Most common 2002 Ford F-550 SD problems
Share of the 22 complaints; one complaint can involve more than one system. "~" is the median mileage when the problem started.
Ford F-550 SD complaints by model year
Best F-550 SD years: 2018, 2013, 2017. Years to avoid: 2000, 1999, 2004, 2006, 2005. Compare all years →
2002 Ford F-550 SD recalls (4)
Exterior lighting › Brake lights
Ford is recalling certain model year 2011 ranger trucks built from January 25, 2011, through April 25, 2011 at the twin cities assembly plant, and service parts distributed to dealers for certain 2004 through 2011 model year ranger trucks, 2002 through 2005 model year excursion vehicles, and 2002 through 2007 model year f-250,…
Remedy: Dealers will replace the switches free of charge. The safety recall began on August 15, 2011. Owners May contact Ford motor company customer relationship center at 1-866-436-7332.
Vehicle speed control
Ford is recalling model years 1995-2003 windstar, 2000-2003 excursion diesel, 1993-1997 and 1999-2003 f-250 sd through f-550 sd diesel, 1992-2003 e-150 through e-550, 1995-2002 explorer, 1997 and 2002 Mercury mountaineer, 1995-1997 and 2001-2003 ranger, and 1994 f53 vehicles equipped with the texas instruments speed control…
Remedy: Ford will notify owners that dealers will install a fused wiring harness in line with the scds. On 1999-2003 windstar vehicles with a leaking scds, dealers will also inspect the ABS control module connector and repair…
Engine and engine cooling › Engine › Diesel
On certain heavy duty trucks equipped with 7.3l diesel engines, the camshaft position sensor located on the engine of the vehicle May function intermittently, possibly resulting in an engine stall.
Remedy: Dealers will inspect the sensor and replace it with an improved camshaft position sensor free of charge. The recall began on December 29, 2007. Owners May contact Ford at 1-866-436-7332.
Vehicle speed control
On certain trucks equipped with speed control, gasoline or natural gas engines, the speed control deactivation switch May overheat.
Remedy: Dealers will install a fused wiring harness into the speed control system free of charge. The recall began on August 7, 2006. Owners May contact Ford at 1-866-436-7332. (note: also see recalls 05V017 and 05V388)
NHTSA defect investigations
Federal safety investigators have looked into 3 possible defects involving the 2002 Ford F-550 SD:
Engine stalling
In a December 3, 2007 letter, Ford advised NHTSA that it will conduct a safety recall to replace the cam position sensor (cps) in approximately 1.2 million subject vehicles to address reports of engine stalling.a new design cps with improved performance and durability will be installed as a remedy.owner notifications will begin in December 2007.
Engine compartment fires
Ea05-005 is closed with Ford?s actions in recalls 05v-017, 05v-388, and 06v-286, recalling approximately 6.7 million vehicles equipped with texas instruments speed control deactivation switches (scds).the brake systems in these recalled vehicles generate a vacuum that can potentially cause the scds to fail and, in certain switch installation orientations, catch fire.Ford is also including the entire population of…
Accelerator pedal sensor (etc)
Failure counts from odi?s analysis are stated above; see the additional problem experience discussion in the summary report.Ford data contained duplicative reports for 4 odi complaints and 1 crash.three crashes were allegedly due to intermittent operation of the electronic throttle control (etc) pedal, one crash occurred when an etc disabled vehicle was struck by another motorist, one report contained no detail.the…
What 2002 Ford F-550 SD owners say
Fuel & propulsion system
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.
2002 Ford f550 super duty diesel with 44,000 miles has a rusting fuel tank causing the fuel filter, pump, and injectors to get clogged. Only diesel fuel has been used. When under any strain or load the engine with begin to lose power and sputter. Once the engine runs for a few minutes at idle it seems to clear up again until load is put on the truck. The truck is only possible to move around at a crawl. The fuel filter was replaced and it was completely covered with rust. There where fines and larger particles which were obviously rust. I have been searching for replacement tanks without success.
Engine & cooling
Tl* the contact owns a 2002 Ford f-550 SD. The contact stated that while driving approximately 60 MPH, thick white smoke was seen from underneath the vehicle. After inspecting the vehicle, the contact discovered flames coming from under the hood and front of the vehicle. The vehicle was destroyed. The fire department extinguished the flames. During the incident the contact sustained injuries to the back and shoulder while attempting to extinguish the fire. The manufacturer was not notified of the defect. The VIN was not available. The failure mileage was 212,000.
The vehicles engine had a hole in it. The vehicle was taken to the dealer who indicated that the oil looked bad. The consumer indicated that coolant had been leaking into the crankcase. The mechanic stated that he would void the remainder of the consumer's warranty. He then called the manufacture and they stated that they would support their dealer.
Wheels & tires
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.
2002 Ford f550 has problems with oil leaks, steering, electrical shorts, brake and wheels fell off. The vehicle also consumed excessive amounts of oil.
Frequently asked questions
Is the 2002 Ford F-550 SD a good car?
Based on 22 owner complaints filed with NHTSA, the 2002 F-550 SD rates use caution: 2.4× as many complaints as a typical year of the F-550 SD at the same age. It is one of the F-550 SD years we suggest avoiding. Complaint counts don't account for sales volume or individual maintenance, so have any used car inspected before buying.
What is the most common problem with the 2002 Ford F-550 SD?
The fuel & propulsion system — 10 complaints, 45% of all complaints for this model year, most often about storage. Next are the engine & cooling (5) and wheels & tires (3).
How many recalls does the 2002 Ford F-550 SD have?
There are 4 recalls for the 2002 Ford F-550 SD, the most recent from July 13, 2011 (brake lights). Recall repairs are free at any authorized dealer — check whether yours has been done with the VIN recall check.
What are the best and worst years of the Ford F-550 SD?
The best years by complaints, compared at the same age, are 2018, 2013 and 2017. Years to avoid or approach with caution: 2000, 1999, 2004, 2006 and 2005. See the full Ford F-550 SD years comparison.
At what mileage do 2002 Ford F-550 SD problems happen?
The median mileage reported in complaints is about 59,000 miles; 40% of problems with a recorded mileage started before 50,000 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.