Which parts fail
Components named in complaints (fuel pump, injectors, fuel tank, hybrid and EV propulsion).
Mileage when the problem started
Owner reports
Selected complaints filed with NHTSA by 2006 Ford F-450 SD owners, lightly cleaned up (personal details are redacted by NHTSA).
"delamination of fuel tank" after only having the vehicle for shortly over four months, the truck would not crank. The truck was parked on a city street in washington, dc where I racked up 2 parking tickets. I had it towed to the dealer and they said that the tank is corroding. I've had issues with the truck since I purchased it. The gas gauge would go out periodically along with the power. I called the dealer and had it checked out, and they said they couldn't find any issues. Now that the 90 day warranty is over, the goes out completely in 120 days. It took the dealer a month to deliver the truck to me after I purchased it.
Tl* the contact owns a 2006 Ford f-450 SD. The contact stated that the inner lining of the fuel tank would flake causing the fuel system to become clogged. As a result, the vehicle would lose power while driving. The failure recurred numerous times. The vehicle was taken to an independent mechanic, where it was diagnosed that the injectors and front fuel tank had to be replaced. The vehicle was repaired. The manufacturer was made aware of the failure. The failure mileage was 156,000.
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. …
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 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. …
While traveling on the 290 hwy around buffalo ny the truck stalled in the middle lane at 60 MPH fortunately the driver was able to coast over to the right shoulder. Upon examination of the problem we found the fuel filters plugged with debris from the deteriorating liner of the fuel tank. When I contacted the dealer it was found that Ford was replacing these under its emissions warranty and that if past that you were on your own , to the tune of $1000.00. We have had Ford diesels since 1974 and over 250,000 miles on them without this problem. What ever Ford did is causing fuel pump, injecter , and gas tank issues on the 6.0 diesel, which is the worst diesel Ford ever made. …
Tl* the contact owns a 2006 Ford f-450. While the vehicle was parked it would not start. The vehicle was taken to the dealer for diagnostic testing. The technician stated the fuel filter had to be replaced. The technician stated the failure was caused by bad fuel. After the vehicle was repaired the failure continued to occur. The contact drained the diesel fuel tank and noticed flakes in the fuel. The contact stated the fuel tank was delaminating causing silver flakes to enter the fuel system and clog the fuel filter. The manufacturer was made aware of the failure but did not provide assistance. The vehicle was not repaired. The approximate failure mileage was 23,000.
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.
Tl* the contact owns a 2006 Ford f-450 SD. The contact stated that the vehicle stalled while driving 55 MPH. The contact was able to restart the vehicle after waiting a few minutes. The failure had since recurred intermittently. The vehicle was taken to an authorized dealer and the contact was informed that the fuel tank was deteriorating. The contact was also informed that the fuel tank needed to be replaced. The vehicle was not repaired. The manufacturer was not made aware of the failure. The failure mileage was 75,000.
Tl contact owns a 2006 Ford 450. He stated that the fuel tank had delaminated, causing shards of the tank to break off into the fuel line. The vehicle was diagnosed by a local dealer who confirmed repairs would need to be made to the fuel tank, at the owner's expense. The contact was concerned with the defective fuel tank affecting the fuel injectors and the motor. Repairs were made to the vehicle by the owner and an independent mechanic. The approximate failure mileage was 135,000 and the current mileage was 135,000.
Fuel System complaints in other F-450 SD years
Frequently asked questions
How common are fuel system problems on the 2006 Ford F-450 SD?
NHTSA has 26 complaints about the fuel & propulsion system of the 2006 Ford F-450 SD, 74% of the model year's 35 complaints. The component named most often is fuel injection system (4 mentions).
Is there a recall for 2006 Ford F-450 SD fuel system problems?
No. NHTSA lists no fuel & propulsion system recall for the 2006 Ford F-450 SD, though it has 1 recall for other components. 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 2006 Ford F-450 SD fuel system problems start?
Half of the complaints with a recorded mileage happened before about 55,000 miles, and 22% before 25,000 miles.
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.