Ford 250 DEF system failure

In all actuality, when you do a delete, the engine runs much cooler, gets better fuel mileage and performs better. Of course the downside is, it won't pass an emissions test. Not something I worry about myself but if you live in a test area is't a major concern.

Under warranty, I'd just let the Ford dealer deal with it and I'd get the extended warranty, the Ford Motor extended Red Carpet Warranty administrated by Ford and no other (It's listed in your owners mauual under 'warranty' and can be initiated over the phone with a call to Ford in Dearborn, Michigan.

I have it on my new Focus, not because I'm anticipating issues but because of all the electronic gizmo's. Nice thing about the Red Carpet extended warranty is when you get it, Fords immediately initiates it with ALL Ford authorized dealers so you are on file, everywhere with no hassle from any dealer. For me, it's worth the extra expense.

We happen to be a Ford family so we all drive the company product which is, neither here nor there actually but, IMO, Ford builds a quality product for the most part, however the emissions components are not Ford but other suppliers. I cannot see playing 'Russian Roulette' with components that may fail when I can buy the extended warranty and be 100% covered for the mileage and time I feel necessary.

jamesroadking wrote:

blofgren wrote:
OP, another option if you're open to it is deleting the emissions equipment on the truck and being done with it. Of course this will likely end your engine warranty....

Also you won't be able to trade your Deleted truck into a dealership, in the future, if you want to sell it you'll have to sell it to a private party in a state that does not have smog testing.
My 2011 6.7 has not had this issue.

The op is from Canada ,in my part of the country your vehicle is E tested every 2 years.
So a delete is not advisable is you want your plates renewed.

blofgren wrote:
OP, another option if you're open to it is deleting the emissions equipment on the truck and being done with it. Of course this will likely end your engine warranty....

Also you won't be able to trade your Deleted truck into a dealership, in the future, if you want to sell it you'll have to sell it to a private party in a state that does not have smog testing.
My 2011 6.7 has not had this issue.

Thanks, everyone. The truck is at the Ford dealership so we'll see what their answer is. The previous reset was done in a very small dealership in northern Montana and we never really got an answer. The truck is still under warranty, thank goodness.

Check with different dealer, there was a updated sensor strip and a PCM reflash.
Had to do it on a truck with same problem as you

blofgren wrote:
OP, another option if you're open to it is deleting the emissions equipment on the truck and being done with it. Of course this will likely end your engine warranty....

And if the warranty is almost up anyhow, this course of action makes even more sense. Simplify the system, one less thing that can go wrong, and you will have made your truck (statistically) more reliable.

OP, another option if you're open to it is deleting the emissions equipment on the truck and being done with it. Of course this will likely end your engine warranty....

Presumably you're not out of warranty, but looking for the peace of mind that you are after, maybe find exactly what code(s) it's throwing and what the particular diagnoses and repairs are so you can help direct the dealer to replacing whatever needs replaced to keep it running for good.
When you said they "went through the systems twice" the last time, find out what they did, should be on the service order.
Another website like thedieselstop.com will be of more help to you as well. It's a Powerstroke forum.

Not a truck but I had the exact same problem with a piece of equipment. Read low, filled it up and still read low, de rated power and could not move.

Our mechanic said it is not worth diagnosing and just replaced the DEF tank which also had a level sensor and pump in the assembly. Machine has been fine since.

I had the def heater element fail on my 2011 f350. The heating element is part of the def reservoir which is made by Bosch. The reservoir also has rods installed in it that sense the def level. I ended up buying a complete def system off someone who did a delete on his f450 and I installed it myself. I think it cost me a couple hundred dollars. I think Bosch makes the def components for Ford GM and likely Ram through Kenworth as well. It's not a big job to do yourself ..... I think figuring out how to uncouple the wire harnesses was the toughest part. The def reservoir sits behind the fuel tank and I can't remember for sure but I think I removed the fuel tank to access it. I found it interesting to discover that the f450 def tank has a different part number than the f350. The parts are identicle other than the length of one of the level rods. The 450 tank has a shorter rod that will cause the warning light to turn on with a tiny bit more def in the tank than the f350 tank. The f450 is a little less expensive. My guess is that the dealer will charge you $1000 to fix it.