Ford Super Duty Fuel Pump Recall: A Complete Guide for Owners​

If you own a Ford Super Duty truck from the 2017 to 2022 model years with a 6.7L Power Stroke diesel engine, your vehicle may be part of a critical safety recall for a potentially defective fuel pump. ​The immediate action you must take is to determine if your specific truck is included and to heed Ford's warning not to drive it if you experience symptoms of fuel pump failure.​​ This recall is serious, involving a component whose failure can lead to a sudden loss of engine power while driving, increasing the risk of a crash. This comprehensive guide details everything you need to know, from identifying the problem and checking your VIN to navigating the repair process and understanding your rights.

​Understanding the Recall: The Heart of the Matter​

The National Highway Traffic Safety Administration (NHTSA) recall number is 23V-838, and Ford's internal number is 23S65. Announced in December 2023, this recall specifically targets certain Ford F-250, F-350, F-450, and F-550 Super Duty trucks equipped with the 6.7-liter Power Stroke diesel engine and a high-pressure fuel pump manufactured by Bosch. The core issue resides within this pump. ​The fuel pump in question may contain a contamination of silica from a specific seal, which can lead to the premature wear and failure of the internal components.​​ Unlike a simple clog or electrical fault, this is a material defect that causes the pump to degrade from the inside out.

When this wear occurs, metallic debris is circulated throughout the critical high-pressure fuel system. This debris can damage other essential components, including fuel rails and injectors, leading to a cascade of failures. The most dangerous outcome is a sudden and complete loss of engine power while the vehicle is in motion, whether at highway speeds or in city traffic. This complete stall, without warning, removes power steering and brake boost, making the vehicle difficult to control and dramatically elevating crash risk. It is not an issue of rough idling or reduced performance; it is a critical safety fault that can render the truck inoperable.

​Which Vehicles Are Affected? The Specific Model Years and Build Dates​

The recall is not for every single Super Duty truck on the road. It is limited to a specific production window. The affected population includes approximately 142,410 trucks in the United States and federalized territories. ​The vehicles under recall are certain 2017-2022 Ford F-250, F-350, F-450, and F-550 Super Duty trucks, built at the Kentucky Truck Plant from December 1, 2016, through August 31, 2022.​​ The key determinant is the installation of a specific Bosch high-pressure fuel pump, which was used during this period.

It is crucial to understand that not every Super Duty within those model years is included. Trucks with gasoline engines are not part of this recall. Furthermore, some diesel trucks may have received a fuel pump from a different batch or supplier that is not subject to the defect. The only definitive way to know if your truck is included is by checking its unique 17-character Vehicle Identification Number (VIN). Owners should not rely solely on model year or make assumptions.

​Symptoms and Warning Signs: What to Listen and Look For​

Before a complete failure occurs, the failing fuel pump may exhibit warning signs. Ford has instructed owners to be acutely aware of these symptoms. ​If you notice any abnormal engine noise, a noticeable loss of engine power, or the illumination of the malfunction indicator lamp (check engine light), you should park the vehicle safely and contact a dealer immediately.​​ Do not continue driving.

More specifically, the symptoms may include:

• A loud, abnormal whining, grinding, or knocking noise coming from the engine bay, particularly from the fuel pump area.
• A noticeable hesitation or lack of power during acceleration.
• Engine stumbling, rough idling, or erratic performance.
• Ultimately, the engine may stall completely and will not restart.

If you experience a stall while driving, maneuver the truck to the safest possible location, such as the right shoulder, turn on your hazard lights, and exit the vehicle on the side away from traffic. Then, contact roadside assistance and your Ford dealer. ​Continuing to drive with these symptoms can cause extensive additional damage to the fuel system and is a significant safety hazard.​​

​The Immediate Steps Every Owner Must Take​

Your action plan is straightforward and critical.

1. ​Check Your VIN:​​ Immediately visit the official NHTSA recall website () or Ford's owner recall lookup page (). Enter your full VIN. This will confirm if your specific vehicle has an open recall for campaign 23V-838/23S65. You can also call your local Ford dealership and provide your VIN for verification.

2. ​Do Not Ignore the Notice:​​ Ford began mailing formal notification letters to registered owners in late January 2024. If you receive this letter, treat it with urgency. It is not a routine maintenance reminder or a marketing piece; it is a federally mandated safety recall notice.

3. ​Schedule the Repair:​​ If your VIN is included, contact an authorized Ford dealership immediately to schedule the recall repair. ​You must schedule an appointment; dealers will not have the extensive parts inventory to handle walk-in requests for this complex repair.​​ Describe that you are calling for recall 23S65 regarding the high-pressure fuel pump. The repair is performed at no cost to you, regardless of the truck's age or mileage.

​The Repair Process: What the Dealer Will Do​

The remedy for this recall is extensive and involves significant labor. It is not a simple "replace the pump" operation. ​The authorized repair involves the complete replacement of the high-pressure fuel pump and a thorough cleaning or replacement of the entire fuel system to remove any contaminating debris.​​ This is a critical step; simply installing a new pump into a contaminated system would cause the new pump to fail quickly.

The dealer technician will:

• Remove the defective Bosch fuel pump.
• Inspect the entire fuel system for damage and metallic debris.
• Clean the fuel system comprehensively. This includes flushing fuel lines, rails, and other components. In many cases, the fuel rails and injectors may need to be replaced if they are found to be damaged by the debris.
• Install a new, redesigned high-pressure fuel pump that does not contain the problematic seal material.
• Prime the system, clear any diagnostic trouble codes, and perform a full functional test to ensure proper operation.

Due to the complexity and the need to ensure the entire system is clean, this repair can take a full day or more, depending on the dealership's schedule and workload. Owners should be prepared for this and arrange for alternate transportation if needed. Some dealers may offer a rental vehicle, but policies vary, so you should inquire when scheduling your appointment.

​Background and History: Why This Recall Happened​

This recall did not happen in a vacuum. Ford and NHTSA monitor field data, customer complaints, and warranty claims for patterns. ​An investigation by Ford determined that the root cause was the degradation of a specific seal within the Bosch pump, introducing silica contamination into the fuel circuit.​​ This was a supplier component issue, but as the vehicle manufacturer, Ford holds the ultimate responsibility for the safety and reliability of the final product.

It is important to note that recalls of this scale often follow a period of investigation. Owners may have reported issues for months or even years before the pattern becomes clear enough to warrant a formal recall. The decision to recall over 140,000 heavy-duty trucks is not taken lightly, given the immense cost of parts, labor, and logistics. It is undertaken because the engineering analysis and safety risk assessment conclude it is necessary.

​Owner Rights and Frequently Asked Questions​

• ​Is the repair really free?​​ Yes. By law, all safety recall repairs must be performed at zero cost to the vehicle owner. This applies even if your truck is out of the standard bumper-to-bumper or powertrain warranty.
• ​What if I already paid for a fuel pump repair?​​ If you paid for a repair for symptoms related to this specific defect before the recall was announced, you may be eligible for reimbursement. You must contact Ford Customer Service and provide proof of the repair (paid invoice, work order) for review. There are time and mileage limitations, so act promptly.
• ​Can I sell or trade in my truck with an open recall?​​ Legally, you can. However, you must inform the buyer of the open recall. Ethically and practically, it is best to get the recall repaired first. A dealership will significantly reduce their trade-in offer for a vehicle with a critical, unrepaired safety recall.
• ​What if my truck hasn't shown any symptoms?​​ You must still get the recall performed. The defect is latent and can manifest at any time. The recall repair replaces the faulty part with the improved design to prevent the failure from ever occurring.
• ​Is there a loaner or rental car provided?​​ Ford has authorized dealers to provide a rental vehicle for owners experiencing the failure symptoms and for those whose repair will take more than a day. Availability is at the dealer's discretion, and you must confirm this when scheduling. For owners not experiencing symptoms, rental coverage is less common but can be requested based on hardship.
• ​What about secondary damage?​​ The recall repair covers the replacement of the pump and the cleaning or replacement of fuel system components damaged by the pump failure. If the failing pump caused damage to unrelated systems (which is unlikely), that would typically not be covered under the recall but could be a subject for discussion with Ford Customer Service.

​The Broader Context: Fuel Pump Recalls in the Industry​

While alarming, widespread fuel system recalls are not uncommon in the automotive industry, especially for complex modern engines with high-pressure direct injection systems. Diesel engines, in particular, operate at extremely high fuel pressures, making pump integrity paramount. ​This Ford Super Duty recall shares similarities with other major fuel pump recalls across various manufacturers, where a single supplier component flaw can affect hundreds of thousands of vehicles.​​ The response—complete system replacement and cleaning—is the industry-standard corrective action for this type of contaminant-induced failure.

​Final and Essential Recommendations​

1. ​Act Now:​​ Do not procrastinate. Check your VIN today.
2. ​Heed Warnings:​​ If your truck shows any symptom, stop driving it and have it towed to a dealer.
3. ​Use Official Channels:​​ Schedule repairs only with an authorized Ford dealership to ensure the correct parts and procedures are used and to guarantee the work is performed at no cost.
4. ​Keep Records:​​ Save all communication and paperwork related to the recall and repair.
5. ​Stay Informed:​​ Ensure your contact information is up-to-date with Ford and in your vehicle registration, so you receive all future communications.

The Ford Super Duty fuel pump recall is a significant and serious safety campaign. By understanding the issue, recognizing the symptoms, and taking prompt, informed action, you can ensure this problem is resolved correctly and your vehicle is returned to safe, reliable operation. Your safety and the safety of others on the road depend on it.