Diesel Fuel System Problems of Ford F-450 - part 2

The coating on the interior of Ford diesel fuel tanks corrodes and collects as sediment in the fuel system. The sediment, collects at the botton of the fuel tank and is sucked into the fuel system. The fuel lines become fouled, the fuel pumps become clogged and require replacement. As the coating continues to deteriorate, the only recourse it to change the fuel tank, the sensors, and entire fuel delivery system. We have had 3 Ford vehicles f series experience this problem. The average repair is approximately $2180 per vehicle. We are reporting this as it seems to be a defect in all the Ford diesel fuel systems. As the fuel systems become clogged, the vehicles lose power without warning and create a safety issue and driving hazard not only to the vehicle operator but other motorists.

See all problems of the 2003 Ford F-450 🔎.

My 2006 Ford f450 [bought in 2007 as a left over] fuel tank is delaminating and caused $2200 in damages to my fuel system. Ford does not want to warranty it. There are 17 pages on the internet with people with the same problem. Some of the truck is still under warranty .

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The contact owns a 2006 Ford f450. While driving approximately 40-45 mph, the vehicle stalled. The contact was able to move off the roadway and after several attempts to restart the vehicle; the vehicle was towed to an authorized dealer. The dealer replaced the fuel tank, fuel pump, filters and fuel injectors at the contact's expense. The manufacturer was not contacted. The VIN was not available. The failure mileage was 135,000 and the current mileage was 150,000.

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Sept. 9, 2008 - truck started missing changed fuel filter when in shop for normal service March 18, 2009 - truck stalled and would not start, towed to shop, did diagnostics , regular service, and put on fuel regulator oct. 12, 2009 - truck missing and overheating, replace fuel filter and radiator tank Aug. 11,2010 - truck missing again would not start , smoking, towed to cauthorns,, then to Ford garage. Warranty work completed on truck, they thought head gaskets blown, replaced egr cooler and oil cooler, cleaned turbo, , replace fuel filter and replaced battery. Aug. 17, 2010- vehicle towed to cauthornes auto from Ford garage to have fuel tank replaced due to peeling and slivers in tank. Seeing as how this is the third truck we have had to have the fuel tank replaced on we have saved the old fuel tank and have it on hand at our shop for inspection.

See all problems of the 2005 Ford F-450 🔎.

I have a 2005 Ford F-450 that was loosing power going down the road. I had just replaced the fuel filters about two thousand miles before. When I removed the frame mounted fuel filter it was full of silver metal flakes. I called the service manager at Ford and was told it was delamination of the fuel tank. Of course my three year / thirty six thousand was out . The one hundred thousand on my motor covered everything but the fuel lines and fuel tank. I think this is bull and Ford should be responsible for this problem. By the way I've seen many complaints on this problem. My truck has fifty eight thousand miles on it . Ford told me it was costing me about one thousand dollars to fix it. To me its just going to be a temporary fix from what I can tell from all the complaints.

The contact owns a 2005 Ford F-450 sd. The contact stated that the fuel tank was delaminating and causing fuel to become clogged. The dealer was contacted and denied any assistance with repair to the vehicle. The manufacturer was not made aware of the failure. The vehicle was not repaired. The failure mileage was 45,000 and the current mileage was 70,000. The VIN was unavailable. The consumer stated the vehicle was repaired, but not at a Ford dealership, since the refused to acknowledge the fuel tank delaminated into the fuel and then plugged the fuel filter more than once. Updated 08/26/11.

Ford diesel fuel tank delamination. Sudden loss of power on the freeway, due to delamination particles clogging the injectors.

The lining of the fuel tank is flaking off into my fuel lines. This condition has caused major hesitation and lack of power. Need further investigation to know the extent of damages.

The contact owns a 2006 Ford f450. While replacing the fuel filter, the mechanic found chips of paint from the lining of the fuel tank. The contact was informed that this failure could possibly clog up the fuel injectors and cause the entire fuel line to fail. The vehicle is currently being repaired at the cost of $400. The contact is in the process of notifying the manufacturer. The failure and current mileages were 45,000.

The diesel fuel tank on my 2004 Ford f450 is delaminating on the inside of the tank and causing fuel contamination with metalic particles. If this condition had gone undiscovered it would have resulted in failure of the injector pump and ultimatly the engine itself. This is a serious factory defect with driver/passenger safety implications for all late model Ford super duty trucks. Ford should be forced to recall these trucks and replace the defective tanks reengineered fuel tanks.

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Purchased an new F-450 work truck for our small minority owned business, no issues with it until the last two weeks,it started running really weird with no pickup at all. . (15 miles per hr) took it to the Ford dealer where purchased and they determined that the fuel tank lining was disintegrating it is just out of warranty and 40,000 miles I have filed a complaint with Ford on this issue the dealership wants 1800. 00 to repair Ford also told me that fuel tank disintegration was not a manufacturers defect and no warranty would cover it anyway. Ford built the truck not me, I am finding through internet research and discussion with others that this is a common problem. I thought Ford trucks were built tough? yeah tough for the consumer to pay for repairs that should not have to be done on a truck with so little miles and years. Please advise any actions I may take on this situation. I also voiced my displacement at the dealership where purchased and the head of all parts/service was supposed to get back with me and you guessed it, I have heard nothing which I suspect I will not.

I own a 2008 Ford F-450 with a 6. 4 diesel motor. I have numerous issues with drive train problems since I took delivery. Finally, while driving on a 4-lane highway doing 50mhp the motor quit running. Bake and steering failure followed. After getting towed to a dealer and after 3 days to find the problem, I was told there was a burnt wiring harness inside the high pressure fuel pump system. I asked if this was a single issue or wide-spread. I was told that there is a TSB (tech service information) regarding this failure. I asked why no recall and was told this is not a safety issue. I consider my truck to stop running at any speed to be a safety issue. The repair took 11 days to complete. In order to make the repair the cab and the front body have to be removed from the chassis. I can see why Ford would not want to replace these defective pieces on all the 6. 4 diesel motors, however by waiting for each one to break down, and possibly causing a serious accident is a terrible business decision. Please help other owners!!.

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I have 2 2005 Ford f450's that both have had fuel tank delamination. I have talked with the dealer at length about the situation. Off the record the service advisor acknowledged that this is a huge problem and there is no promise the new tanks will not have the same problems. After searching online message boards I have found that the problem is widespread. Basically the fuel tank that the manufacturer chose to use when building the truck will not hold up to the fuel type that the manufacturer requires to be used in the truck.

1)traffic systems has a fleet of vehicles to perform our business which include all manufactures(chevy,Ford,International,isuzu,etc). The events that lead to failure is the deterioration of the fuel system,which leads to engine shut down. 2)the failure occurs every 4000,5000 miles. 3)everytime this happens the trucks shutdown in the middle of driving anywhere they are. Our business has employees that drive and work out of these trucks, every time this happens we have to get the trucks towed to dealer and pickup our employees.

This complaint stems from problems experienced with my 2004 Ford F-450 diesel powered truck. I purchased this 2004 Ford new truck in late 2004. At present, the odometer reads approximately 63,000 miles. I experience loss of power at various intervals which causes the vehicle to slow down and power is limited to a few miles-per-hour. I have returned the truck to Ford for repair numerous times and Ford has not been able to repair the problem. Ford has replaced the turbo two times, the wiring harness, the egr and other parts in the attempt to repair the problem. I returned this truck to Ford again on 12-26-2008. The service department removed the fuel filter and they found that the lamination or lining of the fuel tank has separated from the metal which makes up the fuel tank. This appears as a flaky silver substance which clogged the fuel filter and lines and is very expensive to repair. I have researched this failure on the internet and it appears that there are hundreds of complaints which point to the same failure of the Ford fuel tank, especially on diesel powered vehicles. . Read more...

The lining of the fuel tank has been flaking off into my fuel lines, which is restricting my fuel filters. Because of the lack of fuel, 2 fuel injectors went bad and had to be replaced. And the turbo was over compensating for the lack of power, due to fuel shortage, so the turbo had to be replaced as well. Now that we have found the source of the problem, the fuel tank and fuel pump has to be replaced as too. Into this for $5000 already without replacing the tank and pump. Need some help.

The lining of the diesel fuel tank flaked off which clogged the fuel filters, which resulted in poor engine performance.

Sept. 30, 2008 - vehicle engine started missing - taken to shop fuel filter changed along with regular service of engine. July 19, 2010 - vehicle missing and smoking, taken to repair shop , diagnostics were done, showed injector problem, injector problem covered under warranty transferred to Ford garage. Checked codes and inspect test cylinder balance compression fuel tet code po281, code paa9u replaced # 7 fuel injector, bleed , road tested after completion, returned to repair shop replaced fuel filter at repair shop during state inspection. Ticket closed and returned truck to us on July 19, 2010. Aug. 12, 2010 - truck started missing again and stalled would not start, towed to a different Ford garage. Checked and advised to change injector # 1 and # 5, test drove to verify repair, key on engine off check, key on engine off self test, fuel contamination check, electric fuel pump pressure test, diesel hard start/ no start- diagnostic / pin point test , fuel injector or nozzle for injection pump, remove and replace, Aug. 18, 2010 vehicle was towed from Ford garage to repair shop to replace fuel tanks due to peeling and slivers inside of the fuel tank . This is the 4th vehicle that we have had to replace the fuel tank on among other repairs that this problem has caused my company. The fuel tank is stored at my shop and available for inspection upon request.

I have a complaint about the fuel tank in my 2004 F-450, the truck was losing power and driving like a plugged fuel filter and after changing fuel filters many times I had found a "grey flake like" materials in both filters. I decided to take truck to Ford dealer in Lincoln, ne to have looked at and fixed. They called back telling me the fuel tank lining was bad in the fuel tank and needed to be replaced at my expense. It also caused one injector to go bad(hopefully not more) and a "nozzle assembly". They charged me to dispose of the 25(or so) gallons of fuel, and charged me for new fuel. The total bill was $2066. 23. They said they talked to Ford and Ford would not warranty anything. In looking on internet there are many people with same problem. The tank has a liner in it that has dissolved causing the problems. I am the original owner, truck has 32000 miles and should not! need a fuel tank after 4 years. I have old fuel tank. Thanks, chris kems.

Vehicle was driven to the dealership for sluggishness. I was told that the fuel filter was dirty. Service person replaced the fuel filter and now the truck won't run at all. I am informed that there is fuel contamination. Towed the vehicle to another repair station and I am informed that the lining of the fuel tank is peeling off and the peeling material is now clogging the fuel pump and injection.

The contact owns a 2006 Ford F-450. The contact stated that the fuel tank had to be replaced once under warranty and was failing again. The liner in the tank was eroding, rusting and causing the vehicle to leak diesel fuel. When the failure would occur, the vehicle would stall without warning. The vehicle was not repaired. The failure and current mileage was unknown.

The coating on the interior of Ford diesel fuel tanks corrodes and collects as sediment in the fuel system. The sediment, collects at the botton of the fuel tank and is sucked into the fuel system. The fuel lines become fouled, the fuel pumps become clogged and require replacement. As the coating continues to deteriorate, the only recourse it to change the fuel tank, the sensors, and entire fuel delivery system. We have had 3 Ford vehicles f series experience this problem. In this instance, the truck was returned to the dealer for repair. After spending $1912. 11 in remedies, the final recourse was to have our own mechanics replace the fuel sytem from the tank itselt upto and including the fuel pump. This was an additional expense of approximately $1000. We are reporting this as it seems to be a defect in all the Ford diesel fuel systems. As the fuel systems become clogged, the vehicles lose power without warning and create a safety issue and driving hazard not only to the vehicle operator but other motorists. Upon complaints to the dealer, and to Ford, the dealer referred us to the odi website to final a safety complaint as this has occurred over and over.

Our 2001 F-450 diesel truck has lost power. We had the fuel filter changed and had to have the sending unit cleaned out due to sediment in the bottom of the tank from the take peeling. It is doing it again and I heard of a lot of these diesel trucks having the same problem. This truck only has 90,000 miles on it. I would like reimbursement for this new tank I have to buy which is $500. 00.

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This 2006 Ford e450 super duty with a 6. 0l engine has been trouble right from the start. The first thing to go wrong was the turbo that went out on 09/18/2007 with only 12,000 miles. Next at 15,000 miles the vehicle had starting and running problems and the dealer replaced several parts on top of motor. From this time forward up to 29000 miles the squad was towed several times for more engine repairs and replacement parts. From 29,000 to 53,000 things got worse. The vehicle was towed in again for egr cooler problems, injector problem and radiator failed. Two of these times was when we had a patient and had to call for a back up unit to respond. From 53,000 miles to 62,000 miles we had several more times of no start and no power problem that left the squad only able to go 35 mph. We had more engine parts replaced and computers. The last event was when we had fuel getting into the coolant and found both heads cracked and egr cooler bad again. We had engine repaired with all after market parts costing over $9000. In one year squad was out of service for over 2 months with engine problems. Squad has been out of service for about 12 months since new. All problems have been engine related.

In August of 2007 5 of the 8 ambulances in our municipal fleet began to stall and loose power and not be able to get over 35-40 mph. We found the fuel filters full of silver flakes. After removing the fuel tank we found the lining of the fuel tank flaking off. Even though these units were out of warranty Ford paid 50% to replace the tanks, fuel pumps and sending units. Today 2 of the same units began to experience the same drivable problem. This time we found rust particles in the fuel filter housing and the filter plugged with these rust particles. After removing the fuel tank we found the bottom half of the fuel tank completely covered with rust. These units never get below a half tank of fuel. We have tested our diesel fuel and the samples have come back from the lab normal. We also replaced the filters on the other 3 units that had tanks replaced last August and found the filters plugged with rust also. We have a total about 40 diesel vehicles in our fleet and these 5 vehicles are the only ones experiencing a problem. We cut open filters in other diesel vehicles in our fleet and found no problems. This presents a safety issue with vehicles that potentially could fail while transporting patients. The affected vehicles are 2002-2003 Ford f40 with 7. 3 diesel engines.

See all problems of the 2002 Ford F-450 🔎.

Jan 23, 2007-the truck was taken to the shop due to missing while driving and stalling out. Diagnostics were done, changed the fuel filter and replace cam shaft sensor. Feb. 12, 2007 - same issues missing in engine and stalled out. Taken to auto repair shop . Cleaned all cables and charged batteries. March 2, 2007 - missing in engine and stalls out. Diagnostics time 60 or 65 no power . Replace air filter and unstick turbo July 9, 2007- missing in engine and stalling out. Taken to shop. Diagnostics done. Replaced wire assembly and gasket. Sept. 12, 2007 - still missing replaced fuel filter whining in shop for state inspection. Sept. 24, 2007 - engine missing , while in shop to replace transmission added can of carb cleaner Nov. 21, 2008 - missing, stalled on road, would not start towed to the shop , diagnostics done. Repair shop did research and found out about problems with fuel tanks peeling and slivering inside which would get in injectors and cause missing and stalling of engine. Diagnostics were done. Removed and drained fuel tank, replaced fuel tank added carb cleaner, replaced fuel filter, cleaned fuel pick up filter and lines .

Operating in route to a medical emergency call. Removed foot from accelerator to apply brakes, when returned to throttle; engine remained at idle. Had to dispatch another ambulance to the call. Towed the iunit to a local dealer. Dealer has replaced the throttle sensor. Unknown if retained old part.

Problems with fuel system on 2000 f 450. While driving the vehicle would stall and sputter. The consumer replaced the fuel filter and found it to be restricted. The next day the stalling resurfaced and the vehicle was taken to the dealer. The dealer determined that he inner coating of the fuel tank was coming apart. The dealer suggested the consumer have the fuel tank, sending unit and fuel filter replaced and the injectors cleaned. The consumer contacted the manufacturer but they were not willing to provide any assistance.

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Truck has no power when first starting and the front end shimmies something terrible. Hard to control.

The contact has a fleet of Ford ranger ranging in age from 1999-2007 that all have a problem with tank dilapidation. The liners in all of the fuel tanks are wearing out and costing the vehicles to stall. This has been happening to their fleet for the past 6 years. The contact will send a copy of all the vehicles in question along with the VIN number when the form is returned.

See all problems of the 1999 Ford F-450 🔎.