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Ford · Known Issues

2015 Ford F-250 Super Duty Problems: 5 Known Issues

2015 model year · 6,880+ owner reports · Updated September 2026

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Issue summary

According to Au7o's analysis of 6,880+ owner reports, the 2015 Ford F-250 Super Duty has 5 documented known issues, with 2 rated critical. The most serious are 6.7L Power Stroke EGR Cooler Clogging and Failure ($800-$3,500 repair) and 6.7L Power Stroke CP4 High-Pressure Fuel Pump Failure - Catastrophic Fuel System Contamination ($8,000-$15,000 repair). The most commonly reported issue is 6.7L Power Stroke EGR Cooler Clogging and Failure with 3,450 owner reports. Across all issues with published estimates, repair costs range from $100 to $15,000. DIY maintenance guides at au7o.io.

In This Article

  • F-250 Super Duty Engine3
  • F-250 Super Duty Exhaust1
  • F-250 Super Duty Steering1
  • FAQ
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In This Article

  • Engine3
  • Exhaust1
  • Steering1
  • FAQ

All 5 Known Issues

Filter:
ALL YEARS202520242023202220212020201920182017201620152014201320122011201020092008200720062005200420032002200120001999

When Issues Typically Appear

Steering Damper Failure and Shimmy
50K-80K
6.7L Power Stroke CP4 High-Pressure Fuel Pump Failure - Catastrophic Fuel System Contamination
80K-120K
6.7L Power Stroke EGR Cooler Clogging and Failure
96K-144K
038K75K113K150K mi
Community reported
3,450 owners

On the 2011-2019 Ford F-250 Super Duty 6.7L Power Stroke Diesel, the EGR (Exhaust Gas Recirculation) cooler on 2011-2019 6.7L Power Stroke diesel engines is prone to clogging with soot and eventually failing, particularly on trucks used for highway driving, light loads, or trucks that idle extensively. The EGR cooler recirculates cooled exhaust gas back into the intake to reduce NOx emissions. Over time, soot accumulates in the cooler's internal passages until coolant flow is restricted, causing the cooler to overheat and fail. When it fails, exhaust gases enter the coolant system, causing overheating and "puking" coolant from the degas bottle. The 2011-2014 models are particularly susceptible due to narrow internal coolant passages. Ford issued TSBs for 2011-2014 trucks covering EGR cooler cleaning/replacement under extended warranty up to 120,000 miles. The EGR cooler for 2011-2016 is OEM part BC3Z-9V425-A; 2017+ is HC3Z-9V425.

This issue also affects: Ford Bronco, Ford Bronco Sport, Ford E-Series

Common Symptoms

  • Coolant loss with no visible external leak
  • Coolant reservoir overflows or "pukes" coolant
  • White smoke from exhaust (coolant in combustion)
  • Engine overheating warning
  • DTC codes P0401 (Insufficient EGR Flow) or P2457 (EGR Cooler Performance)
  • Bubbling or foaming in coolant degas bottle
  • Loss of power under load (especially towing)
  • White deposits around degas bottle cap

How to Fix

Replace EGR cooler (BC3Z-9V425-A for 2011-2016; HC3Z-9V425 for 2017+). Check if truck qualifies for Ford extended service coverage with active DTC P0401 (Insufficient EGR Flow) or P2457 (EGR Cooler Performance). Some 2011-2014 trucks covered to 120,000 miles. Preventive: use a fuel additive (Diesel Kleen, Hot Shots Secret EDT) to reduce soot. Perform regular EGR cleaning at 60,000-mile intervals. Upgrade kits from Sinister Diesel and Dorman (904-405 kit) include both EGR cooler and gaskets.

Typical repair cost:$800 - $3,500

Research This Issue

Based on 3,450 owner reports

GoogleRedditYouTubeNHTSA
Community Reported
High Confidence3,450 owner reportsLast reported by owners Dec 2025Reviewed Feb 2026
Community reported
1,870 owners

On the 2011-2016 Ford F-250 Super Duty 6.7L Power Stroke Diesel, the 2011-2016 6.7L Power Stroke uses a Bosch CP4.2 high-pressure fuel injection pump that is fundamentally incompatible with North American diesel fuel specifications. US diesel fuel has lower lubricity than European fuel, and the CP4 pump relies on fuel for internal lubrication. Over time, the CP4 pump's internal metal components grind and generate metal shavings that are distributed throughout the entire high-pressure fuel system at 30,000+ PSI. Metal contamination destroys all downstream injectors, fuel rails, and low-pressure system components. A class action lawsuit filed against Ford alleges the company knew the CP4 was incompatible with US fuel. Catastrophic failure can occur as early as 80,000-120,000 miles and requires complete fuel system replacement costing $8,000-$15,000.

This issue also affects: Ford Escape, Ford F-150, Ford Fiesta

Common Symptoms

  • Loss of power during acceleration
  • Engine hesitation and stumbling under load
  • Hard start or no-start condition
  • Smoke from exhaust (black or white)
  • Check engine light with fuel system pressure codes
  • Loud ticking or knocking from injector area
  • Fuel rail pressure too low codes (P0087, P0191)
  • Complete engine shutdown on the road

How to Fix

Complete fuel system replacement required: CP4 pump, all 8 injectors, high-pressure fuel rails, low-pressure pump, fuel filter housing, all fuel lines (metal contamination spreads everywhere). Ford kit EC3Z-9B246-C covers the repair for some years. Total cost $8,000-$15,000. Prevention: add diesel fuel lubricity additive (Stanadyne Performance Formula, Hot Shots Secret DIESEL EXTREME) at every fill-up. Some owners install a CP3 conversion pump kit (eliminates the CP4 with a more reliable Bosch CP3).

Typical repair cost:$8,000 - $15,000

Research This Issue

Based on 1,870 owner reports

GoogleRedditYouTubeNHTSA
Community Reported
High Confidence1,870 owner reportsLast reported by owners Nov 2025Reviewed Feb 2026
Community reported
1,560 owners

On the 2015-2022 Ford F-250 Super Duty 6.7L Power Stroke Diesel, the Selective Catalytic Reduction (SCR) system on 2015-2022 6.7L Power Stroke trucks - which uses Diesel Exhaust Fluid (DEF) to reduce NOx emissions - is prone to failure, most commonly triggering DTC codes P207F (Reductant Quality Performance) and P20EE (SCR NOx Catalyst Efficiency Below Threshold). Causes include degraded or crystallized DEF fluid (DEF has a shelf life of 1-2 years and degrades faster in heat), a failed DEF injector, SCR catalyst failure, DEF quality sensor failure, or NOx sensor failure. In limp mode, the truck's performance is severely limited. The system is complex and diagnosis requires a professional scan tool. The DEF injector is a particularly common failure point on 2017+ trucks.

This issue also affects: Ford Transit

Common Symptoms

  • Check engine light with P207F (Reductant Quality Performance) code
  • Check engine light with P20EE (SCR NOx Catalyst Efficiency Below Threshold)
  • Reduced engine power / limp mode
  • DEF gauge or warning light showing issue
  • Truck will not restart after excessive limp mode cycles
  • Rough running at idle
  • Increased fuel consumption

How to Fix

Diagnose with Ford IDS or quality OBDII scanner capable of reading all PCM codes. Common fixes: (1) Drain and refill DEF tank with fresh fluid (AutoZone DEF, Ford Motorcraft DEF VC-10-B) - $15-$30. (2) Replace DEF quality sensor ($150-$300). (3) Replace DEF injector ($300-$600 + labor). (4) SCR catalyst replacement ($2,000-$4,000). Always use fresh, quality-brand DEF (avoid bargain/store-brand DEF). Do not let DEF tank run to empty repeatedly.

Typical repair cost:$3,000 - $4,500

Research This Issue

Based on 1,560 owner reports

GoogleRedditYouTubeNHTSA
Community Reported
High Confidence1,560 owner reportsLast reported by owners Nov 2025Reviewed Feb 2026

On the 2011-2022 Ford F-250 Super Duty, the 6.7L Powerstroke diesel engine exhaust manifold studs are prone to breaking due to thermal cycling. The extreme heat cycles of the diesel exhaust cause the studs to fatigue and snap, creating an exhaust leak at the manifold-to-head junction. This produces a ticking noise on cold starts that may diminish when warm, exhaust smell in the cabin, and can trigger check engine lights for exhaust leaks. The driver side manifold is more commonly affected.

This issue also affects: Ford Escape, Ford Explorer, Ford F-150

Common Symptoms

  • Ticking noise on cold start from engine
  • Exhaust smell in cab, especially with windows open
  • Check engine light with exhaust leak codes
  • Visible soot at manifold-to-head junction
  • Noise diminishes as engine warms up

How to Fix

Replace the broken exhaust manifold studs. Stud extraction can be challenging if broken flush — a skilled diesel shop can often drill and extract without removing the head ($500-1,200). If multiple studs are broken, manifold removal and replacement with upgraded ARP studs is recommended ($800-2,000). Upgraded ARP stainless steel studs ($50-80 for a set) are significantly stronger than the factory studs and resist thermal fatigue.

Typical repair cost:$500 - $2,000

Research This Issue

GoogleRedditYouTubeNHTSA
Community Reported
High Confidence

On the 1999-2025 Ford F-250 Super Duty, the factory steering damper on the F-250 Super Duty wears out and fails, leading to increased steering shimmy, vibration at highway speeds, and reduced ability to dampen road imperfections. The single factory damper is often inadequate for the weight and solid front axle of the Super Duty. A worn damper does not cause death wobble directly but removes the last line of defense against oscillation. Most factory dampers are worn out by 50,000-80,000 miles.

Common Symptoms

  • Shimmy or vibration at highway speeds
  • Steering feels loose over bumps
  • Front end wanders on rough roads
  • Visible oil leaking from damper
  • Increased effort to keep truck centered in lane

How to Fix

Replace the steering damper with a heavy-duty aftermarket unit. Fox 2.0 ($150-250), Bilstein 5100 ($100-150), or Rancho RS9000XL ($100-150) are popular upgrades. Some owners install dual steering damper kits ($200-400) for additional stability. Installation is a simple bolt-on job taking 30-60 minutes. Replace the damper every 50,000-60,000 miles as preventive maintenance.

Typical repair cost:$100 - $400

Research This Issue

GoogleRedditYouTubeNHTSA
Community Reported
Medium Confidence
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Frequently Asked Questions

What are the most common Ford F-250 Super Duty problems?

According to Au7o's analysis of 6,880+ owner reports, the 2015 Ford F-250 Super Duty has 5 documented issues. The most frequently reported are: 6.7L Power Stroke EGR Cooler Clogging and Failure, 6.7L Power Stroke CP4 High-Pressure Fuel Pump Failure - Catastrophic Fuel System Contamination, 6.7L Power Stroke DEF/SCR System Failure - P207F and P20EE Codes. Of these, 2 are rated critical and should be addressed promptly.

Is the Ford F-250 Super Duty reliable?

The 2015 Ford F-250 Super Duty has 5 known issues documented across 6,880+ owner reports. 2 issues are rated critical: 6.7L Power Stroke EGR Cooler Clogging and Failure and 6.7L Power Stroke CP4 High-Pressure Fuel Pump Failure - Catastrophic Fuel System Contamination. Prospective buyers should inspect for these issues and factor potential repair costs into their purchase decision. Regular maintenance following the manufacturer's schedule helps prevent many common problems.

How much does it cost to fix common Ford F-250 Super Duty problems?

Repair costs for known Ford F-250 Super Duty issues range from $100 to $15,000, depending on the specific problem and whether you choose DIY or professional repair. The most critical issue, 6.7L Power Stroke EGR Cooler Clogging and Failure, typically costs $800-$3,500 to repair. Au7o provides step-by-step DIY maintenance guides that can help reduce repair costs.

What is the 2011-2019 Ford F-250 Super Duty 6.7L Power Stroke EGR Cooler Clogging and Failure?

The EGR (Exhaust Gas Recirculation) cooler on 2011-2019 6.7L Power Stroke diesel engines is prone to clogging with soot and eventually failing, particularly on trucks used for highway driving, light loads, or trucks that idle extensively. The EGR cooler recirculates cooled exhaus… Repairs typically run $800-$3,500. Severity: high.

What is the 2011-2016 Ford F-250 Super Duty 6.7L Power Stroke CP4 High-Pressure Fuel Pump Failure - Catastrophic Fuel System Contamination?

The 2011-2016 6.7L Power Stroke uses a Bosch CP4.2 high-pressure fuel injection pump that is fundamentally incompatible with North American diesel fuel specifications. US diesel fuel has lower lubricity than European fuel, and the CP4 pump relies on fuel for internal lubrication. Repairs typically run $8,000-$15,000. Severity: high.

Content on this page was compiled with AI assistance using NHTSA complaints, TSBs, owner reports, and public automotive data. While we strive for accuracy, this information may contain errors. Always verify repair procedures and specifications with your vehicle's service manual or a qualified mechanic.

Data sourced from 6,880+ owner reports, NHTSA recalls, TSBs, and automotive forums.

What is the 2015-2022 Ford F-250 Super Duty 6.7L Power Stroke DEF/SCR System Failure - P207F and P20EE Codes?

The Selective Catalytic Reduction (SCR) system on 2015-2022 6.7L Power Stroke trucks - which uses Diesel Exhaust Fluid (DEF) to reduce NOx emissions - is prone to failure, most commonly triggering DTC codes P207F (Reductant Quality Performance) and P20EE (SCR NOx Catalyst Efficie… Repairs typically run $3,000-$4,500. Severity: medium.

What is the 2011-2022 Ford F-250 Super Duty 6.7L Powerstroke Exhaust Manifold Stud Failure?

The 6.7L Powerstroke diesel engine exhaust manifold studs are prone to breaking due to thermal cycling. The extreme heat cycles of the diesel exhaust cause the studs to fatigue and snap, creating an exhaust leak at the manifold-to-head junction. This produces a ticking noise on c… Repairs typically run $500-$2,000. Severity: medium.

What is the 1999-2025 Ford F-250 Super Duty Steering Damper Failure and Shimmy?

The factory steering damper on the F-250 Super Duty wears out and fails, leading to increased steering shimmy, vibration at highway speeds, and reduced ability to dampen road imperfections. The single factory damper is often inadequate for the weight and solid front axle of the S… Repairs typically run $100-$400. Severity: low.