The 2019 F-250 with the 6.7L Power Stroke is a workhorse diesel that's generally solid, but the fourth-gen Power Stroke (2017-2019) suffers from a catastrophic CP4.2 high-pressure fuel pump failure issue and some transmission cooling concerns that can sideline trucks unexpectedly.
CP4.2 High-Pressure Fuel Pump Catastrophic Failure
Occasional · high severityTypical onset: 30,000-150,000 mi
Symptoms: Sudden loss of power and no-start condition, Metal shavings found in fuel system, Entire fuel system contaminated when pump grenades internally, Often occurs with no warning after using low-quality or contaminated diesel
Fix: Complete fuel system replacement including injectors, fuel rails, lines, tank cleaning, and CP4.2 pump itself. 25-35 labor hours depending on contamination severity. Many owners opt for CP3 conversion kit during repair to prevent recurrence.
Estimated cost: $8,000-15,000
Transmission Oil Cooler Line Failure and Leaks
Common · medium severityTypical onset: 60,000-120,000 mi
Symptoms: Transmission fluid pooling under truck near radiator area, Low transmission fluid warnings on dash, Burnt transmission fluid smell, Harsh shifting or slipping when fluid runs low
Fix: Replace transmission oil cooler lines and connections, sometimes requires cooler itself if internal failure. Quick-connect fittings corrode and crack. 3-5 hours labor for lines, 6-8 if cooler is involved.
Estimated cost: $600-1,800
EGR Cooler Clogging and Failure
Common · medium severityTypical onset: 80,000-150,000 mi
Symptoms: Check engine light with P0401 or P0402 codes (insufficient/excessive EGR flow), White smoke on cold starts, Loss of coolant with no visible external leaks, Reduced power and poor fuel economy
Fix: EGR cooler replacement or delete (off-road only). Cooler clogs with soot or develops internal leaks mixing coolant and exhaust. Ford updated the design in later years. 8-12 hours labor for cooler replacement including EGR valve cleaning.
Estimated cost: $1,800-3,200
Turbocharger Wastegate Rattle and Sticking
Occasional · medium severityTypical onset: 70,000-130,000 mi
Symptoms: Rattling noise from engine bay at idle or light throttle, Turbo underboost or overboost codes (P0234, P003A), Intermittent loss of power during acceleration, Excessive black smoke under load
Fix: Turbocharger wastegate actuator replacement or complete turbo replacement if internal damage present. Actuator rod can seize or rattle loose. 6-9 hours labor for turbo R&R on these.
Estimated cost: $1,500-3,500
DEF (Diesel Exhaust Fluid) System Failures
Occasional · medium severityTypical onset: 50,000-100,000 mi
Symptoms: DEF system fault warnings with speed derate countdown, Poor quality DEF message on dash, DEF heater failures in cold climates causing crystalization, Injector clogging from crystallized DEF
Fix: DEF injector, heater, or quality sensor replacement. Sometimes requires tank flush if contaminated. Truck will limit speed to 5 mph if not addressed before countdown expires. 4-7 hours labor depending on component.
Estimated cost: $800-2,200
Transmission Mount Failure
Common · low severityTypical onset: 60,000-100,000 mi
Symptoms: Clunking noise when shifting from park to drive or reverse, Excessive driveline vibration, Visible sagging or torn rubber on transmission crossmember mount
Fix: Replace transmission mount and inspect surrounding mounts. Heavy-duty use and diesel torque tear these apart. 1.5-2.5 hours labor.
Estimated cost: $300-600
Rear Axle Seal Leaks (Dana Super 60/70)
Occasional · low severityTypical onset: 40,000-80,000 mi
Symptoms: Gear oil dripping from rear wheel hubs or differential cover, Oil-soaked backing plates on rear brakes, Low differential fluid causing whining noise
Fix: Axle seal replacement, sometimes requires bearing replacement if seal failure damaged them. 3-4 hours per side labor. If differential cover gasket is leaking instead, 1.5 hours to reseal.
Estimated cost: $400-900
Buy one if you need the towing capacity and can afford the CP4.2 insurance policy—otherwise the 2020+ trucks with updated fuel systems are safer used purchases.
AI-assisted summary drawn from NHTSA recall data, our labor-times database, and platform knowledge. Not a substitute for a pre-purchase inspection on a specific vehicle.