Ford Super Duty Fuel Pump Recall: Critical Facts for Affected Owners

Ford issued multiple recalls for certain Super Duty trucks equipped with faulty fuel pumps, primarily in high-pressure diesel fuel systems. These defective pumps can fail suddenly, leading to engine stalling, loss of power, and an increased risk of accidents, fires, or injury. If you own a 2019-2022 Ford Super Duty (F-250, F-350, F-450, F-550) with the 6.7L Power Stroke diesel engine, especially earlier production models, you must check for open recalls immediately and contact a Ford dealership to schedule a free, permanent repair. Continuing to drive without addressing a known fuel pump recall presents a significant safety hazard.

Understanding the Core Problem: Why These Recalls Matter

At the heart of these recalls lies a critical failure point within the fuel system. Fuel pumps, particularly high-pressure fuel pumps (HPFP) in diesel engines, are engineered to withstand immense pressure—often exceeding 20,000 PSI or more. This pressure is essential for atomizing diesel fuel correctly for efficient combustion within the engine cylinders. The recalled pumps suffered from manufacturing defects or component weaknesses that compromised their integrity under these extreme operating conditions.

This weakness manifested in several potential failure modes:

1. Internal Seizing: Metal components within the pump could seize, instantly stopping fuel flow.
2. Premature Wear: Critical surfaces experienced accelerated wear due to insufficient material hardness or inadequate lubrication, leading to rapid deterioration and metal debris generation.
3. Bearing Failure: Bearings supporting rotating shafts could break down, causing the pump to lock up.
4. Body Cracking or Fracturing: The actual pump housing could crack or fracture under pressure, causing catastrophic fuel leaks.

The Critical Risks of a Failing High-Pressure Fuel Pump

The failure of a high-pressure fuel pump is not a minor inconvenience. It poses immediate and severe dangers:

• Sudden Loss of Power/Stalling: The most direct consequence is an instantaneous loss of fuel pressure. When the pump fails while driving, power steering and power brakes may become significantly harder to operate as the engine dies, dramatically increasing the effort required to steer or stop the vehicle. Stalling on highways, busy intersections, or while towing large trailers creates a high potential for rear-end collisions or losing control of the vehicle and trailer combination.
• Failure to Restart: Once the pump fails, the engine typically will not restart until the faulty pump is replaced. This leaves drivers stranded, potentially in hazardous locations or weather conditions.
• Fuel Leaks: A fractured pump housing or damaged lines can spray high-pressure diesel fuel directly onto hot engine components, including the exhaust system. Diesel fuel is highly flammable, especially when atomized under pressure and contacting surfaces exceeding its auto-ignition temperature. This creates a significant, well-documented fire hazard.
• Secondary Engine Damage: When internal pump components disintegrate (like bearings or plungers), the resulting metal debris is pumped through the entire fuel system. This metallic contamination can destroy other expensive components such as fuel injectors and the fuel rail, requiring replacements costing thousands of dollars beyond the pump itself.
• Excessive Heat Generation: A failing pump experiencing internal friction can generate extreme localized heat, contributing further to the fire risk and potentially damaging surrounding engine components.

Which Ford Super Duty Models Are Affected? Key Recall Details

Ford Motor Company has issued several related recalls concerning the high-pressure fuel pumps on Super Duty trucks, primarily focusing on specific model years and production periods.

• Recall 21S-42 / NHTSA 21V-852 (Originally Announced Dec 2021):
  • Models: Certain 2017-2022 Ford F-Series Super Duty vehicles equipped with the 6.7L High Output Power Stroke diesel engine. While the recall notice mentions starting from 2017, the overwhelming majority of confirmed failures and the primary focus for repairs landed on 2019-2022 model years.
  • Problem: The high-pressure fuel pump could seize during operation. Ford identified the root cause as a specific supplier manufacturing process flaw (involving improper heat treatment of a steel component) leading to premature wear and potential seizure.
  • Risk: Sudden engine stall without restart, increased risk of crash and fire.
  • Remedy: Dealers replaced the high-pressure fuel pump assembly with a redesigned pump manufactured to corrected specifications. The fuel rails and fuel injectors also required inspection for contamination damage and replacement if necessary, using a specific Ford service procedure.
  • Note: Initial repairs under this recall involved installing an interim fix – a fuel pump control module update and a fuel leak sensor. However, Ford later determined these measures were insufficient to fully address the seizure risk. The only complete and final remedy became the replacement of the high-pressure fuel pump with the redesigned unit.
• Recall 23S-52 / NHTSA 23V-699 (Issued Sep 2023 - Follow-Up):
  • Models: Certain 2020-2022 Ford F-Series Super Duty vehicles with the 6.7L High Output Power Stroke diesel engine and previously repaired under Recall 21S-42 with the original, non-final remedy. This recall specifically targeted trucks that only received the initial software update and fuel leak sensor.
  • Problem: Ford determined the earlier repairs (software update and sensor) did not prevent the underlying pump seizure failure. Trucks repaired only with the interim solution remained at risk of the original dangerous stall condition.
  • Risk: Continued risk of sudden engine stall without restart, increased risk of crash and fire.
  • Remedy: Replacing the original high-pressure fuel pump with the same redesigned unit used as the final fix under Recall 21S-42. Dealers also inspected/replaced fuel injectors and cleaned the fuel system as needed based on contamination levels. Importantly, this recall corrected the earlier mistake of not requiring the physical pump replacement upfront.

Identifying Your Truck's Status: How to Check for Recalls

Do not assume your vehicle is unaffected based solely on its model year. Recalls depend on specific production dates and build configurations.

The absolute most authoritative methods to check for open recalls on your Ford Super Duty are:

1. Ford Recall Lookup Website: Visit the official Ford Recall Information page: https://www.ford.com/support/recalls/ Enter your 17-character Vehicle Identification Number (VIN). This will display all open safety recalls specific to your exact vehicle, providing the recall number (e.g., 21S42, 23S52) and description. Keep a record of this.
2. NHTSA Recall Lookup Website: The National Highway Traffic Safety Administration (NHTSA) database is the official US government record: https://www.nhtsa.gov/recalls Enter your VIN for a comprehensive list of unrepaired recalls across all manufacturers. Cross-checking with Ford's site is wise.
3. Contact Your Local Ford Dealership: Provide the dealership's service department with your VIN. They can access the Ford database and instantly confirm any open recalls, including the fuel pump recalls. They can also schedule the repair appointment.

Never rely solely on mailed recall notices. While Ford makes efforts to mail notices to registered owners based on state records, notices can get lost, or ownership may have changed without perfect record updating. VIN lookup is the only reliable method.

Symptoms of a Potential High-Pressure Fuel Pump Failure

While recall repairs are preventative, being aware of warning signs can be crucial, especially if you suspect a recall repair wasn't performed or the pump begins to fail just before the issue manifests fully. Be vigilant for these symptoms:

• Engine Stalling: The most critical sign. The engine suddenly shuts off while driving, idling, or after starting. It likely will not restart.
• Rough Running/Loss of Power: Noticeable hesitation, shaking, jerking, or significant loss of engine power during acceleration or under load, especially when towing.
• Difficulty Starting: Increased cranking time before the engine starts, or failure to start entirely.
• Loud, Unusual Noises from Engine Bay: Grinding, whining, knocking, or rattling noises originating from the vicinity of the high-pressure fuel pump (typically located on the engine).
• Illuminated Check Engine Light (CEL) or Reduced Power Light: While these lights can indicate many issues, they warrant immediate diagnosis, especially in conjunction with other symptoms. Specific diagnostic trouble codes (DTCs) related to low fuel pressure (like P0087) or fuel rail/system pressure problems are strong indicators. You will need a professional scan tool to read these codes.
• Smell of Diesel Fuel Under the Hood: A clear indication of a potential fuel leak, which is an emergency situation. Pull over safely immediately and have the vehicle towed.
• Visible Diesel Fuel Leak: Seeing fuel dripping, pooling, or sprayed around the engine compartment requires immediate attention. Do not drive the vehicle. Shut off the engine, exit safely, and arrange for towing.
• Loss of Fuel Economy: A significant and unexplained drop in miles per gallon.

If you experience ANY of these symptoms, especially stalling, rough running, or signs of a leak, do not continue driving your Super Duty. Safely pull over, turn off the engine, and arrange for towing to a qualified repair facility – preferably a Ford dealership – for immediate diagnosis. Emphasize the symptoms and the truck's recall history to the service advisor.

The Recall Repair Process: What to Expect

If your Super Duty is subject to Recall 21S42 or 23S52, the repair process is straightforward and free of charge to the vehicle owner. Here's what happens:

1. Confirm Recall Status: Use the VIN lookup methods described above to confirm your truck has an open recall requiring the HPFP replacement.
2. Contact Your Ford Dealer: Call the service department of your preferred Ford dealership. State that your vehicle has an open recall (provide the recall number if known) related to the high-pressure fuel pump requiring replacement. Schedule an appointment. While recall repairs are prioritized, some dealers may experience backlogs or parts delays depending on volume and supply. Be polite but firm about the safety-critical nature of the repair.
3. Drop Off Your Vehicle: Bring your truck to the dealer at the scheduled time. No need to bring paperwork beyond identification and proof of ownership (if recently purchased), as the recall status is tied to the VIN in Ford's system. However, having any recall notices you received can be helpful.
4. The Dealer Performs the Repair:
   • The core remedy is the replacement of the original high-pressure fuel pump assembly with the redesigned, improved unit. This is a physical hardware change.
   • Dealers are also required to inspect the fuel injectors and the fuel rail/rails connected to the HPFP for damage caused by metal contamination. This involves specific diagnostic procedures.
   • If contamination is found (metal debris), the affected fuel injectors and/or the fuel rail(s) will be replaced at no cost to you.
   • The fuel system will be flushed and cleaned to remove any residual contaminants before installing the new components.
   • Dealers may also perform related software updates if needed, but the pump replacement is the essential fix.
5. Vehicle Return: Once the repair is complete and the vehicle passes inspection/testing, you'll be contacted to pick it up. You should receive documentation of the completed recall repair (work order/invoice showing $0 cost and the recall numbers satisfied). Retain this documentation indefinitely for your records.

Important Considerations During the Repair Process:

• Free to Owner: Ford covers all parts and labor costs associated with the recall repair under warranty.
• Loaner Vehicle/Rental: While not automatically guaranteed, especially for very long delays, dealerships often provide loaner vehicles or rental car reimbursements for recall repairs, particularly for safety-critical ones like this that require the vehicle to stay overnight or longer. Discuss rental arrangements when scheduling your appointment.
• Repair Time: Replacing the HPFP and inspecting/replacing related components is a complex job. Plan for the vehicle to be at the dealership for at least one full day, potentially longer depending on contamination findings and parts availability.
• Post-Repair Monitoring: While the redesigned pump addresses the known manufacturing flaw, it's prudent to pay attention to your truck's performance after the repair for any unusual symptoms. Report any concerns back to the dealer immediately.

Reimbursement for Previous Repairs

Did you pay out-of-pocket to replace a high-pressure fuel pump, fuel injectors, or fuel rail before a recall was announced specifically for your VIN? Ford may reimburse you. Here's how it generally works:

1. Determine Eligibility: The repair must address the exact condition covered by the recall (failure of the HPFP potentially leading to stall/fire, or related contamination damage) and must have been performed prior to the announcement date of the specific recall affecting your VIN. The recall must also still be open for your vehicle.
2. Gather Documentation: Collect all detailed repair records:
   • Original paid work order/invoice clearly showing your VIN, date of service, mileage, description of the repair performed (including replaced parts, e.g., "High Pressure Fuel Pump," "Fuel Injectors"), the total amount paid, and the repair facility's name and address.
   • Proof of payment (cancelled check, credit card statement).
3. Submit Claim: Contact Ford Customer Relationship Center (CRC):
   • Phone: 1-866-436-7332
   • Website: Ford's Owner Support site usually has a recall reimbursement claim section.
   • Mail: Send copies of your documentation (never originals!) to the address provided in your recall notice or on the Ford CRC site. Include a letter summarizing your request.
4. Ford Review: Ford will review your documentation against the eligibility criteria for the specific recall.
5. Reimbursement: If approved, Ford will typically issue a check for the qualifying amount paid.

Important Reminders About This Recall

• Stop Driving if Critical Symptoms Appear: Do not continue driving if your truck stalls, exhibits severe loss of power indicating imminent stall, or shows visible/smelled diesel fuel leaks. These warrant immediate towing.
• Check Your VIN: Never assume your vehicle isn't affected based on hearsay or model year. The VIN check is mandatory.
• Recalls Never Expire: Safety recalls remain open indefinitely until the repair is performed. It doesn't matter if the truck is out of warranty, has changed ownership multiple times, or is many years old. The free repair offer is perpetual.
• Safety Takes Precedence: Delaying recall repairs, especially for a critical component like the fuel pump that can cause engine shutdown and fire, endangers yourself, your passengers, and others on the road. Completing the recall repair promptly is a vital safety responsibility.

Key Ford Contact Information

• Ford Recalls Website: https://www.ford.com/support/recalls/
• Ford Customer Relationship Center (CRC): 1-866-436-7332
• Ford Social Media: @FordHelp on Twitter/X or Facebook Messenger (useful for initial contact)
• NHTSA Recalls Website: https://www.nhtsa.gov/recalls
• NHTSA Vehicle Safety Hotline: 1-888-327-4236 (TTY 1-800-424-9153)

Ford Super Duty Fuel Pump Recall Action Checklist:

1. Locate Your VIN: Find your 17-digit VIN (dashboard lower corner driver's side visible from outside, driver's side door jamb sticker, registration, insurance card).
2. Check Recall Status: Immediately look up your VIN on Ford's recall page or NHTSA's site. Bookmark the result.
3. Schedule Repair if Required: If an open recall (21S42 or 23S52) exists, call a Ford dealership service department. State it's for a safety recall repair. Schedule the appointment.
4. Prepare for Repair: Ask the dealer about rental/loaner arrangements. Remove personal belongings before drop-off.
5. Get Repair Documentation: When picking up your truck, ensure you receive paperwork confirming the HPFP replacement/recall completion.
6. Report Symptoms Immediately: If you experience ANY stalling, significant power loss, or fuel leaks before or after repair, stop driving if unsafe and contact Ford/dealer immediately.
7. Seek Reimbursement (If Applicable): If you paid for related repairs before the recall announcement for your truck, gather documentation and submit a reimbursement claim to Ford.

Ignoring this recall puts lives at risk. Responsible Ford Super Duty owners must verify their recall status and act without delay to ensure their vehicle receives this critical, free repair. Your safety and the safety of those sharing the road with you depend on it. Contact Ford or your dealer immediately if your vehicle is affected.