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 2004 Ford F-550 SD owners, lightly cleaned up (personal details are redacted by NHTSA).
Dt: the vehicle surged and accelerated on its own. This happened this has happened a t least 50 times or more. While driving 43 MPH vehicle shut down. Had to slam on the emergency brake and pull it to the curb. Also, while driving at 38 MPH or 1100 rpms there was vibration coming from the engine. It felt like it was coming right from consumer's feet. It felt like transmission disengaged. Then, after 10-15 seconds it felt like it kicked back in. There was a loud pop when this happened. The vehicle was burning more fuel than it did when first purchased it. Sometimes the water and fuel lights came on. The dealer told him that when this happened he should pull over. But when he does there is no water in the fuel. The fuel gauge will completely go to low then come back up after about 10-15 miles. Also, the air bag light will come on. …
I own two 2004 Ford f-550 and one 2003 f-550 superduty trucks. Interior fuel tank coating is de-laminating and rusting at around 100,000 miles. Vehicles stop without any warning. Silvery material in water separator and fuel filters. I know of several vehicle owners that have this same problem and Ford will do nothing. My vehicles stop suddenly in heavy traffic and we were lucky no one was injured. I have replaced the 2003 and one 2004 tank assembly. Other 2004 is showing silvery residue also. I know of a dealer in st louis mo., that has replaced many tanks for customers with the same problem. This is a defective tank coating and Ford should be held responsible. It is my understanding they (Ford) have known of this issue since 2005 and will do nothing. Do people need to be hurt/killed before action is taken? …
The truck in question is a 2004 Ford f-550 diesel. Upon depressing gas pedal, truck stalled and no longer worked properly. Truck was towed to local Ford dealer where it was determined that the fuel tank was suffering from rust inside the tank. Based on the work done, rust particles that formed inside the tank were forced through the fuel pump and filter damaging both and causing an issue with the fuel injectors. I called Ford directly to ask about any recalls for this issue and they told me there was no recall currently for this problem. They said the truck was out of warranty and there was nothing they could do about the $3000 bill from their independent dealer. I find it hard to believe that a truck that is not used for plowing and only has 36,000 miles would suffer such a catastrophic failure. …
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. …
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. …
Tl* - the contact owns a 2004 Ford f550. The contact stated that approximately 1 year the vehicle had an electrical short., took the vehicle to be repaired and that very same day had problems with the transmission slipping. The contact stated that approximately one year later in January 2007 the transmission would not engage, and one could drive down the road and the transmission would just stop working. The truck was currently in the repair shop, and it has taken Ford over a week to diagnose the problem. The current diagnosis showed that all 4 solenoids in the transmission needed to be replaced. The contact stated that the transmission needs to be totally replaced. The contact stated that neither speed nor the weather were factors. The dealer stated performed the recall pertaining to fuel injector control module wiring and charged air cooler duct.
November 2008, our Ford truck broke down due to fuel problems. Truck was towed in and fuel filter was checked. Tiny silver flakes clogged the filter. Mechanic alerted us that Ford is having a problem with their fuel tank liners separating, and that they are not taking claim on it. Truck filter was changed and it ran fine for about a month.. We pulled the fuel filter again only to find "flakes" in the filter again. Searched on the internet showed countless people having the same problem, and having to dish out thousands in repair costs only to have it happen again to them. No replacement available on the market that will solve the problem for good, everyone is forced to buy fords replacement. Also no one knows if this will result in failure of the fuel filter and injectors down the road after the warranty on these items runs out.
Follow up to original complaint I had originally thought that a missed recall repair was the reason for the engine stalling...and not restarting. After having the vehicle towed and inspected by hub city Ford...the mechanics found slime in both fuel tanks. The slime had clogged the fuel system and caused the motor to stop. Hub city Ford's personnel were all as surprised as I was. They were helpful in showing extra attention to this...and have repaired it all. I believe the slimy substance had been put in before they had it...and before I bought it. Possibly during the previous ownership. This is to close this complaint. I am satisfied with all hub city Ford has taken care of for me...with great care. The sales person I bought it with...mr. Bill boudrier...the service mgr....mr. Carroll and the tech's. Thank you.
Tl* the contact owns a 2004 Ford f-550 SD. The contact stated the vehicle would intermittently lose power when driving at various speeds. On one occasion that the failure occurred, the contact shut off the engine and when restarting, he was able to drive a very short distance before the failure recurred. The vehicle would not accelerate past 5 MPH. The vehicle was taken to an authorized dealer where the contact was informed that the fuel pump, filters, fuel tank and eight fuel injectors would need to be replaced because the fuel tank was rusted. The manufacturer advised the failure occurred because the contact failed to keep the fuel tank full. The vehicle was not repaired. The failure mileage was 27,120 and the current mileage was approximately 46,000.
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.
Fuel System complaints in other F-550 SD years
Frequently asked questions
How common are fuel system problems on the 2004 Ford F-550 SD?
NHTSA has 26 complaints about the fuel & propulsion system of the 2004 Ford F-550 SD, 53% of the model year's 49 complaints. The component named most often is storage › tank assembly (2 mentions).
Is there a recall for 2004 Ford F-550 SD fuel system problems?
No. NHTSA lists no fuel & propulsion system recall for the 2004 Ford F-550 SD, though it has 2 recalls 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 2004 Ford F-550 SD fuel system problems start?
Half of the complaints with a recorded mileage happened before about 44,000 miles, and 13% 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.