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ipeltier's avatar
ipeltier
Explorer
Dec 17, 2017

Ford 250 DEF system failure

We have a 2015 Ford 250 Superduty with the Diesel Exhaust Fluid requirement. Several months ago, the sensor indicated that the fluid was low and we refilled the tank. The sensor would not recognize the full tank, and within 80 km our truck was reduced to idle function. We were pulling a 5th wheel and in the middle of nowhere without cell service in Montana, so it was a stressful situation. We had to abandon the 5th wheel on the side of the road, have the truck towed 40 miles to a Ford dealership, stay in a hotel (in the midst of wildfires), waste two days of vacation. (Ford Assistance would pay only $75.00 of the $275.00 tow bill). After many attempts at repair, the service tech ran the computer system through its paces twice back-to-back and the truck's functions were restored. Now, 3000 km later, the same thing has happened. We are at home, and have taken the truck to a dealership, but in January we are planning to drive south from Alberta to Arizona--over mountains, possibly through poor winter driving conditions, and we're very concerned that we may be stranded again. Has anyone else had problems with their DEF truck systems?
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  • Sgeorge's avatar
    Sgeorge
    Explorer
    Dec 18, 2017
    Go to FTE - www.fordtruckenthusiats.com and do some research for yourself. You will find a significant amount of reading on this subject. I am Ford guy but I have stayed away from their diesels because of the expensive issues that can come up related to emission controls. Check in out for yourself.
  • blofgren's avatar
    blofgren
    Explorer
    Dec 18, 2017
    Yes, many people have had DEF issues with all makes of the newer diesel trucks.

    I would see if the issue is the same as last time and go from there. Be sure to only use good, fresh DEF from a reputable source and don’t let it get too old in the tank. If you have the same problem there could be another problem that is causing it that Ford must fix. Be persistent with your dealer! :)

    Please let us know the outcome and good luck.
  • lenr's avatar
    lenr
    Explorer III
    Dec 17, 2017
    OP should Google this question, particularly DieselStop.com. I have read of a few cases there. However, those who have no failures don't seem to post much.
    I don't believe that this is a frequent issue. It is unfortunate that Ford chose to use level sensors (like on your RV tanks) instead of a level gauge as is used by Ram. I've had one false indication in 82K miles on our 2012 F-350. The owner's manual says that it will reset the DEF management system warnings in 4 starts, and mine did. These 6.7 engines are worlds better than either the 6.0 or 6.4.
  • DanNJanice's avatar
    DanNJanice
    Explorer
    Dec 17, 2017
    I have had a couple of issues with "exhaust filter saturated errors" while towing my trailer, forcing the truck into limp mode. In one case, I had to have the truck towed 60 miles (nearest dealer). In the other case I got the same message driving across central Nevada. I dropped the truck down to 4th gear, drove it for an hour at 3000 rpms and it eventually cleaned itself. I have not heard of any issues with the tank sensor though.
    Sadly, modern diesels have become so complex that only the most experienced dealerships can fix them.
    I have about 2500 miles before my bumper to bumper warranty runs out. I am still trying to decide if I should pay Ford even more money for the extended warranty. Something about paying even more money to the same company that produced the problem sticks in my craw.

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