It’s no secret that Ford’s 6.7-liter Power Stroke V8 diesel engine has been a tad problematic since its inception. Produced by Ford since 2011, we have seemingly seen one Power Stroke recall after another. Early models (2011 to 2014) were prone to turbocharger failures due to a unique single sequential turbo design, which utilized ceramic ball bearings that struggled under heat and stress. High-pressure fuel pump failures, particularly with the Bosch CP4.2 pump, are another critical issue. EGR system failure and clogged diesel particulate filters (DPF) have caused drivability issues. And oil cooler clogging and coolant system issues have led to overheating issues. While Ford has made many improvements over the years to increase both power and reliability, the engine remains somewhat temperamental.

No Current Recall Over Leaking Fuel Filter Housing

It has now come to light that as of May of 2024 federal regulators with the U.S. Office of Defect Investigations (ODI) are looking into complaints that Ford F-Series Super Duty trucks powered by the 6.7-liter engine may be susceptible to a fuel leak caused by faulty fuel filter housing parts. The National Highway Traffic Safety Administration (NHTSA) estimates that a total of 210,960 2015 to 2021 model year Ford trucks may be at risk. Should a leak occur, the proximity to hot engine and exhaust components only increase the likelihood of a fire.

The NHTSA say it has, so far, received 27 complaints from owners alleging that they have experienced an unexpected fuel leak. Of those, 12 claim that a fire occurred and four of which have led to injuries.

The issue stems from a faulty secondary fuel filter housing. Allevard Sogefi USA, which manufactures the filter housings for Ford, stated the truck’s low-pressure fuel system can run at a maximum pressure of 8.5 Bar (123 psi). However, the secondary filter housing had only been tested to 7 Bar (101.5 psi). A change in the manufacturing process in 2022 means that those trucks, and newer, shouldn’t be affected by this issue.

If this all sounds familiar, Ford has issued a recall for this very problem. In February of 2022 the company recalled nearly 20,000 F-Series Super Duty trucks built for the 2021 model year to replace the secondary fuel filter housing.

A Firsthand Power Stroke Fire Account

Recently, we posted about the current Ford recall for its 6.7-liter CP4 high-pressure injection pump. While Ford maintains that there is no risk of fire from this current recall, we were contacted by reader Kevin C. from Missouri with a harrowing truck fire tale of his own. He’s willingly shared photos and is allowing us to tell the story in hope that more owners will get their trucks fixed.

“Here is the story: On November 17th, 2024, at about 5pm in the evening my wife and I were coming home from horseback riding at St. Joe State Park in Farmington, Missouri. At the time I was pulling a 14-foot aluminum gooseneck horse trailer with my 2019 Ford F-350 Super Duty. I bought the truck from a dealer in Baltimore and had it shipped to me. The truck was bone stock with no modifications and just 19,987 miles on the odometer.

About 13 miles from home a car pulled up beside me, furiously blowing the horn and pointing at the front of the truck. She was screaming ‘You’re on fire!’

I immediately looked back at the trailer thinking I had a brake/axle/bearing on fire. Thankfully, I was near an off-ramp and quickly darted off the highway. There were no smells, no dash lights, no loss of power, nothing to indicate there was an issue with the truck. As soon as I got off the ramp the truck died. I tried putting the truck in park, but nothing happened, the truck began rolling backwards. At this point I saw fire coming from under the hood.

Thankfully, an onlooker who saw the situation unfold hopped off the highway with me and was able to quickly toss a block under the trailer tires. We quickly unloaded the horses and got them away unharmed. When the fire department arrived, the truck was fully engulfed. It burned to the ground in less than 15 minutes. The police and firemen on scene knew immediately what the cause was and commented that were seeing as many as one a week of fires just like this.

Insurance covered part of the value of the truck, but not enough to make whole everything that was in it (including a full tank of fuel). When I contacted Ford about the issue the company’s response was simply, ‘Well, there’s no recall. Thank you for being a member of the Ford family.’”

A New Power Stroke Recall For 2025

Now, as of May of 2025, Ford has issued a new Power Stroke recall. This time its is recalling a small number of 2025 model year F-Series Super Duty trucks equipped with, you guessed it, the 6.7-liter PowerStroke engine. The focus of this recall is a fuel return line assembly, which can develop cracks at the fitting leading a fuel leak and potential for fire. Supplied by Bosch Mexico Sistemas Automotrices, it is suspected that the return line assemblies were damaged by the supplier during a tooling fixture change.

LC3Q-9K022-AX is Ford’s part number for the fuel return line assembly, which were used on F-250 and F-350 trucks built on March 22nd, 2025, at Ford’s Kentucky Truck Plant. According to the NHTSA, this recall may only affect three trucks that could be in customer hands. Nonetheless, a recall has been issued.