2002 Ford F-550 SD: complaints, problems and recalls

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 failu…

Look up ODI 11659733 at NHTSA ↗

THE TURBO BEARING FAILED IN THE TRUCK AT 21,101 MILES. THE DEALERSHIP REPLACED IT, BUT SINCE THEN I HAVE SPENT WAY TOO MUCH TIME AT THE DEALERSHIP FOR PROBLEMS WITH THIS TRUCK THAT I SHOULD NOT BE HAVING. THERE IS ALSO A TYPEWRITER TICKING NOISE COMING FROM THE ENGINE AFTER OIL CHANGES, FORD IS AWARE OF IT, BUT SAYS IT IS NOT A PROBLEM. THEY STATE THAT SOME MOTORS DO IT, AND SOME DON'T. AGAIN THIS SOUNDS LIKE A SERIOUS QUALITY CONTROL PROBLEM. I NOTICED THE A/C WAS NOT WORKING IN APRIL OF THIS YEAR, THE FIRST TIME IT WAS WARM ENOUGH TO U…

Look up ODI 10594281 at NHTSA ↗

TURBO WILL OVER BOOST TO 31 PSI AND THE ENGINE WILL GO IN TO A FAIL SAFE MODE REDUCING POWER TO 5 MILES AN HOUR WITHOUT WARNING. CAUSING YOU TO HAVE TO PULL TO THE SIDE OF THE ROAD AND TURN OFF THE ENGINE AND RESTART TO CLEAR THE FAIL SAFE MODE. THIS HAS HAPPEN TO ME OVER 12 TIMES. FORD HAS REPLACED THE TURBO TWICE UNDER WARRANTY. THE PROBLEM SEEMS FIXED FOR THE FIRST 30 - 40 THOUSAND MILES. THEN THE SAME PROBLEM RECURS. THE BIGGEST HEADACHE WITH THIS PROBLEM IS IT TAKE WEEKS AND SOME TIMES MONTHS FOR FORD TO DIAGNOSE. DO TO THE FACT THAT WHEN …

Look up ODI 10608208 at NHTSA ↗

TL* THE CONTACT OWNED A 2014 FORD F-550 CRANE VEHICLE. WHILE THE VEHICLE WAS PARKED AND UNOCCUPIED, IT CAUGHT FIRE OVERNIGHT UNDER THE HOOD. THE FIRE DEPARTMENT ARRIVED AND EXTINGUISHED THE FIRE. THE FIRE DEPARTMENT PROVIDED BFI JOB NUMBER: 304652019, WHICH INDICATED THAT THE FIRE ORIGINATED IN THE ENGINE COMPARTMENT. THE VEHICLE WAS DESTROYED. THE MANUFACTURER AND DEALER WERE NOT CONTACTED. THE APPROXIMATE FAILURE MILEAGE WAS 26,242. THE VIN WAS INVALID.

Look up ODI 11252907 at NHTSA ↗

TL* THE CONTACT OWNS A 2015 FORD F-550 SD. WHILE DRIVING APPROXIMATELY 30 MPH IN REVERSE, THE VEHICLE STALLED. THE VEHICLE HAD TO BE PUSHED INTO THE CONTACT'S DRIVEWAY. THERE WERE NO WARNING INDICATORS ILLUMINATED. THE VEHICLE WAS TAKEN TO THE DEALER FOUR TIMES, BUT THE FAILURE COULD NOT BE DUPLICATED. THE FAILURE ALSO OCCURRED WHILE IN DRIVE. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE VEHICLE WAS NOT REPAIRED. THE APPROXIMATE FAILURE MILEAGE WAS 25,000.

Look up ODI 10882923 at NHTSA ↗

I paid 5000.00 to have an upper oil pan gasket replaced , itbwas leaking oil. Now 5 months later and 3000 miles it is leaking again, was told there was a 2 year unlimited milage warranty on the repair. It is now leaking again, after contacting several dealers they will not fix it with out me paying again, im not rich and can not afford to pay again, can really not afford to go back to dealer that did the work originally. We are full time rvers,

Look up ODI 11509021 at NHTSA ↗

Operator was completing an inspection of their secondary fuel filter and found that the newly replaced fuel filter was leaking fuel. The filter had been replaced on 5/31/24.

Look up ODI 11594882 at NHTSA ↗

While driving down the road at approximately 45 mph, under normal conditions, with no warning indicators the low fuel pressure light came on. When the driver stopped the vehicle he lost all power and observed smoke emanating from the underside and hood of the vehicle. Prior to him exiting the vehicle he observed flames shooting out from under the console towards his feet. Upon exiting the vehicle I saw flames under the hood of the vehicle and utilized his supplied fire extinguisher to attempt to put the fire out. This was futile and to our …

Look up ODI 11433239 at NHTSA ↗

The contact owned a 2022 Ford F-550. The contact stated that while driving 20 MPH, the vehicle started smoking and flames came from the left side of the engine. The vehicle inadvertently veered to the right of the road. In addition, the contact noticed smoke and flames were coming from the front passenger’s side and the rear of the vehicle. As a result, of the fire the contact sustained smoke inhalation that required medical attention. The Fire Department extinguished the fire. The contact was unaware of a Police report being filed. The vehicle…

Look up ODI 11617935 at NHTSA ↗

FUEL TANK DEVELOPS A LEAK AND WE HAVE REPLACE FOUR FUEL TANKS SINCE WE HAVE OWNED IT.

Look up ODI 10860895 at NHTSA ↗

I'M REPORTING A SERIOUS PROBLEM THAT MY 2015 FORD F550 WAS JUST DIAGNOSED WIT. THE DEALER IS ASKING $15,800 TO REPAIR IT. THE FUEL SYSTEM, IS CONTAMINATED, IS HAS A LOT OF OXIDATION, THE FIX INCLUDES REPLACING THE ENTIRE FUEL SYSTEM.

Look up ODI 11398024 at NHTSA ↗

TL* THE CONTACT CALLED ON BEHALF OF HER SON WHO OWNS A 2016 FORD F-550. THE CONTACT STATED THAT WHILE DRIVING AT VARIOUS SPEEDS, THE VEHICLE LOSS POWER AND SHUDDERED WHILE THE CHECK ENGINE WARNING LIGHT WAS ILLUMINATED. THE VEHICLE WAS TAKEN TO (FORD & LINCOLN OF SMITHTOWN 440 EAST JERICHO TURNPIKE, ST JAMES, NY 11780, [phone removed]) WHERE IT WAS DETERMINED THAT THE FUEL TANK DELAMINATION WAS DEFECTIVE AND CONFIRMED THAT THE FUEL TANK AND FUEL LINES NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE FAILURE RECURRED INTERMITTENTLY. THE…

Look up ODI 11308950 at NHTSA ↗

WHILE DRIVING THE TRUCK DOWN THE INTERSTATE THE REDUCED ENGINE POWER LIGHT WILL ILLUMINATE AND THE TRUCK WILL BEGIN TO LOSE SPEED AND THE ENGINE WILL DIE, RESULTING IN DIFFICULT STEERING AND BRAKING. THE FORD DEALER HAS INDICATED THIS ISSUE IS BEING CAUSED BY WATER CONTAMINATION IN THE FUEL, ALTHOUGH THE WATER IN FUEL LIGHT HAS NEVER BEEN ON AND THE DEALERSHIP NOT BEEN ABLE TO PROVIDE ANY CONCLUSIVE EVIDENCE OF WATER CONTAMINATION.

Look up ODI 11121002 at NHTSA ↗

The secondary fuel filter. There was a loud boom and the engine compartment caught on fire. Within 10 minutes the whole truck was engulfed in flames. The truck is completely burnt. The insurance company has inspected the vehicle. No warning lights on the console lit up, no prior symptoms or failure. All happened very suddenly.

Look up ODI 11742936 at NHTSA ↗

I have more files and receipts Vehicle Information: •Make: Ford •Model: F-550 Super Duty •Year: 2020 Issue Summary: After a recall service (22E04) for powertrain and transmission software updates, the vehicle experienced a complete power failure within 40 miles, leading to a stall and loss of control, resulting in the vehicle veering into a ditch. Incident Details: •Recall Service Date: ] •Mileage at Service: 63,993 •Incident Mileage: ~64,030 miles •Description: Post-recall, multiple warning lights activated, including powertrain malfunction…

Look up ODI 11643042 at NHTSA ↗

While driving down the road at approximately 45 mph, under normal conditions, with no warning indicators the low fuel pressure light came on. When the driver stopped the vehicle he lost all power and observed smoke emanating from the underside and hood of the vehicle. Prior to him exiting the vehicle he observed flames shooting out from under the console towards his feet. Upon exiting the vehicle I saw flames under the hood of the vehicle and utilized his supplied fire extinguisher to attempt to put the fire out. This was futile and to our …

Look up ODI 11433239 at NHTSA ↗

No recall information found Unrepaired recall information was not found for this VIN 2025 F-550 Please create a Campaign# for the following Safety Recalls* Fuel injector return line replacement Recall incomplete Brake booster pushrod retainer spring Recall incomplete Steering column inspection Recall incomplete Rear camera screen software update Recall incomplete As "steering", "fuel injection", and "braking" are detrimental for proper vehicle operations on highways during travel. This RECALL is a IMMEDIATE Report for any owner operatin…

Look up ODI 11679482 at NHTSA ↗

INCIDENT #1: IT WAS DETERMINED DURING THE ASSEMBLY PROCESS THE MANUFACTURER OF MY EXPEDITION VEHICLE/MOTOR HOME (MH) WAS NOT IN COMPLIANCE WITH NATIONAL HIGHWAY TRAFFIC SAFETY ADMIN., DOT REGULATION UNDER 571.108 COVERING LAMPS, REFLECTIVE DEVICES, AND ASSOCIATED EQUIPMENT. SPECIFICALLY MY MH WAS MISSING TWO AMBER CLEARANCE LAMPS ON THE FRONT, AND TWO RED SIDE MARKER LAMPS ON THE REAR. AFTER MANUFACTURER WAS INFORMED OF THE VIOLATION THEY CORRECTED THE MISTAKE. INCIDENT #2: IT WAS DETERMINED 08/07/2012 DURING THE ASSEMBLY PROCESS THE MANUFA…

Look up ODI 10585720 at NHTSA ↗

COMPLETE TREAD SEPARATION OF DRIVER FRONT TIRE LESS THAN 3 YEARS OLD AND LESS THAN 20,000 MILES ON I-10 NEAR WILCOX, AZ. ENROUTE TO AS MUTUAL AID SEARCH AND RESCUE CALL NORMAL TRAFFIC TRAVELING APPROX. 70 MPH.

Look up ODI 10762741 at NHTSA ↗

Between August 5 and August 9, 2025 we purchased 46 Nebula brand 245/70R 19.5 16PR tires. We experienced a complete tire failure on one of our trucks while operating on the highway. Fortunately, our driver was able to safely steer the truck to the shoulder with minimal damage to the tow truck. Upon closer inspection of the tires we noticed 32 of the tires installed on our fleet began showing a seem all the way around the sidewall. It was the same seem location for all tires. The seem showed visual signs of deterioriation almost as if it wa…

Look up ODI 11737551 at NHTSA ↗

WE JUST HAD TO PAY AN $800.00+ BILL FOR PINCHED WIRES UNDER THE CAB OF THE TRUCK CAUSED BY THE MANUFACTURER NOT PROPERLY ROUTING THE HARNESS, THEREFORE CAUSING A DEAD SHORT IN THE TRUCK AND CAUSING THE REPLACEMENT OF 4 BATTERIES SINCE JUNE 2015. THE SERVICE WRITER SAID THIS WAS DONE BY FORD AND NOT COVERED UNDER WARRANTY! BECAUSE OF THE PINCHED WIRE THE DRIVER HAD TO FIRST STEP ON THE BRAKE PEDAL THEN TURN TO KEY TO START

Look up ODI 10786146 at NHTSA ↗

GOOD DAY ON JUNE 11TH 2018 MY BUS #1611 VIN#(XXXXXX) DURING MY DAILY VEHICLE INSPECTION AT THE LAWRENCE BERKELEY NATIONAL LABORATORY SHUTTLE SERVICES IN 1 CYCLOTRON ROAD BERKELEY CALIFORNIA. *DT AT THE BUS STAGING AREA NEAR BLDG 67 BEHIND BLDG 33 AT APPROXIMATELY 6:30AM A MECHANICAL MALFUNCTION INVOLVING THE PARKING BRAKE IT WOULD NOT HOLD AT 1100 RPM IN PARK THE PARKING BRAKE CABLE CONNECTOR CLIP REULTING IN THE VEHICLE MOVING WHILE ON PARK WHICH RESULTED IN A COLLISION WHERE I WAS CRUSHED BY THE BUS SHUTTLE #1611 WHILE I CONDUCTED THE DVI DA…

Look up ODI 11210435 at NHTSA ↗

Since I took delivery of the vehicle the dash goes completely blank at temperatures below 32 degrees and above 90. Ford has been unable or unwilling to fix the problem for over two years resulting in my driving for extended periods with no dashboard information of any kind.

Look up ODI 11641537 at NHTSA ↗

Several dash warnings came on the dash. cruise control stopped working, hill assist, parking brake, many others. 4 wheel drive quit working!. I looked on line. Several forums stated to look for a loose connection at the rear of the truck, so it must be a rather common problem. I took the truck to the dealer, they refused to make a warranty repair because the cable was moved when the dump bed was installed. They said the cable was "bent" It is a cable, not a piece of glass. I am sure a new harness will be coiled and not shipped on a 6 ft x 1…

Look up ODI 11629957 at NHTSA ↗

Description In some of the affected vehicles, the rear right-hand axle shaft may have been manufactured without properly completing the electromagnetic induction heat treatment process, making the axle shaft susceptible to fracture. Safety Risk A fractured rear axle shaft could result in a loss of motive power while driving, or vehicle rollaway when the vehicle is placed in park and the parking brake is not applied. Either of these scenarios can increase the risk of a crash. Remedy Parts are now available to repair your vehicle. Ford Motor…

Look up ODI 11744338 at NHTSA ↗

While driving down the road at approximately 45 mph, under normal conditions, with no warning indicators the low fuel pressure light came on. When the driver stopped the vehicle he lost all power and observed smoke emanating from the underside and hood of the vehicle. Prior to him exiting the vehicle he observed flames shooting out from under the console towards his feet. Upon exiting the vehicle I saw flames under the hood of the vehicle and utilized his supplied fire extinguisher to attempt to put the fire out. This was futile and to our …

Look up ODI 11433239 at NHTSA ↗