Ford F-550 SD Fuel System Problems

Fuel System complaints by model year

Which parts fail

• Storage › Tank assembly
  19
• Delivery › Fuel pump
  7
• Fuel injection system
  2
• Delivery
  1
• Inverter
  1
• Storage
  1
• Fuel injection system › Injectors
  1
• Fuel filter
  1

Components named in complaints (fuel pump, injectors, fuel tank, hybrid and EV propulsion).

Mileage when the problem started

• Under 25k
  1612%
• 25k–50k
  4836%
• 50k–75k
  2519%
• 75k–100k
  129%
• 100k–150k
  2116%
• 150k+
  108%

What owners report

The contact owns a 2021 Ford F-550 SD. The contact stated that while an employee was driving 65 MPH and towing a vehicle, the vehicle inadvertently lost motive power. The driver was unable to pull over to the shoulder of the roadway due to a loss of electronic power steering; however, the vehicle was able to restart. After restarting the vehicle, the vehicle returned to normal functionality, but the failure became a regular occurrence. No warning lights were illuminated. The vehicle was taken to the dealer, who was unable to duplicate the failure. The vehicle was not repaired. After investigating the failure, the contact related the failure to NHTSA Campaign Number: 24V957000 (Fuel System, Diesel); the VIN was included, but parts were not yet available. The manufacturer was notified of the failure, a case was opened, and the contact was referred to the NHTSA Hotline for assistance. …

While driving down the road at approximately 45 mph, under normal conditions, with no warning indicators the low fuel pressure light came on. When the driver stopped the vehicle he lost all power and observed smoke emanating from the underside and hood of the vehicle. Prior to him exiting the vehicle he observed flames shooting out from under the console towards his feet. Upon exiting the vehicle I saw flames under the hood of the vehicle and utilized his supplied fire extinguisher to attempt to put the fire out. This was futile and to our benefit he had a pressure washer and 119 gallons of water that he was able to put into action to subdue the fire. Noting that the drivers side front fender melted off and a hole melted in the drivers side hood from the fire. …

I have more files and receipts Vehicle Information: Make: Ford Model: F-550 Super Duty Year: 2020 Issue Summary: After a recall service (22E04) for powertrain and transmission software updates, the vehicle experienced a complete power failure within 40 miles, leading to a stall and loss of control, resulting in the vehicle veering into a ditch. Incident Details: Recall Service Date: ] Mileage at Service: 63,993 Incident Mileage: ~64,030 miles Description: Post-recall, multiple warning lights activated, including powertrain malfunction and traction control off. The vehicle stalled, became unresponsive, and veered off the road. After multiple attempts coming after multiple attempts to call the dealership and corporate with no answer, forced to leave a bad survey and then someone contacted Follow-Up Actions: The dealership attributed the issue to a missing 10-amp fuse. …

Attempting registration renewal on 01/30/2025, and DMV has rejected, but cashed our check for registration renewal. Upon research of FORD Recall Available to Remedy, the SOFTWARE is NOT Available to Remedy since January 1st, 2025. How do we handle not being able to remedy FORD MANUFACTURER RECALL #22E04 ? Please ADVISE at your earliest opportunity? How to complete DMV registration when serious remedy is NOT available and registration has been expired since 03/31/25. We have sent CARB registration, copies of all RECALL Notices received not able to remedy and DMV continues no reject renewal until Recall can be completed.

My f-550 super duty diesel dump truck lost power on the highway because of a known fuel injector pump defect. The pump exploded into metal pieces that clogged all fuel lines leading to a loss of power on a highway putting everybody at risk of a collision. This fuel injector problem is known to ford and is subject to class action lawsuits. The dealer confirms that this is the problem. Apparently for the last decade, this pump has been known to fail because it was designed for European diesel not American diesel which because of the low sulfur content makes the pump cavitate because of lack of lubrication and explode. There was no indication of failure prior to the incident.

This submission is more related to a brand-new fuel line that was purchased from the Ford dealer for this vehicle upon failure of the existing line. When the new line was removed from the packaging, the mechanic inspected the clip that secures the line to the secondary fuel filter housing. It was observed that the brand-new clip was defective and that even the slightest touch of the clip would unlock the line. It is believed that if this line were installed in the vehicle, the vibration of the engine could potentially unclip the line causing fuel to spray in the hot engine compartment. The line was retained and can be provided for examination.

Brought the truck in to ford and they told me that paint lining from the tank may of gone into the fuel lines and system so they suggested that we replace the tank and they also replaced 2 injectors and the wiring harness for the injectors and reset the check engine light drove fine till the check engine light come on then its in limp mode and only drives at 40 miles per hour it is unsafe to drive on the highway and I do like this truck

The truck has not run properly since it was purchased, and the motor was replaced back in 2013 with mileage of 31,00 due to oil being splattered all over and no power. We had spend over 10,000.00 to fix the defective issues. Now almost 2 years to the day the engine has again failed. Ford offers no help or explanations as to why this continues to happen..

Related recalls (6)

NHTSA investigations