Which parts fail
Components named in complaints (engine, cooling system, oil leaks, timing chain, exhaust).
Mileage when the problem started
Owner reports
Selected complaints filed with NHTSA by 2003 Ford E550 owners, lightly cleaned up (personal details are redacted by NHTSA).
Since May 2nd, 2003 have had farm truck, f550 6.0 liter diesel 4x4 cab & chassis, into dealer six (6) times for a problem with 6.0 liter diesel motor, have asked twice to fix leaking transmission/transfer case and have complained once about severe front end shake (to which no responce was made and after discovering Ford had installed drive position only tires on front axle, replacement was made with proper steering tires). Truck used for long distance transportation of hay, straw, cattle and machinery. Engine since having 2,000 miles has rough idle, excessive smoking, engine miss (skip) under load or idling, poor fuel economy. On August 1st, 2003 the engine lost power, a short while later stalled, while under load and on a major interstate. This caused significant loss of braking capacity on the pulling unit, with a heavier load or on a grade this could have been serious. …
2003 Ford super duty f350 6.0 liter diesel: the first time I tried to pull my 5th wheel with this truck, it would buck furiously and I could only stop the bucking by depressing the accelerator pedal to the floor of immediately let up off the pedal. During this trip with the 5ht wheel in tow, at 815 miles the engine quit at the most inopportune times. I was climbing a 5% grade and traveling in the truck slow lane on interstate 68. I managed to get the rig to the shoulder but still in a very dangerous situation. It took 3 hours to get the rig moved to a safe location. The fuel injection control module (ficm)had failed. Ford has designed this ficm no less than 4 times. The mechanic told me that I had a fuel injector misfiring since day one of this truck being in service. The truck was out of service for 5 days while repairs were made. …
2003 Ford f250 6.0 diesel, the hose between the tubro and the intercooler is blowing off. This results in a loss of power and if the clamp cuts the belt it will result in the failure in the power steering and power braking systems. Ford has a upgrade hose kit (5c3z*6c646) for $100.00 if the truck has more than 36000 miles.mine has 41000. The hose failed on interstate 26 as I was pulling my 29' travel trailer up a 6% grade at the saluda mountains, after the hose failure I was only able to proceed at 20mph, not good on a interstate with trucks going by at 60-70mph. Ford motor co. Customer assistance dept. Stated this problem was a engineering problem not a warranty issue.both the dealers, the dealer that sold me the truck and the one which repaired it said it was a common problem with the 6.0 engine) , therefore there is no recall, only a upgrade kit after failure. …
VIN number [redacted] this is an 03 Ford f350 4x4 crewcab , automatic with the 6.0 power stroke diesel. In June or there abouts this vehicle received the recall where they replaced the icp and flashed the computer. The truck now exhibits extremely low power below 1800 RPM making it dangerous to pull out into traffic. There is approximately a 4 to 5 second delay from stepping on the gas to where there is adequate power to pull into traffic. I have had several near misses to the situation. When to power does come on it is suddenly and can cause the tires to lose traction. Prior to the re-flash the truck was fine with a smooth power increase form the point of stepping on the gas. I was told Ford detuned these trucks with the re-flash( without my knowledge of the reduction in power). …
I bought a 2003 Ford f250 super duty with a 6.0 l diesel 5/2003. Since the purchase, there is a noticable lack of power below 1800 rpms. I have taken the vehicle into the Ford dealership 6 times with the same complaint. The dealership has continually attempted to repair the problem, but on the most recent visit, I was advised all of the 6 liter motors are experiencing this problem. The dealership advised there is nothing they can do. They advised Ford has not provided a solution to the problem. A close friend recently purchased a 2004 6 liter motor and is experiencing the same problem. This is a huge safety issue, especially in heavy traffic. The vehicle hesitates at the start of acceleration and has placed me in several comprimising positions since I have owned the vehicle. The vehicle is especially bad when I start from a stop. …
Turbo charger hose keeps blowing off pull a horse trailer w/f350 diesel 2003 Ford & on nov. 19,2003 I got my right hand burned trying to put turbo hose back on, to get truck & trailer off road Ford dealer would not come out. Ilgot to a deler in gerstown ,maryland & got new hose & clamps after being on the road for over 12 hours to go 175 miles. This is the 5th time it has happened to me the truck has only 23000 miles; truck loses power & when on a hill will not move happened 5 times; Ford installed new turbo charger & it lasted approx.3000 miles & hose blew off again; I am afraid to use this truck to pull my horse trailer & I am invoking the lemon law.
Failure of the cam positioning sensor on a 2001 f250 7.3 diesel pickup with 35,00 miles. The truck started dying at stops. And slow speed. Had to put the truck in neutral and restart 8 times. Left the truck with Ford dealer for 2 days(they drove it home and put 150 miles on truck) nothing. Paid $140 for 2 hours labor. Next day paid $256 to get a new cps installed and one week later no problem. The Ford diesel forum on the internet has hundred of truck owners in the same boat. We all pay $100 or more and carry a spare cps. NHTSA should look into this and recall this item or put Ford on notice because one of these days someone is going to get killed.
I was driving my Ford f150 (51K miles) through town when all of a sudden boom. My children were scared to death and I was more than a bit concerned. When I was able to pull over and analyze the situation I found the coil on plug blown off of the #3 plug on the passenger side. Upon further inspection I found the actual spark plug had blown out of the cylinder head. The truck was towed to the dealership from which it was bought and repair costs were in excess of $3100. This is a design flaw and Ford should fix the problem. Why else do you change designs in the next model year vehicle?
The cold air tube to the turbo blew loose on a uphill pull. I experienced a severe loss of power and lots of black smoke. I am pulling a 5th wheel trailer and had this been on a mountain pass I feel I could have lost control, thus resulting in a deadly accident. Country Ford at las vegas re-attached the hose b ut gave no guarantee that it would not happen again. I believe Ford should re-engineer the tube with a more severe flange that could be better secured.
No warning/symptom camshaft position sensor failed -10* outside with icy roads 7:00 pm moderate traffic on freeway engine shut down this is a 1ton pickup going 55 MPH with very little steering control with lack of power steering. My understanding this is a common occurrence with the Ford 7.3 diesel poor design this is also a dealer only part that cost $175.00 I was just glad I was able to get the vehicle on the side of the road and avoid an accident.
Engine complaints in other E550 years
Frequently asked questions
How common are engine problems on the 2003 Ford E550?
NHTSA has 20 complaints about the engine & cooling of the 2003 Ford E550, 31% of the model year's 65 complaints. The component named most often is engine › diesel (9 mentions).
Is there a recall for 2003 Ford E550 engine problems?
No. NHTSA lists no engine & cooling recall for the 2003 Ford E550. If the problem is widespread, a repair may still be covered by an extended warranty or a manufacturer service bulletin — ask a dealer.
At what mileage do 2003 Ford E550 engine problems start?
Half of the complaints with a recorded mileage happened before about 35,000 miles, and 50% before 25,000 miles.
Is it dangerous?
Owners linked 0 crashes, 0 fires and 1 injury to engine & cooling problems on this model year. If you notice symptoms, have the car checked before driving further.
Source: U.S. National Highway Traffic Safety Administration (NHTSA) — owner complaints through October 20, 2026, recalls and defect investigations; fuel economy from the EPA. Complaints are unverified reports and are not proof of a defect. How we rate model years.