Diesel Fuel System Problems of Ford F-550 - part 2

We own a fleet of Ford diesel engine trucks which continue to experience fuel delivery problems. The problem is engine cut-off and surging and hard starting. Ford says not their problem and charges us. I don't think we have the only ones. Toyota is not the only company not dealing with this problem. Think only the government will make them fix it.

See all problems of the 2004 Ford F-550 🔎.

We purchased a Ford f550 6. 0l diesel truck new in 2004 and have been the only ones to drive it and have done proper care and maintenance of this vehicle. It has less than 40,000 miles on it. The vehicle would not start for no reason on April 29, 2010 necessitating it being towed to the local Ford dealership. They diagnosed a bad ficm (fuel injection control module) and replaced it. I have found there was a recall on this vehicle for this problem, campaign number 05v270000 on 6/10/05. Due to the low miles and proper care of this vehicle I am wondering if this problem is related to that recall. We use this in our work and had the ficm gone out while we were driving it with a load of chips it could have potentially been extremely hazardous.

My 2006 F-550 diesel truck has had problems with stalling,rough idle. Dealer tells me that my fuel tank is rotting from the inside. Ford service tells me its from contamiated fuel. This truck is still under extended warranty. They want me to pay2500 to fix it. I own a 1983 diesel Ford and a 2001 diesel Ford truck. I use the same fueling station for all 3 trucks. I have no problems with fuel issues in the 83 or 01 trucks. This is the 2nd time in for repair for fuel problems on my 06. Maybe Fords bad design junk steel for fuel tanks or poor vent tube design may be at fault. After Ford giving me lie after lie about this issue I don`t know what to do. This truck has 29,000 miles on it.

See all problems of the 2006 Ford F-550 🔎.

I am contacting you to file a complaint with Ford motor company regarding the fuel tanks on 450 and f550 trucks that we own. I have more than one vehicle that is and has been affected by this. The fuel tanks are degrading from the inside, causing fuel system damage and creating a hazard due to the fact that as large as these vehicles are they can be disabled in traffic. I do understand that any vehicle could be rendered disabled. However this would be for a known cause. Ford dealerships are well aware of the problem as are many tank repair facilities in new england. I understand through research these tanks have been defective since 1998. Ford is trying to say it is due to bio-diesel. If you looked inside the tank, you would see it is like paint flaking off of a wall. This situation has been doing damage to pumps and injectors causing breakdowns. Ford is well aware of this and has done nothing to resolve it to the best of my knowledge.

See all problems of the 2005 Ford F-550 🔎.

I am having problems with my Ford tank falling apart inside - have done my research and read about 100+ posts from other people with the same problem, no caused by the fuel, but by the tanks cheap design. Its going to cost thousands of dollars to fix - this is not fair - Ford knows of this problem, and they should fix it!!!!!.

See all problems of the 2001 Ford F-550 🔎.

2004 and 2006 Ford f550 fuel tank delamination. Fuel system is compromised when tanks delaminate causing the filters to be blocked, robbing the engine of the fuel it needs to run. Have replaced tanks - Ford refuses to pay. This is a safety issue and should be recalled immediately. Upon changing the filters, they were found with rust particles which enabled the engine from running. The fuel sending unit was also rusting from the inside out. Updated 04/28/10.

I purchased a 2004 f550 Ford truck in 2005 with 13,000 orginial miles. I statrted having problems at 40,000 miles when the warranty ran out. I have two major problems: (1) the liner in the fuel tank separated from the tank and went through the fuel system. I had to replace the tank, injectors, and injector pump. (2) the head gaskets blew and the truck has no power. I plan on repairing the gaskets this week. When driving at any speed, the truck suddenly stops. I have contacted my dealer and went through their assistance program. They did not help with the repairs. I have contacted Ford's customer complaint division and experienced the same results. I spoke with several Ford mechanics and the above two items are ongoing major problems. I am looking for immediate assistance with repairing the 6. 0 diesel engine. The vehicle is unsafe to drive and a hazard to other drivers on the road. This is a severe highway safety issue. Please contact me as soon as possible to resolve these problems. Thanks. Pat christoff 301-748-5466.

Vehicle stopped working. The culprit was the Ford fuel tank that had delaminated. The tank had to be replaced. The cost: $1600. 00. Additionally, there was a loss of revenue as this vehicle is used for production purposes. Ford denied responsibility for any defects of their fuel tanks. With no other choice, we had to pay for the repairs out of pocket. This is a safety issue, as these vehicles are used for commercial usage daily. This is also a financial burden that has been forced onto us unfairly. They need to take responsibility and recall these fuel tanks.

See all problems of the 2003 Ford F-550 🔎.

2006 Ford f550 with 33,000 miles diesel fuel tank delamination. Clogged up fuel system and was not covered under warranty by Ford. $2200 to fix so far as long as the injectors are ok. If not $5000 to fix. And who is to say I wont have this problem again.

Vehicle had loss of power and ran rough. Finally vehicle stopped working. The culprit was the Ford fuel tank that had delaminated. The tank had to be replaced. The cost: $1600. 00. Additionally, there was a loss of revenue as this vehicle is used for production purposes. Ford denied responsibility for any defects of their fuel tanks. With no other choice, we had to pay for the repairs out of pocket. This is a safety issue, as these vehicles are used for commercial usage daily. This is also a financial burden that has been forced onto us unfairly. They need to take responsibility and recall these fuel tanks.

See all problems of the 2002 Ford F-550 🔎.

Engine failed and vehicle stopped working. The culprit was the Ford fuel tank that had delaminated. The tank had to be replaced. The cost: $2223. 41. Additionally, there was a loss of revenue as this vehicle is used for production purposes. Ford denied responsibility for any defects of their fuel tanks. With no other choice, we had to pay for the repairs out of pocket. This is a safety issue, as these vehicles are used for commercial usage daily. This is also a financial burden that has been forced onto us unfairly. They need to take responsibility and recall these fuel tanks.

Our Ford lcf has had a continual stalling problem when we drive out on the highway. Our vehicle is now three years old and everytime we go out of town we have stalling problems with the vehicle. The dealer has replaced injectors and other fuel components but nothing directly related to this problem. The last time the dealer changed the oil saying that was the problem. We had about 3000 miles since the last change.

We have a 2006 Ford 550 diesel with 37,000 miles on it. The fuel tank has corroded and affected the fuel pump and fuel injectors. The dealership invalidated my warranty, said we used bad diesel in the tank. We have other vehicles on the same fuel, with no issues. This is my 15th Ford truck. This is my first truck with this kind of issue. Ford said it would cost me $6,500 to repair. The internet is full of trucks with this same issue. A recall.

Discovered my f550 superduty 6. 0 diesel at 94000 miles with 8 months over its warranty had an exhaust leak coming from both sides of its 6. 0 liter diesel engine exhaust manifolds. These fumes were coming into the passenger compartment at idle. At the same mileage, dealer discovered that engine had oil in coolant and that its entire passenger side injectors were malfunctioning along with the fuel pump and its regulator. Excessive fuel in engine, running very lean could cause engine to cease while driving. Dealer advised that oil in coolant is common for these engines and that this causes a other malfunctions such as head gaskets to go. The exhaust manifolds were repaired at approx. $1172. The other engine work was not repaired as of yet due to it costing approx. $4240. The head gasket work would cost another $6000. Ford said it would not cover the repairs because I was the second owner. Bbb complaint filed and in search for class action law suit to cover repairs only.

The diesel fuel tank had corroding and showing rust on the inside of the tank. Seems like a delamination problem. The truck is still within the warranty period but Ford refuses to cover the problem because they do not consider it a manufacturer's defect. They blame the diesel fuel companies. Ford said the tanks were manufactured for the diesel fuel specifications at that time, not now. The delaminated material is the lining of the fuel tank. This also cost two fuel injectors to fail. The truck stalled and would not run or start. Had to call the Ford dealer to tow my truck to their site. Had to replace the fuel tank and two injectors at a cost of $3,000. This problem is not happening to a GMC, chevy. Or Dodge diesel truck.

See all problems of the 2007 Ford F-550 🔎.

The contact owns a 2006 Ford f550. The contact stated that when driving uphill the vehicle dowhnshifts and shakes. The vehicle was taken to the dealer, in which a technician concluded that the fuel pump and injector needed to be replaced at an expense of $1800. 00. No repairs have been made. The manufacturer was notified, but no assistance was provided. The failure mileage was 30,444. The current mileage was 30,560.

04 Ford f550 sd dump truck was bought new on 12/04. . In April 2005 transmission leaked fluid while in park and truck was towed to dealer. The dealer claimed cause of problem was due to loose bolts on trans case. Transmission continued to slip but dealer could not find problem. February 2006, approximately 16,000 miles on truck, transmission completely fails. Truck towed to dealership and new transmission installed. On June 2008 (approximately 56,000 miles) while driving on major highway, truck begins to lose power and black smoke pours out of muffler. The truck was driven to local dealership and diagnosed with a blown turbo. Ford did not cover cost of repair. I paid $4,500. 00 out of pocket to replace turbo. August 2009 (approximately 68,000 miles) again while driving on major highway, truck loses power and stalls. Truck was towed to Ford dealership and diagnosed with clogged injectors due to deteriorating gas tank. Dealer advised me that all 8 injectors would have to be replaced and new fuel pump installed. The total cost of repairs would be $4,300. 00 and it would not be covered by Ford. I was incensed to say the least. . . After getting a second opinion, I paid an additional $475. 00 and had the truck towed to another Ford dealership which made the repairs without any cost to me. The fuel tank was not replaced even though it was the cause of the problem. I replaced the tank and paid $750. 00 out of pocket. . . December 27, 2010 (96,000 miles) without warning, transmission begins to slip. I contacted the Ford dealership that made the last repairs. I was told the transmission was out of warranty and would not be covered by Ford. It would cost $4,200. 00 to replace. I took truck to a local transmission repair shop and paid $3,000. 00 to rebuild transmission. Its obvious that Ford does not back up their product. I will never buy another Ford again!!!!.

Fuel tank delamination. Clogs fuel system, and trashes injectors and pumps. New tank, injectors, pump. Clean fuel system. Ford says biofuel, never use biofuel.

2005 F-550 having fuel tank liner failure problems.

We own a 2005 Ford F-550 diesel truck. We are having problems with the fuel tank delaminating and causing the fuel flow to stop to the engine. This is a common problem on alot of Ford diesel trucks, Ford does not want to take responsibility for the tank delamination, causing the truck to stop running. We are having to pay for the repair, even though the truck is still under warranty. They say that we are running bio-diesel through the truck and this is what is causing the liner separation.

1. The truck was losing power and could barley make it up any hill. 2. The fuel tank is delaminating, aluminum flakes are clogging the filters and injectors. 3. Injectors were replaced along with the fuel filters.

The coating on the inside of the fuel tank delaminated sending debris through the fuel lines pump and filters. Due to the debris the vehicle's fuel system the vehicle lost power and eventually stalled. The vehicle involved is a 2006 Ford F-550 sd with a 6. 0 liter powerstroke diesel ambulance.

2000 Ford F-550 fuel tank liner failures. Tank liner coming apart causing the fuel tank needing to be relined, and replacing the fuel pump and fuel filter.

See all problems of the 2000 Ford F-550 🔎.

2005 Ford F-550 fuel tank liner failures. Tank liner coming apart causing the fuel tank needing to be relined, and replacing the fuel pump and fuel filter.

The contact owns a 2007 Ford f550. While driving at speeds of 30 mph, the vehicle began to decrease in speed without warrant and then stalled. The contact was unable to restart the vehicle and had it towed to the dealer. The dealer advised the failure was due to the usage of bad diesel fuel. The vehicle was repaired by the dealer. The contact stated the failure recurs intermittently. The failure mileage was 15,000 and the current mileage was 22,000. The consumer stated the truck stalled on the highway. The truck was towed to the dealer where they stated water was in the fuel tank. They drained it an put in a new pump assembly. Updated 09/30/10.

Truck started losing power on the highway. Would hardly climb an incline. We exited the highway, truck was running worse, and finally stalled out. It would only restart and run rough for a minute or two after letting it sit for a while, and then stall again. I had to get the truck towed back to my shop. We changed the fuel filters, and the one in the frame rail had a silver flaky substance inside the filter. I had to put the truck on a trailer, and bring it to the dealership. I was told I needed a new fuel tank, a new fuel pump, new fuel filters, and the fuel system needs to be flushed. They said they are aware of the problem, and they called a warranty rep. They refused to help me. I called Ford roadside assistance, and they refused to help me. I now have to spend thousands to fix this. The parts salesman at the dealership say that this happens all the time, and sometimes the replacement tanks do the same thing. I know of about a dozen or a dozen and a half Ford trucks that have had this exact problem. There is actually a dealership in CT that stocks a bunch of these tanks because this happens so much.

The contact owns a 2006 Ford f550 superduty diesel truck. The contact stated that his vehicle was running roughly and was difficult to start. The dealer suggested that the primary fuel filter was clogged with rust because the fuel tank was laminated with rust inside. The dealer wants to remove the tank from the vehicle so that it can be realigned and installed again. The contact would have to pay $650 for this service. The vehicle is still under warranty, but the dealer does not want to repair the vehicle under the warranty. The manufacturer is ignoring the contact. The failure mileage was 22,000.

I own a 2006 Ford F-550 diesel pick-up truck. Bought the truck when it was new. At 4,000 miles several of the injectors went bad. Over the past few years I have had to replace the fuel filter 7 different times in order to get the truck to run right. Or what I thought was right. It never has gotten very good fuel mileage, and I now know why. A few weeks ago the truck started running horrible. I took the fuel filter off, as well as captured the fuel into a clean glass jar. It was full of what appears to be silver flakes as well as rust from the inside of the fuel tank. Needless to say it has also clogged the injectors. The truck is starving for fuel. Ford said the tank needed to be replaced, however, at our expense. Through further research I now find out this problem is all over the us. (I have also contacted the ftc about this) the tanks are delaminating. In other words, they are rotting. Every article I have read describes the same exact issues. Ford claimed that nothing was wrong with the tank. I took it to a local radiator shop, and they said the whole top of the tank is completely rusted out. The laminate that was put on at the factory is falling off into the tank, then running through the entire fuel system. This continues to be at the expense of the consumer, on a product that clearly is defective!!! what is it going to take, my wife breaking down with this truck, and getting killed while she waits for help??? this is a national problem. Their are thousands of people with fleets of Ford trucks that are all having the same issues. These tanks need to be recalled. It is very wrong that we the consumer should have to continue paying for repairs on a defective product. Most of these vehicles cost more than your average home. This is not a small problem. It has happened to fleets of ambulances. I sure hope I don't have a family member that needs to be transported to the hospital by one of these defective vehicles, and they break down on the way to the hospital.

2004 Ford model 5500 f series dump truck with 43,000 miles diesel fuel tank delamination & damage caused to motor.

Loss of power so we pulled the fuel filters. The fuel filters were packed with a gray,flaky substance looking like paint chips. When we took the truck to the dealer they said the fuel tank was "delaminating".

We own a 2006 F-550 Ford dump truck. With 22,000. 00 miles on it. It was in the shop last year because of no turbo power. Dealer couldn't figure the problem out. We change the oil every 2,000 miles plus change fuel filters, etc. At the same time. Last week no power. Took to another dealership and upon inspection tech found fuel tank, sending unit. Filters lines failed/clogged. Had to replace fuel tank and fuel filters. Flushed out sending unit and fuel lines. It cost me $2,105. 91 out of my pocket. I called Ford customer relations dept. And was told this is not Ford's problem that it is the fuel that did the damage. This problem should be a recall problem with this truck. It is still under warranty and they won't pay !.

My 2002 for f 550 was driving and lost power in traffic eventually losing power and stalling in traffic on a very busy road. The truck was towed to a local dealer and I was informed that the inside of the gas tank was delaminating which caused a failure in the gas tank, failure in the sending unit,the failure in the fuel pump,and the failure of the filters. Ford has also advised me of possible destroyed fuel injectors. Ford takes no responsibility for the defect in the fuel tank.

2004 Ford f550 44k miles truck stopped running dealer told me that the fuel tank is rusting from the in side out. Dealer told me that they changed out about 50 tanks so far and Ford would not cover it . Ford is say its a fuel problem. This fuel problem is not affecting chevy truck fuel tanks. The mechanic let me look in side old tank you can see debris floating in tank. Fords failure to fix this cost me $2370. And the worst part they put the same tank in new one but the same. Dealer said I should look for a after market tank online that what other customer are doing. I read on line 75,000 tank failure so far. Ford need to admit their is a problem.

Truck was running rough and was loosing power. They replaced the gas tank injectors and a pump. The dealer stated that the diesel was eating away at the liner of the tank. My truck is only 5 years old. It has cost hundreds of dollars to fix. The truck is in the shop right now for same problems no power.

I have two 2006 f550 that the fuel tanks have delaminated and for will not pay for them . They both had problems in the passed year and we were just told 2 months ago that it was the tanks delaminating. So we had them put two new tanks in . With the new takes it is only time till I have the same problem .