NHTSA launches investigation into more than 210,000 Ford F-250 diesel trucks over fuel leaks and fire concerns

US safety regulators have launched an investigation into Ford over complaints about diesel leaks in its Super Duty trucks.

On Thursday, the National Highway Traffic Safety Administration (NHTSA) released documents with a preliminary assessment of 210,960 Ford F-250 to F-550 trucks. Leading up to this investigation, the agency received no fewer than 27 complaints about alleged diesel leaks, including 12 reports of fires and four injuries.

In particular, the problem is due to a rupture in the engine’s secondary fuel filter housing. Parts supplier Allevard Sogefi USA said it only tested the secondary fuel filter to a pressure of 7 bar (101.5 psi) during the manufacturing process. Ford told NHTSA that the fuel system can actually operate at an operating pressure of 8.5 bar (123.3 psi). According to the initial CV to initiate the investigation, both parties have made changes starting with the 2022 model year, which is why current generation trucks are not affected by this particular investigation.

NHTSA’s Office of Defects Investigation (ODI) initiates a preliminary assessment to determine the scope and severity of a safety issue after the agency receives a large number of complaints. In this case, the proximity of the secondary fuel filter to strong heat sources can pose a serious fire hazard, although there is no formal recall to address the issue at this time. Ford could voluntarily recall the trucks, or the results of the ODI investigation could trigger a recall campaign at some point in the future.

Ford told reporters it is working with NHTSA to help investigate the issue.