Ford Super Duty Fire Risk Recall: Cracked Fuel Line Connectors Safety Concerns

Unfortunately, there is no specific number of vehicles affected in the recall. Ford Motor Company has only mentioned that a small number of the 2025 F-250 and F-350 trucks equipped with the 6.7-liter Power Stroke V8 turbo diesel have been recalled due to a fire risk.

However, the automaker failed to specify the cab style of the affected trucks, which makes it impossible to determine whether they were assembled at the Kentucky or Ohio Plant. From the Ford F-250 to the F-450 trucks, the automaker lists three cab options, two box lengths, and either single or dual rear wheels.

The F-550 comes in XL, XLT, and Lariat cab style options, and two free-breathing V8 gas engines and one punchy turbo diesel engine option.

It was not the first time Ford Super Duty trucks faced a recall situation. After a month, around 850,000 Ford Super Duty trucks were recalled due to low-pressure fuel delivery module failures that may lead to engine stalling while driving, significantly increasing the risk of a crash.

What Caused the Ford Super Duty Fire Risk Recall?

According to the recall report, the fuel return line connectors may be cracked, increasing the risk of a fire. The suspect fuel return line assemblies were supplied by Bosch Mexico Sistemas Automotrices, potentially damaging them during a tooling fixture changeover.

During the changeover, the hose insertion fixture was misaligned, resulting in radial movement and causing a crack in the connectors.

Other Possible Reasons Behind Cracked Fuel Return Line Connectors

In Ford Super Duty trucks, the cracks in the fuel return line connectors mainly occur due to a manufacturing defect. However, several other reasons are also contributing to the issue. Let’s discuss them in the article below.

• Exposure to Heat and Moisture: Over time, exposure to heat, moisture, and other contaminants can cause the plastic or rubber materials of fuel lines to degrade and weaken, leading to cracking.
• Using Aftermarket Connectors: If you’re using aftermarket fuel line connectors, be aware that they are not designed for vehicles, as they may not withstand the pressure or chemical composition of diesel or gasoline, which can cause them to crack.
• Poor Quality Materials: If connectors are made from low-quality materials, they may not withstand the harsh conditions of the fuel system.
• Constant Vibrations: Over time, continuous vibrations can cause stress in fuel line connectors, potentially leading to cracking.
• Corrosion: Exposure to moisture can cause the metal parts of the connectors to rust and corrode, weakening them and potentially leading to cracks.
• Chemical Exposure: If the fuel line system is exposed to battery acid, it can cause chemical corrosion, leading to stress corrosion and resulting in cracks.
• Fuel Contamination: When the fuel comes in contact with water, dirt, and metal ions, it can cause corrosion, destabilizing the fuel and damaging the connectors.
• High Pressure: If you’re driving a diesel car, be aware of excessively high fuel flow when the outlet in the diesel system is partially or fully closed. It can create high pressure within the return fuel lines, straining the connectors and potentially causing cracks, which may lead to failure.

Warning Signs of Cracked Fuel Return Line Connectors

Some of the most common warning signs of a crack in the fuel line connectors are mentioned below:

• One of the most common signs is reduced engine performance, such as misfires, stalling, and rough idling.
• You’ll notice puddles or wet spots under your vehicle, or where the fuel lines run, or around the engine.
• When there is a leak in the fuel system, it may lead to fuel loss, increasing the risk of excessive fuel consumption.
• Inspect the fuel return line connectors for any signs of corrosion or dryness.
• Check your vehicle’s dashboard for the check engine light to see if it is blinking.
• Due to the leak, air enters the fuel system, or it fails to hold sufficient pressure, making the engine difficult to start.
• You may notice a strong smell of gasoline in or around your vehicle.

If you notice any of these warning signs, shut off the engine immediately and have the fuel lines inspected by a professional.

Ignoring these signs can lead to significant hazards, further damaging the fuel system and engine.

How Did Ford Fix the Issue?

According to Ford, authorized dealers replaced the defective fuel return line assemblies at no charge. The affected owners can run the 17-character VIN on the automaker’s website to determine if their Super Duty diesel trucks are included in the recall.

Is the 6.7-liter Power Stroke V8 Turbo Diesel a Good Engine?

Since its launch in 2011, the 6.7-liter Power Stroke V8 Turbo Diesel engine has established a strong reputation for delivering exceptional performance, reliability, and towing and hauling capacities. The engine has steadily increased its power output.

Its early versions delivered around 400 horsepower and 800 lb-ft of torque. In comparison, recent versions can reach 500 horsepower and 1,200 lb-ft of torque, making it one of the most powerful diesel engines.

The engine achieves 15-20 mpg on highways, which seems impressive given the power these engines produce. Moreover, this power stroke diesel engine is built for longevity, with many vehicles equipped with this engine reaching well over 200,000 miles with proper maintenance.

Like many other engines, the 6.7-liter Power Stroke engine isn’t without its issues. There were some turbocharger issues in earlier versions of this engine, but they were resolved in later versions.

Wrapping Up

While the Ford Super Duty fire risk recall may have only affected a small number of vehicles, the potential risk associated with this issue underscores the importance of timely recalls and proactive repairs for driver safety.

Ford has taken immediate action by replacing the defective fuel return line connectors at no charge. However, the 6.7-liter Power Stroke V8 turbo diesel engine remains one of Ford’s most celebrated engines.

If you own a 2025 Ford Super Duty truck, please check your vehicle’s VIN and schedule the recall repair immediately.

If you find this article helpful, feel free to check out my other recall articles associated with fire risks: Ford Escape and Bronco Sport recalled for risk of underhood fires, and 2020–22 Ford Escape SUVs with 1.5-Liter Engines Recalled for Possible Engine Fires.

Sources: Auto Evolution, Riser Ford