2015 Ford Transit Fuel System Problems

My 2015 Ford Transit 350 equipped with the 3.2L diesel engine experienced a failure of the high-pressure fuel injection pump at approximately 72,000 miles. The pump generated metallic debris which contaminated the entire fuel system. The vehicle began experiencing drivability problems including loss of power and intermittent stalling. The vehicle was diagnosed by a Ford dealership, where metal contamination was found in the fuel system. The repair required replacement of the high-pressure fuel pump, injectors, high-pressure fuel lines, and fuel rail, along with flushing and cleaning of the fuel tank and fuel system. The total repair cost was approximately 11,500. This failure appears to match the defect described in Ford safety recall 16S32 for certain 2015–2016 Ford Transit vehicles equipped with the same 3.2L diesel engine, where scuffing in the fuel injection pump can create metallic debris that contaminates the fuel system. My vehicle was built July 16, 2015, essentially within the same production period described in the recall, but my VIN was not included in the recall population. Because this failure required replacement of most of the fuel system components and created a sudden loss of power risk while driving, I am reporting this issue so it can be investigated and considered for inclusion with similar failures.

The car stalled without warning while driving in heavy fast traffic which nearly caused a accident. It turns out that the recall Ford program [XXX] that addressed this issue was not performed by the dealership (even when it was serviced repeatedly at dealer) as they did not have the parts. Now Ford claims they will not fix the issue as the program expired months ago. Former ford stock owner (never again). [XXX] [XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

The contact owns a 2015 Ford Transit. The contact stated that while driving at various speeds, the vehicle stalled while depressing the accelerator pedal. No warning lights were illuminated. The vehicle was towed to a local dealer, where it was diagnosed that the throttle body actuator needed to be replaced. The vehicle was repaired. The manufacturer was made aware of the failure and advised the contact to file a complaint with the NHTSA Hotline. The failure mileage was unknown.

The contact owns a 2015 Ford Transit. The contact stated while driving at an undisclosed speed, the check engine warning light illuminated, and the vehicle lost motive power. The vehicle was taken to the dealer where it was diagnosed with a fractured front windshield cowl. In addition, rainwater was entering the engine compartment due to the fractured windshield cowl. The vehicle was diagnosed with a failed fuel rail. The contact was informed that the fuel rail needed to be replaced. The vehicle was repaired; however, the failure reoccurred. The vehicle was taken back to the dealer where it was diagnosed with a failed fuel system, failed fuel injector, and a failed glow plug. The contact was informed that the fuel system, fuel injector, and glow plug needed to be replaced. The vehicle was not repaired. The failure reoccurred. The vehicle was not diagnosed or repaired by an independent mechanic or the dealer. The contact researched Technical Service Bulletin: 19-2091. The manufacturer was made aware of the failure but provided no assistance. The failure mileage was approximately 120,000.

TL* THE CONTACT OWNS A 2015 FORD TRANSIT. THE CONTACT STATED THAT THE VEHICLE WOULD NOT START. THE VEHICLE WAS TOWED TO AN INDEPENDENT MECHANIC WHERE THE FAILURE WAS DIAGNOSED AS A FUEL MODULE AND FUEL PUMP THAT NEEDED REPLACEMENT. THE VEHICLE WAS REPAIRED. THE CONTACT STATED HE RECEIVED AN UNKNOWN MANUFACTURER RECALL NOTICE SEVERAL DAYS LATER AND WAS UPSET THAT HE WAS NOT NOTIFIED THAT RECALLS WERE REPAIRED FREE OF CHARGE. THE MANUFACTURE WAS NOTIFIED OF THE FAILURE. THE CONTACT WAS NOT PROVIDED AN EXPLANATION ABOUT THE REIMBURSEMENT POLICY. THE APPROXIMATE FAILURE MILEAGE WAS 112,760.

TL* THE CONTACT OWNS A 2015 FORD TRANSIT. THE CONTACT STATED WHILE DRIVING 60 MPH, THE VEHICLE STALLED WITH THE FUEL FILTER CLOGGED MESSAGE DISPLAYED. THE CHECK ENGINE WARNING LIGHT ALSO ILLUMINATED. THE VEHICLE WAS TOWED TO AN INDEPENDENT MECHANIC WHO INFORMED THE CONTACT OF NHTSA CAMPAIGN NUMBER: 15V005000 (FUEL SYSTEM, GASOLINE) AND REFERRED THE CONTACT TO THE DEALER. THE VEHICLE WAS TOWED TO PHIL LONG FORD OF MOTOR CITY (1212 MOTOR CITY DR, COLORADO SPRINGS, CO 80905, (844) 237-2169) AND DIAGNOSED WITH SHARDS OF FUEL PUMP IN THE FUEL LINE. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS CONTACTED AND INFORMED OF THE FAILURE. THE CONTACT WAS INFORMED THAT THE VIN WAS NOT INCLUDED IN NHTSA CAMPAIGN NUMBER: 15V005000 (FUEL SYSTEM, GASOLINE). THE APPROXIMATE FAILURE MILEAGE WAS 77,000.

TL* THE CONTACT OWNS A 2015 FORD TRANSIT. THE CONTACT STATED THAT THE VEHICLE FAILED TO START WHEN ATTEMPTING TO DRIVE. THERE WERE NO WARNING INDICATORS ILLUMINATED. THE VEHICLE WAS TAKEN TO MURRAY MOTOR (85 GRIFFITH RD, MUNCY, PA 17756, (570) 546-2222) WHERE IT WAS DIAGNOSED THAT A METAL FLAKE WAS FOUND IN THE FUEL AND THE HIGH PRESSURE FUEL INJECTION SYSTEM NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE AND DID NOT ASSIST. THE APPROXIMATE FAILURE MILEAGE WAS 142,000.

WATER LEAKS INTO AIR FILTER, CAUSING STALLING AND EXTENSIVE ENGINE DAMAGE HAD THE STALLING OCCURRED IN HEAVY TRAFFIC AN ACCIDENT COULD EASILY HAPPENED

TL* THE CONTACT OWNS A 2015 FORD TRANSIT. WHILE DRIVING APPROXIMATELY 50 MPH, THE POOR FUEL FILTER INDICATOR ILLUMINATED. THE VEHICLE WAS TAKEN TO SCAFFIDI AUTO STEVENS POINT (888-718-5340, LOCATED AT 3733 STANLEY ST, STEVENS POINT, WI 54481) WHERE METAL FILINGS WERE FOUND IN THE FUEL FILTER. THE TECHNICIAN REPLACED THE FUEL FILTER. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE AND REFERRED THE CONTACT TO NHTSA. THE FAILURE MILEAGE WAS 61,495.

TL* THE CONTACT OWNS A 2015 FORD TRANSIT. WHILE DRIVING 70 MPH, THE ENGINE STALLED AND THE VEHICLE WENT INTO LIMP MODE. THE VEHICLE WAS TAKEN TO FOX FORD MAZDA (3560 28TH STREET GRAND RAPIDS MI, 49512 PHONE: (616-956-5511)) WHERE IT WAS DIAGNOSED THAT THERE WERE METAL SHAVINGS IN THE FUEL INJECTOR AND FUEL TANK. THE FUEL INJECTOR, FUEL PUMP, AND FUEL FILTER WERE REPLACED AND THE FUEL TANK WAS CLEANED. THE MANUFACTURER STATED THAT THE VEHICLE WAS NOT INCLUDED IN NHTSA CAMPAIGN NUMBER: 16V618000 (FUEL SYSTEM, DIESEL, ENGINE AND ENGINE COOLING). THE APPROXIMATE FAILURE MILEAGE WAS 15,000.

TL* THE CONTACT OWNS A 2015 FORD TRANSIT. THE CONTACT STATED THAT THE VEHICLE STALLED NUMEROUS TIMES WHILE DRIVING ON AN INCLINE OR ON A NORMAL ROAD SURFACE, AND WHEN THE CRUISE CONTROL WAS ENGAGED. THE CONTACT HAD TO PLACE THE VEHICLE IN NEUTRAL AND TURN OFF AND RESTART THE ENGINE IN ORDER FOR THE VEHICLE TO REGAIN NORMAL FUNCTION. ALSO, WHILE DRIVING 30 TO 70 MPH, THE REDUCE ENGINE INDICATOR ILLUMINATED. THE VEHICLE WAS TAKEN TO LOGANSVILLE FORD FIRST (3460 HIGHWAY 78, LOGANSVILLE, GA 30052, 770-554-9994) DIAGNOSED THAT THE FUEL TANK FAILED. THE FUEL TANK CONTAINED METAL FRAGMENTS. THE VEHICLE WAS ALSO TAKEN TO AKINS FORD (220 WEST MAY STREET, WINDER GA, 30680, 770-867-9136) FOR A SECOND OPINION. AKINS FORD ALSO STATED THAT THE FUEL TANK HAD METAL FRAGMENTS. THE DEALER STATED THAT THE FUEL SYSTEM MUST BE CLEANED AND FLUSHED. THE DEALER FLUSHED THE FUEL SYSTEM, REPLACED THE RAILING FIVE INJECTOR, THE FUEL TANK WAS FLUSHED AND CLEANED, AND THE FUEL LINES WERE CLEANED. IN ADDITION, THE FUEL FILTER HOUSING WAS REPLACED. THE CONTACT ALSO STATED THAT THE FUEL INJECTOR PUMP CAUSED THE METAL FLAKES TO ENTER THE FUEL TANK; HOWEVER, THE FUEL INJECTOR PUMP WAS NOT REPLACED. THE VEHICLE WAS NOT REPAIRED. THE CONTACT STATED THAT THE VEHICLE ENTERED LIMP MODE AND THE CONTACT HAD TO TURN THE ENGINE OFF TO REGAIN NORMAL FUNCTION. THE FAILURE OCCURRED WHEN DRIVING 70 TO 80 MPH AND WHEN DRIVING UP AN INCLINE AT ANY SPEED. THE MANUFACTURER WAS CONTACTED, THE MANUFACTURER STATED THAT THE VEHICLE WAS NOT INCLUDED IN AN UNKNOWN RECALL REGARDING THE FUEL INJECTION PUMP RECALL. THE APPROXIMATE FAILURE MILEAGE WAS 20,000.

EGR COOLER LEAK CHANGING SECOND TIME IN ONE YEAR AND ALSO I HAVE TO CHANGE OIL COOLER. THIS JOBS IS VERY EXPENSIVE.

VEHICLE FAILS TO START POST FUELING, DRIVER MUST WAIT AND ATTEMPT TO RESTART. THIS MAKE TAKE SEVERAL ATTEMPTS. WE HAVE SEVERAL OF THESE VEHICLE AND THEY ARE ALL EXPERIENCING THE SAME ISSUE.

TL* THE CONTACT OWNS A 2015 FORD TRANSIT. WHILE DRIVING AT VARIOUS SPEEDS, THERE WAS A STRONG FUEL ODOR INSIDE THE VEHICLE. THE VEHICLE WAS IMMEDIATELY TAKEN TO THE DEALER, BUT NO FAILURE WAS FOUND. SHORTLY AFTER, THE FUEL ODOR RETURNED INSIDE THE VEHICLE. THE ODOR MADE THE CONTACT NAUSEAS AND DIZZY. THE CONTACT WAS CONCERNED ABOUT TOXIC POISONING FROM THE FUMES. THE DEALER WAS NOTIFIED. THE VEHICLE WAS NOT REPAIRED. THE FAILURE MILEAGE WAS UNKNOWN.

TL* THE CONTACT OWNS A 2015 FORD TRANSIT. THE CONTACT STATED THAT THE TAILPIPE EXIT WAS IMPROPERLY PLACED WHICH CAUSED AN ABNORMAL DIESEL FUEL ODOR WHEN LOADING THE VEHICLE. THE CONTACT STATED DUE TO THE ODOR IT CAUSED THEM TO FEEL NAUSEOUS. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE MANUFACTURER STATED THAT THE FAILURE WAS INHERENT TO THE VEHICLE. THE FAILURE MILEAGE WAS APPROXIMATELY 35,600.