Diesel Fuel System Problems of Ford F-550 - part 1

The contact owns a 2017 Ford F-550. The contact stated while driving at an undisclosed speed, the vehicle stalled, and the engine seized. The check engine warning light was illuminated. The contact attempted to restart the vehicle; however, the vehicle failed to start as intended. Additionally, the contact stated that occasionally, when the vehicle was started, the vehicle would idle roughly. The contact used a diagnostic machine and retrieved a fault code related to the fuel pump module. The vehicle was towed to an independent mechanic, where it was diagnosed with fuel pump module failure. The contact was informed that the fuel pump module needed to be replaced. The vehicle was not repaired. The contact was informed that when the fuel pump module was removed, there were metal shavings inside. The manufacturer was not made aware of the failure. The failure mileage was 123,483.

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The contact owns a 2021 Ford F-550 sd. The contact received notification of NHTSA campaign number: 24v957000 (fuel system, diesel); however, the part to do the recall repair was not yet available. The local dealer was not contacted. The contact stated that the manufacturer had exceeded a reasonable amount of time for the recall repair. The manufacturer was not made aware of the issue. The contact had not experienced a failure. VIN tool confirms parts not available.

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The contact owns a 2021 Ford F-550 sd. The contact stated that while an employee was driving 65 mph and towing a vehicle, the vehicle inadvertently lost motive power. The driver was unable to pull over to the shoulder of the roadway due to a loss of electronic power steering; however, the vehicle was able to restart. After restarting the vehicle, the vehicle returned to normal functionality, but the failure became a regular occurrence. No warning lights were illuminated. The vehicle was taken to the dealer, who was unable to duplicate the failure. The vehicle was not repaired. After investigating the failure, the contact related the failure to NHTSA campaign number: 24v957000 (fuel system, diesel); the VIN was included, but parts were not yet available. The manufacturer was notified of the failure, a case was opened, and the contact was referred to the NHTSA hotline for assistance. The failure mileage was 195,000.

The contact owns a 2020 Ford F-550. The contact stated while driving 60-70 mph, the contact noticed a strong fuel odor. The message "fuel pressure low" was displayed. The contact was driven to the residence. The contact stated that upon inspecting the vehicle, he noticed that approximately 40 gallons of fuel had leaked out of the vehicle. The dealer was notified of the failure and informed the contact that the VIN was not included in a related recall. The contact later became aware that the VIN was included in NHTSA campaign number: 24v957000 (fuel system, diesel); which the contact related to the failure; however, the part to do the recall repair was not yet available. The local dealer was contacted. The vehicle was not diagnosed or repaired. The contact stated that the manufacturer had exceeded a reasonable amount of time for the recall repair. The manufacturer was not made aware of the failure. The failure mileage was 34,704. VIN tool confirms parts not available.

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The contact owns a 2020 Ford F-550. The contact stated while driving approximately 30 mph the vehicle emitted a strong smell of fuel into the cabin. The contact stated that other drivers were pointing at the underside of the vehicle. The contact pulled over and observed fuel leaking from a filter, the underside of the hood and engine compartment on the drivers side were covered in fuel. The contact stated no warning light was illuminated. The contact called a dealer and was advised to change the filter. The contact stated that the vehicle experienced a filter again and had the vehicle towed to the same dealer. The dealer diagnosed that there was rust in the fuel filter which had contaminated the fuel injection system. The vehicle had not been repaired. The contact had contacted a second dealer and was advised that the failure could be related to NHTSA campaign number: 22v013000 (fuel system, diesel). The manufacturer had been informed of the failure. The failure mileage was approximately 15,000.

The truck in question is a 2004 Ford F-550 diesel. Upon depressing gas pedal, truck stalled and no longer worked properly. Truck was towed to local Ford dealer where it was determined that the fuel tank was suffering from rust inside the tank. Based on the work done, rust particles that formed inside the tank were forced through the fuel pump and filter damaging both and causing an issue with the fuel injectors. I called Ford directly to ask about any recalls for this issue and they told me there was no recall currently for this problem. They said the truck was out of warranty and there was nothing they could do about the $3000 bill from their independent dealer. I find it hard to believe that a truck that is not used for plowing and only has 36,000 miles would suffer such a catastrophic failure. The replacement tank was made of some type of plastic not the oem metal tank that was originally used on the truck which made me question the dealer. They said they had seen this happen on tanks of this model quite often so they replaced them with a pvc model. Upon further discussions through blogs and other online resources I was able to find a few owners of the same trucks that had similar problems. These discussions prompted me to file this claim.

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Ford gas tank delamination. Loss of power. Engine missing. This has brought me extreme heartache at the worst time. I am a seasonal worker who relies solely on his truck. Without it I am out of business. It will cost me anywhere from $2,000 to $6,000 to fix it. And I simply don't have it.

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2006 Ford f550. Consumer states problem with turbo chargers and fuel tank liners the consumer stated the turbo was replaced twice and the fuel tank was replaced once. The fuel tank lining broke down and clogged the fuel filters as well as the fuel injectors. Ford informed the consumer, the problem with the fuel tank was due to the additives in the northeast diesel fuel.

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2002 Ford f550 flatbed truck. Consumer states vehicle is unsafe to drive the consumer stated all of the tires were dry rotted, to the point they could not be re-treaded. The rear brakes and wheel seals needed to be replaced. The fuel sending assembly failed, and had to be replaced at a cost of $ 1251. 46. The upper shocks were rusted, the headlight assembly and marker assembly were broken. The consumer stated the vehicle should not have passed dot inspection.

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It started running really sluggish. Wouldn't go up hills, bogging down, etc. Second time that the dealer told me that their is flaking in the fuel tank. Need to replace the tank because Ford tells me that the diesel gas is causing the flaking in the tank. This happen before just after 3 years and at a cost of $3. 000. Now the same thing, only Fords seem to have this problem with the flaking and they will do nothing about it. All over the internet others with 2005-2007 Ford diesels are having the same problem. I live in new york and problems are having all over the us. In 2 1/2 years should not have a problem with the gas tank again. Ford needs to step up and say that their is a problem with this and cover it!.

The contact owns a 2007 Ford f-350. The contact stated that the vehicle would loose power and would not accelerate over 30 mph. The contact took the vehicle to the dealer and was told that the failure occurred by a delimitation of the fuel tank. The manufacturer was contacted and advised that the failure was caused by the type of diesel being used in the vehicle. The contact stated that the same exact failure occurred in an F-550 model that he also owned. The vehicle was repaired. The failure mileage was unknown. Updated 02/15/lj.

Vehicle (2004 diesel f550 truck) was traveling on I-405 during rush hour traffic when the vehicle stalled. Dealer says that the paint/laminate inside the fuel tank is corroding and pieces of debris are being fed into the fuel system causing sudden stalling of vehicle. No off-road diesel has ever been used in the tanks--standard diesel fuel only.

Driving at approx. 35-40 mph truck lost power and stalled . I cranked several times and then it started . I drove about another mile and this repeated twice ,then I was calling a wrecker for a tow. My mechanic discovered the fuel filter & pump was contaminated with a sludge and then looked in the fuel tank and discovered the fuel tank was flaking from the inside , manufacture defect. The cost of parts and repair was $2100. 00 , the tank is a 40 gal tank that holds diesel fuel at $ 4. 25 per gal. My work associate has the same vehicle and now the same thing happened to him,he will also be filling a report with his win. # ,now we are hearing several of the same occurrences. It sounds like Ford needs to do a recall / class action law suit, reimbursement !!! the defect is costing consumer thousands of dollars and additional expenses.

The contact owns a 2003 Ford F-550. The contact stated that while driving 55-60 mph, the vehicle stalled. The contact inspected the vehicle and noticed that the fuel tank inner lining was DE-laminating and being drawn into the fuel system. As a temporary remedy, the contact decided to DE-laminate the fuel tank. The vehicle was not taken to an authorized dealer for diagnostics. The manufacturer was made aware of the failure, but offered no assistance. The vehicle was not repaired. The failure and current mileages were 100,000.

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I have a 2001 Ford f550 super duty flatbed towtruck, the trucks design is a combination from Ford and International, which due to the faulty fuel tank delaminating and causing a financial lose of not only a days work, but also the need of having a two vehicles which while in tow stop traffic when all of a sudden the truck looses power and service engine soon light turns on. Cost over 1000. 00 just in wrecker bills, and not to mention trashed the injectors, pump, and filter system and all the lines. Ford or International will not take any responsability for a bad fuel tank recall. Truck is still down and seems that I will probably have to replace all parts mentioned at my cost.

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The contact owns a 1997 Ford F-550 super duty. The contact stated the vehicle would stall while driving at various speeds. The vehicle was taken to an authorized dealer where the contact was informed the vehicle was stalling due to delamination of the fuel tank. The vehicle was not repaired. The failure mileage was unknown and the current mileage was 144,250.

Vechile Fordf550 diesel stalled on road. Problem diesel fuel tank delamination clogged filter and fuel pump. Fix was replace fuel tank and replace fuel pump. Have never used bio diesel fuel.

The contact owns a Ford f550. While driving approximately 70 mph the vehicle stalled without warning and was towed to an independent mechanic. The mechanic advised that the fuel tank would need to replace but the vehicle was not repaired. The contact stated that the part was not available because there was a high demand for the fuel tank. The approximate failure mileage was 130,000.

The contact owns a 2005 Ford f550. The contact stated the vehicle started loosing power and stalling while driving. The contact took the vehicle to the dealer who stated that the injection control pressure sensor failed. The contact reviewed NHTSA recall campaign number 05v270000 (electrical system: wiring), but was told by the manufacturer that their vehicle was not included. The failure mileage was 148,000 and the current mileage was 153,000. Fuel injection control module was replaced. Updated 08/31/2011.

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The contact owns a 2005 Ford F-550 super duty. While having the vehicle serviced at an authorized dealer for engine failures, the contact was told the fuel tank was rusting from the inside out. The contact was also informed that the rusting of the fuel tank was causing the engine failures. The vehicle was experiencing troubles starting the vehicle as well as a loss of power while driving. The vehicle was not repaired. The failure and current mileages were 77,000.

The contact owns a 2006 Ford F-550. The contact stated that while driving 45 mph, the vehicle began to stall and shake as if it had run out of fuel. The contact pulled over and the vehicle suddenly shut off. The fuel gauge indicated that the vehicle contained a half tank of fuel. The contact restarted the vehicle which shut off again. The vehicle was towed to an authorized dealer but the vehicle had not been inspected. Prior to the failure, the fuel tank had been replaced three times. The failure mileage was 48,318.

The contact owns a 2007 Ford F-550. The contact stated that the vehicle would loose power and would not accelerate over 30 mph. The contact took the vehicle to the dealer and was told that the failure occurred by a delimitation of the fuel tank. The manufacturer was contacted and advised that the failure was caused by the type of diesel being used in the vehicle. The vehicle was repaired. The failure and the current mileage was 35,000. Updated 02/15/lj updated 02/17/12.

The contact owns a 2001 Ford F-550 sd. The contact stated that the vehicle failed to start. The vehicle was taken to the dealer who diagnosed that the failure occurred as a result of paint delaminating inside of the fuel tank. The manufacturer was made aware of the failure who did not offer any assistance. The vehicle was not repaired. The failure and current mileage was unknown.

The contact owns a 2006 Ford f550. The contact stated that while driving at various speeds, the vehicle would drive sluggish and often stall without warning. The contact was able to restart the vehicle by replacing the fuel filters. He then took the vehicle to a dealer for an inspection and was informed that the fuel tank was delaminating. The vehicle was repaired for the fuel tank, sender, pump and filters. The manufacturer was contacted and informed him that they were aware of the failure but offered no assistance. The failure mileage was approximately 27,700.

I own a Ford f 550 sd 2005, this truck has had fuel system problem off and on since I purchased three years ago. But this past week it started missing and stopping on me in traffic, I took it to the Ford dealer and I'm told that the fuel tank lining is coming off and damaged the fuel pump, filters and injectors, repair to cost $5,000. Also that this is due to the epa's low sulfur requirement on diesel fuels. This may be true but Ford know of this way prior to the start date of this new fuel and still is using defective parts that they will not cover under warranty or a recall today. . . . This parts failure include 2 fuel tanks, fuel pump, fuel filters,and injectors all damaged due to a poor tank lining or coating.

The contact owns a 2003 Ford f550. The contact stated that the fuel tank had delaminated and caused the fuel tank to clogged up. The failure also caused the vehicle to lose power and stall while driving uphill. The was responsible for paying $900 to replace the fuel tank since there were no warranties or recalls. The manufacturer confirmed that there were no recalls and offered no assistance. The failure mileage was 75,000.

Sudden power loss traveling at highway speeds resulting in engine shutting down and not being able to be restarted.

Sudden power loss traveling at highway speeds resulting in engine shutting down and not being able to be restarted.

I own a 2007 Ford f550 diesel truck. The truck suddenly lost power and was on the verge of stalling. The truck was driven back at less than 40 mph on the interstate. After taking it to the dealership they discovered that the fuel tank was delaminating. Ford is not coving the tank under warranty stating that it is was caused by the changes in the epa fuel requirements in 2009. This problem has also caused the fuel pump and 2 injectors to fail also. The repairs are over $2,600. After looking online, it appears that this is a major problem with Ford trucks. It makes for a very unsafe situation considering most of these trucks are used for towing, hauling, ambulances, firetrucks, etc.

The contact owns a 2006 Ford F-550 diesel. The contact stated that the fuel tank was eroding and causing the vehicle to sporadically lose power without warning. The vehicle was taken to the dealer and the contact was informed that the fuel tank would need to be replaced. The vehicle was not repaired. The failure mileage was 59,000 and the current mileage was 60,000.

I have 2 Ford f550 trucks (2001,2003). Both trucks with very low mileage (37k, 56k miles). Both diesel engines. Both have only had either shell or chevron fuel put in them. No bio fuels. The interior of both my trucks fuel tanks are delaminating and causing the various fuel filters to clog with a metallic debris and rust. Ford motor company is blaming the delaminating on the fuel used in the trucks. My dealer (westlie Ford, camas, washington) where I purchased these trucks cannot warranty the replacement tanks needed to remedy this problem. This is an epidemic for Ford motor company! word has it Ford has fixed the problem with the new coating on the new tanks but, I can find no announcement from Ford motor company saying so. Average cost to replace this tank runs between $1,500 - $2,500 dollars. How many people must die when their fuel systems get clogged by the delaminating particles of the fuel tank and stop dead on a freeway or foggy night? Ford motor company should fix this problem!.

The contact owns a 2001 Ford F-550 sd. The contact stated that the vehicle stalled without warning. The vehicle was taken to the dealer who diagnosed that the paint inside of the fuel tank was chipping and contaminating the fuel system. The manufacturer was made aware of the failure who did not offer any assistance. The vehicle was not repaired. The failure and current mileage was unknown.

While driving on the interstate my vehicle lost power very quick. Rust in the fuel tank clogging the filter stopped fuel to the engine was the problem after stopping several times. Having no shoulder on this area of the interstate to exit the flow of traffic, an eighteen wheeler nearly killed us all. We had the tank removed and cleaned.

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The contact owns a 2005 Ford F-550. The contact stated while driving at 65 mph, the vehicle began to independently decrease in speed. The contact attempted to accelerate but the vehicle would not respond. The contact then switched to the rear fuel tank yet the failure persisted. He attempted to switch back to the front fuel tank however the vehicle stalled. The contact continued to switch from the rear to the front fuel tank and each time he would switch to the front fuel tank, the vehicle would stall. The contact stated he attempted to change the fuel filter however it was severely clogged with what appeared to be paint. The vehicle was taken to the dealer where the fuel tank, four fuel injectors and the fuel lines that were connected to the engine back to the tank. The dealer advised the failure was caused by DE-lamination of the fuel tank. There were no recalls for the failure. The failure mileage was approximately 90,000 and the current mileage was approximately 95,400. The vehicle was taken to the dealer where they inspected the front fuel tank and discovered the coating and lining was peeling off inside the tank, which caused fuel shortage to the engine. The dealer replaced the front fuel tank, fuel filters, fuel regulator, fuel injectors and flushed all the fuel lines. Updated evoq 09/08/jb updated 10/04/10. The dealer inspected the tank and found the lining of the front tank peeling off and getting into the fuel tank system. They replaced the front tank and flushed all of the fuel lines. Also, the rear tank revealed paint flaking and replacement of that tank was required. Updated 10/12/10.

Ford f550 truck has fuel tank problem. Fuel lines, pump, filter & injectors getting clogged due to flaking on the inside of the tank. Issue blamed on poor diesel fuel, but have researched several other cases all reporting the exact same issues. Ford is taking no responsibility. Truck will lose power and stall while driving.