2002 Ford F-550 SD fuel system problems

Filed May 17, 2012 · Brakes, Fuel system · WI

2002 ford f550 flatbed truck. Consumer states vehicle is unsafe to drive *tgw 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.

Filed Dec 2, 2011 · Fuel system · MD

Driving vehicle, vehicle lost power. Driver just made it off the road. Had the vehicle towed to a service station. Being told that the fuel tank is de-laminating. They have to replace the whole fuel system. Total cost $3,500.00. Called ford, they are saying there is no known problem. When I do a google search several complaints are posted on different sites about the same problem. It seems as though several years are affected.

Filed Jun 15, 2010 · Fuel system · 142,000 miles · KS

Ford f550 truck has fuel tank problem. Fuel lines, pump, filter & injectors getting clogged due to flaking on the inside of the tank. Issue blamed on poor diesel fuel, but have researched several other cases all reporting the exact same issues. Ford is taking no responsibility. Truck will lose power and stall while driving.

Filed Nov 20, 2009 · Fuel system · 60,507 miles · VA

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.

Filed Apr 23, 2009 · Fuel system · 108,280 miles · CA

Servicing dealer just advised that the diesel fuel tank is delaminating from the inside and causing fuel line, fuel filter, and fuel injector clogging. Although we always used clean diesel only, dealership would not say what caused problem but well aware of it. Quoted $3,500.00 to replace fuel tank and sending unit. Outrageous. Especially when causing stalling and loss of power during driving and possibly causing accident. Found lots of people with the same problem through internet search.

Filed Jan 14, 2009 · Fuel system · 36,000 miles · NY

My 2002 for f 550 was driving and lost power in traffic eventually losing power and stalling in traffic on a very busy road. The truck was towed to a local dealer and I was informed that the inside of the gas tank was delaminating which caused a failure in the gas tank, failure in the sending unit,the failure in the fuel pump,and the failure of the filters. Ford has also advised me of possible destroyed fuel injectors. Ford takes no responsibility for the defect in the fuel tank.

Filed Sep 16, 2008 · Fuel system · 44,000 miles · MD

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.

Filed Jun 13, 2006 · Fuel system · 108,000 miles · NY

Fuel tank on 2002 f series ford dump trucks are coated with a substance that breaks down and causes blockage of fuel lines; original tank replaced august 2005 same problem with replacement tank, 6/06: coating breaking down; causing engine to shut off; extremely dangerous and offers no warning. *jb updated 10/04/06.

Filed May 3, 2006 · Fuel system · 65,000 miles · CA

Fuel tank failure on f450 and f550 ford chassis. We have 2 f450 and 4 f550 buses with factory installed fuel tanks. The f550s have been replaced and are failing the second and third time with no recognition continued problem from ford. One of our f450s failed today. Same problem. The problem appears to failure of the internal coating in the tank. All failures are the same. I believe the cause is improper application of the coating or the wrong coating is being used. I'm sure we are not the only company in the us to experience this problem. The cost to replace the tank is approximately $2000.

Filed Jun 4, 2005 · Fuel system, Suspension · 17,237 miles · CA

Bracket suspension failure allows rear end to shift over 6 - 8 inches puncturing the fuel tank and rendering the vehicle motionless.