NHTSA Complaint #11681907 — 2020 FORD F-250

On or around July 14, 2025, my truck failed to start. The engine would turn over but would not fire. My vehicle was at home and had been driven within the past day before this incident. On July 14, 2025, I had my vehicle towed to Burns Ford of York for a diagnosis. Upon inspection, the Ford technician determined that the high-pressure fuel pump was damaged, causing metal to contaminate the fuel system. At the time of this failure, my odometer had 67,452 miles. A "fuel system replacement" kit and element were ordered - Ford parts #s PC3Z-9N184C & LC3Z-9B246B. As explained to me, the entire fuel system and components had to be replaced because the high-pressure fuel pump "exploded." Knowing there is an active recall on the fuel system (Campaign 24S78/24V957) a request was made to Ford to cover the repair costs since the active recall dealt with a known issue of aged biodiesel causing issues, including a failure to start, which I experienced. Ford failed to approve the repair costs, causing a total expense around $17,000, with approximately $7,000 being out of pocket after my extended warranty company paid the remaining balance. The issue is that there was no intentional direct cause for the fuel pump to fail and given it did so with an active recall on the fuel system and with only 67,000 miles I believe the active recall is associated with my failure and should be on Ford to cover repairs and acknowledge a permanent fix.