free VIN recall check.
- Had this problem? File a complaint with NHTSA. Owner complaints are the evidence ODI uses to open and expand investigations.
Official record: search PE24014 or your vehicle at NHTSA.gov/recalls, which lists investigations alongside recalls. Data: NHTSA ODI investigations file, updated daily. All NHTSA investigations.