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-550 SD owners, lightly cleaned up (personal details are redacted by NHTSA).
While driving the vehicle on the expressway in michigan, it suddenly began losing power. After frequently stopping and restarting the engine, the truck stopped completely. When the dealership investigated the cause, they found specks of paint in the diesel fuel. When the factory installed gas tank was dropped, it was discovered that the coating inside the fuel tank was flaking off and had plugged the fuel filters, contaminated the fuel as well as damaging 3 inverters.. When investigating if others have same complaint, we found many others have had the same problem. Luckily we were not pulling our rv.
TSB 19728 - we own a limousine party coach on a 2006 Ford f-550 chassis and had the pleasure of experience the "fuel tank deterioration" and having a total of 16 fuel injectors and 4 gas tanks replaced in a one year period. Ford refuses to acknowledge that this is a defect in the fuel tank. There are hundreds of people experiencing the same problem throughout the country. The first time the vehicle was under warranty for the repair "as a courtesy" and now one year later the same problem has occurred and now they refuse to warranty or do anything about it! The total repair costs on this defect is $5000.00 dollars for the 2 fuel tanks $2000.00 for the injectors $1200.00 in towing and not to mention the loss of revenue because the bus is out of service. Ford is trying to blame the diesel fuel which is state regulated in new jersey. …
I have a 2006 f-550 Ford 6.0 diesel truck with 17,000 miles and replaced 5 fuel filters at this time and had the truck towed in on 3-2-09 stumbling,hard start .called the dealer and he told me the gas tanks are delaminating from bio fuels,I have a 2004 diesel truck with no problems,and faithfully use sunoco fuel.the shop foreman at hopkins Ford said this is not under warranty, I have rust come out when I change the filters as well as the water separator. This has been an on going problem and am not getting any where with Ford. Red hill Ford told me he never heard of this type of problem,norristown Ford have fuel tanks stacked 10' high,that the replaced for customers because who ever Ford got to coat the inside of fuel tanks ,did a poor job. I have the normal warranty and the extended warranty. I have paid $50,000 for this vehicle and I'm afraid to drive it for fear of an accident. …
Driving at approx. 35-40 MPH truck lost power and stalled . I cranked several times and then it started . I drove about another mile and this repeated twice ,then I was calling a wrecker for a tow. My mechanic discovered the fuel filter & pump was contaminated with a sludge and then looked in the fuel tank and discovered the fuel tank was flaking from the inside , manufacture defect. The cost of parts and repair was $2100.00 , the tank is a 40 gal tank that holds diesel fuel at $ 4.25 per gal. My work associate has the same vehicle and now the same thing happened to him,he will also be filling a report with his win. # ,now we are hearing several of the same occurrences. It sounds like Ford needs to do a recall / class action law suit, reimbursement !!! The defect is costing consumer thousands of dollars and additional expenses.
Driver reported that the truck was not running well on return to warehouse. I sent him to dealer with truck. The engine quit on the way and we had to tow the truck to dealer. The dealer said the fuel tank had delaminated and ruined the fuel pump and several fuel injectors. It would cost over $4000 dollars to repair. I called Ford customer service to complain (the truck was only 1400 miles out of warranty) after several days the dealer called and said Ford would bill it as a warranty claim and split the cost with me which meant I would have to pay $1133 dollars. I had no choice but to pay it. In October 2014 the truck did it again at 232886 miles. I took the truck to someone else and was told the fuel tank had delaminated again. It cost $4295 to replace the fuel tank , fuel pump and three fuel injectors. …
We own a 2006 f-550 Ford dump truck. With 22,000.00 miles on it. It was in the shop last year because of no turbo power. Dealer couldn't figure the problem out. We change the oil every 2,000 miles plus change fuel filters, etc. At the same time. Last week no power. Took to another dealership and upon inspection tech found fuel tank, sending unit. Filters lines failed/clogged. Had to replace fuel tank and fuel filters. Flushed out sending unit and fuel lines. It cost me $2,105.91 out of my pocket. I called Ford customer relations dept. And was told this is not Ford's problem that it is the fuel that did the damage. This problem should be a recall problem with this truck. It is still under warranty and they won't pay !
Tl* the contact owns a 2006 Ford f-550 super duty. The contact stated that while driving 55 MPH, the vehicle stalled and without warning. The vehicle was towed to a dealer. The dealer inspected the vehicle where the fuel tank and the fuel lines were cleaned. In addition, the fuel filters were replaced. The failure recurred several times. The vehicle was taken to dealer where the exact same repairs and maintenance were performed however the failure was not corrected. The contact stated that the fuel tank was delaminating and causing the obstruction. The manufacturer was made aware of the failure however no assistance was provided. The current mileage was 58,300. The failure mileage was 45,963.
My 2006 f-550 diesel truck has had problems with stalling,rough idle.dealer tells me that my fuel tank is rotting from the inside.Ford service tells me its from contamiated fuel.this truck is still under extended warranty.they want me to pay2500 to fix it.I own a 1983 diesel Ford and a 2001 diesel Ford truck. I use the same fueling station for all 3 trucks. I have no problems with fuel issues in the 83 or 01 trucks.this is the 2nd time in for repair for fuel problems on my 06.maybe fords bad design junk steel for fuel tanks or poor vent tube design May be at fault.after Ford giving me lie after lie about this issue I don`t know what to do.this truck has 29,000 miles on it.
Tl* the contact owns a 2006 Ford f-550 SD. The contact stated that the vehicle would stall while driving at various speeds. The vehicle was taken to an authorized dealer where the contact was informed that the lining on the interior of the fuel tank was deteriorating. The vehicle was repaired. Approximately one hour later, the failure recurred. The vehicle was taken back to an authorized dealer where it was again in the process of being repaired. The manufacturer was made aware of the failure and the contact was informed that the failure was due to the corrosion of the diesel fuel tanks. The failure mileage was 15,000. Updated 10/04/11 updated 3/29/12
Tl contact owns a 2006 Ford f550 superduty diesel truck. The contact stated that his vehicle was running roughly and was difficult to start. The dealer suggested that the primary fuel filter was clogged with rust because the fuel tank was laminated with rust inside. The dealer wants to remove the tank from the vehicle so that it can be realigned and installed again. The contact would have to pay $650 for this service. The vehicle is still under warranty, but the dealer does not want to repair the vehicle under the warranty. The manufacturer is ignoring the contact. The failure mileage was 22,000.
Fuel System complaints in other F-550 SD years
Frequently asked questions
How common are fuel system problems on the 2006 Ford F-550 SD?
NHTSA has 36 complaints about the fuel & propulsion system of the 2006 Ford F-550 SD, 82% of the model year's 44 complaints. The component named most often is storage › tank assembly (7 mentions).
Is there a recall for 2006 Ford F-550 SD fuel system problems?
No. NHTSA lists no fuel & propulsion system recall for the 2006 Ford F-550 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-550 SD fuel system problems start?
Half of the complaints with a recorded mileage happened before about 48,000 miles, and 16% 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.