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 2005 Ford F-550 SD owners, lightly cleaned up (personal details are redacted by NHTSA).
Truck started losing power on the highway. Would hardly climb an incline. We exited the highway, truck was running worse, and finally stalled out. It would only restart and run rough for a minute or two after letting it sit for a while, and then stall again. I had to get the truck towed back to my shop. We changed the fuel filters, and the one in the frame rail had a silver flaky substance inside the filter. I had to put the truck on a trailer, and bring it to the dealership. I was told I needed a new fuel tank, a new fuel pump, new fuel filters, and the fuel system needs to be flushed. They said they are aware of the problem, and they called a warranty rep. They refused to help me. I called Ford roadside assistance, and they refused to help me. I now have to spend thousands to fix this. …
1. 2005 Ford f550 diesel truck stalling, rough idle, loss of power completely. 2. The diesel fuel tank is delaminating and has caused $6,000 worth in damages. My truck stopped working completely and was towed to a Ford dealership here in hawaii for diagnosis. My f550 is currently covered with a super duty diesel engine care warranty that cost over $3,000 yet Ford will not replace the defected tank that has caused thousands of problems nationwide to date. The tanks need to be recalled and individuals need to be reimbursed. Ford has taken away from our economy and endangered our roads. 3. Fuel filters, fuel tank, fuel injectors, fuel pumps, fuel pressure regulators, and fuel senders all need to be replaced. They are planning to replace the fuel tank with the same manufactured tank. …
I am contacting you to file a complaint with Ford motor company regarding the fuel tanks on 450 and f550 trucks that we own. I have more than one vehicle that is and has been affected by this. The fuel tanks are degrading from the inside, causing fuel system damage and creating a hazard due to the fact that as large as these vehicles are they can be disabled in traffic. I do understand that any vehicle could be rendered disabled. However this would be for a known cause. Ford dealerships are well aware of the problem as are many tank repair facilities in new england. I understand through research these tanks have been defective since 1998. Ford is trying to say it is due to bio-diesel. If you looked inside the tank, you would see it is like paint flaking off of a wall. This situation has been doing damage to pumps and injectors causing breakdowns. …
My Ford f550 truck is being repaired for a delaminating fuel tank. Ford is trying to say it is from using biofuel,I never used anything but straight diesel. The tank is plastic lined and is coming apart badly and clogging injectors causing the entire fuel system and engine to fail. The dealer said he has seen this before and it is becoming a recurring problem. The truck has 41,777 miles on it. The year is a 2005, it was in for an extreme loss of power while still under warranty,the dealer miss diagnosed the problem, changed the fuel filter and the truck has been running erratic ever since. They said they could not find any problem. Now I am paying to have a new tank installed same as the old one, and the problem is only going to happen again and May even lead to an accident or a blown motor. Please contact me.
I own a Ford f 550 SD 2005, this truck has had fuel system problem off and on since I purchased three years ago. But this past week it started missing and stopping on me in traffic, I took it to the Ford dealer and I'm told that the fuel tank lining is coming off and damaged the fuel pump, filters and injectors, repair to cost $5,000. Also that this is due to the epa's low sulfur requirement on diesel fuels. This May be true but Ford know of this way prior to the start date of this new fuel and still is using defective parts that they will not cover under warranty or a recall today.... This parts failure include 2 fuel tanks, fuel pump, fuel filters,and injectors all damaged due to a poor tank lining or coating.
Truck will have a sudden loss of power when driving on the highway and finally stalls out. It puts the driver and the occupants in a dangerous situation. We do manage to get the truck into the shoulder and attempt to start the truck up. After 10 minutes the truck will start up and drive OK. The truck will continue to do this intermittently putting the occupants at risk. The fuel filter is replaced but continuation of the same problem. The fuel pump is next to be replaced, then the lifter pump with still no results. They finally check the fuel tank and find rust and some sort of brown slime in the tank and replace the tank along with a new fuel filter which solved the problem.
Tl contact owns a 2005 Ford f550. The contact stated the vehicle started loosing power and stalling while driving. The contact took the vehicle to the dealer who stated that the injection control pressure sensor failed. The contact reviewed NHTSA recall campaign number 05V270000 (electrical system: wiring), but was told by the manufacturer that their vehicle was not included. The failure mileage was 148,000 and the current mileage was 153,000. Fuel injection control module was replaced. Updated 08/31/2011
We own a 2005 Ford f-550 diesel truck. We are having problems with the fuel tank delaminating and causing the fuel flow to stop to the engine. This is a common problem on alot of Ford diesel trucks, Ford does not want to take responsibility for the tank delamination, causing the truck to stop running. We are having to pay for the repair, even though the truck is still under warranty. They say that we are running bio-diesel through the truck and this is what is causing the liner separation.
Tl* the contact owns a 2005 Ford f550. The contact stated that while driving approximately 70 MPH, the engine stalled without warning. The failure would occur on an intermittent basis. The vehicle was towed to the dealer who informed the contact that she would need to replace the fuel injector control module and regulator. The fuel injector control module and regulator were repaired. The failure recurred intermittently following repairs. The failure mileage was approximately 123,981.
Tl* the contact owns a 2005 Ford f-550 SD. The contact stated that while driving 50 MPH, the vehicle stalled without warning. The vehicle was taken to the dealer, who stated that the failure was caused by a clogged fuel filter. The fuel tank coating peeled off and obstructed the fuel filter. The vehicle was repaired by replacing the fuel tank and the fuel filter. The failure was reported to the manufacturer. The VIN was not available. The failure and current mileage was 40,000.
Related recalls
Fuel system, gasoline › Delivery › Hoses, lines/piping, and fittings
On certain pickup trucks and chassis cab vehicles equipped with 5.4l or 6.8l gasoline engines, the fuel jumper line May have an incorrect end form.
Remedy: Dealers will install an external retention clip at the fuel jumper line to the main fuel bundle connection. The recall began on June 20, 2005. Owners May contact Ford at 1-800-392-3673.
Fuel System complaints in other F-550 SD years
Frequently asked questions
How common are fuel system problems on the 2005 Ford F-550 SD?
NHTSA has 20 complaints about the fuel & propulsion system of the 2005 Ford F-550 SD, 63% of the model year's 32 complaints. The component named most often is storage › tank assembly (2 mentions).
Is there a recall for 2005 Ford F-550 SD fuel system problems?
Yes — NHTSA recall 05V-266 (hoses, lines/piping, and fittings, Jun 9, 2005). Recall repairs are free at authorized dealers.
At what mileage do 2005 Ford F-550 SD fuel system problems start?
Half of the complaints with a recorded mileage happened before about 50,000 miles, and 5% 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.