2016 Ford F-250 Sd

On [XXX], I was driving westbound on [XXX], between Kerrville and Junction, Texas. I noticed a diesel fuel smell and pulled off the highway to investigate the source. Upon stopping, fire erupted from the engine compartment and quickly spread to the front dashboard and front passenger seating area. No warning lamps, no high temp or abnormal gage levels. The Mountain Home, TX volunteer fire dept arrived about 30 minutes after we called 911 and extinguished the remaining flames. They commented that a cracked / failed secondary fuel filter housing could be to blame. My insurer, State Farm, under claim #[XXX], now has possession of the vehicle remains. I told State Farm that NHTSA opened an investigation into possible fuel filter housing failures / fires. I do not know what their intentions are with the vehicle remains. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

I recently received a warning for P20BA informing me that the truck had a failed DEF heater. The unit was not in warranty and parts estimate for this is $360.00-$400.00 with an additional $400.00 dollars in labor for a total cost at minimum of $800.00 to $1,000.00 to replace a part that Ford Motor Company knew was a high failure rate part that would not meet industry standards.

I was attempting to access the interstate when my truck began to immediately shut down at 70 miles per hour. I received a warning as the engine shut down stating that my engine power was reduced. At the exact moment the message displayed, the truck immediately died at 70 mph leaving me to be forced to wrestle the steering wheel to maneuver the truck to the side of the interstate as I had no power steering due to the failure. I have been informed that my truck is a victim of a catastrophic engine failure as a result of a failed CP4 OEM Bosch high-pressure fuel pump. The failure has resulted in the complete contamination of the fuel system requiring a complete overhaul with parts cost at $6,600.00 and approximately $4,000.00 in labor for a total of more than $10,600.00. on a low mileage diesel.

DEF heater/sender assembly was replaced under Ford 21M01 recall. However, the damaged caused by these defective items caused the need to repair additional component's that was not paid for by Ford. Ford will not reimburse additional cost, and can not furnish a statement from a Ford engineer that states the defective replaced parts did not cause the additional repairs. (expense).

The reductant heater (DEF heater) has went out. Ford will not honor the 5 year/ 60,000 miles power train warranty or the 8 year/ 80,000 mile emissions warranty to repair the issue. According to web sources dealerships maintain a regular supply of these heaters as they replace 5 to 6 a week in the winter. My truck is 4 years and 58,000 miles.

FUEL FILLER NECK ROTTED AWAY ALLOWING FUEL TO RUN DOWN THE INSIDE OF THE FENDERWELL. THE FUEL CAP LIGHT DID LIGHTUP. THIS VEHICLE HAS 25730 MILES ON IT. THE FILLER NECK WAS REPLACED BY MY SERVICE CENTER. I NOTICED THE LEAK WHILE FUELING ABOUT 200 MILES FROM HOME, AND HAD IT CHECKED UPON ARRIVING HOME.IF I HAD BEEN IN AN ACCIDENT THIS WOULD ALLOWED FUEL TO LEAK.

SERVICE ENGINE LIGHT CAME ON TWICE WHILE VEHICLE WAS UNDER WARRANTY. DEALER SERVICED BOTH TIMES AND WAS UNABLE TO RECTIFY OR UNDERSTAND THE PROBLEM. THEY ONLY CLEARED THE FAULT CODES. THE CODE IDENTIFIED WAS FOR THE REDUCTANT HEATER PUMP - LOW VOLTAGE. THE SAME CODE JUST CAME BACK ON FOR THE 3RD TIME - THIS TIME IDENTIFIED BY A DIESEL PERFORMANCE SHOP - WITH ADVICE TO REPLACE THE REDUCTANT PUMP. PREVIOUS MAKE AND MODEL SUPERDUTY TRUCKS HAVE HAD RECALLS FOR THE SAME THING. THIS IS AN OBVIOUS ISSUE, NOT SURE WHY FORD SERVICE SHOPS COULD NOT RECTIFY. TRUCK IS NOW OUT OF WARRANTY AND I AM FORCED TO PAY OUT OF POCKET. UNACCEPTABLE SERVICE AND CARE! -COLD WEATHER EACH TIME -ENGINE LIGHT COMES ON - SAME CODE EACH TIME -REDUCED SPEED AND SLUGGISH PERFORMANCE -CODE CLEARED - TRUCK PERFORMS NORMAL -OBVIOUS THAT THE REDUCTANT HEAT PUMP IS NOT DOING WHAT IT IS DESIGNED TO DO.