2004 Ford F-550 SD engine problems

Filed Feb 25, 2013 · Engine, Fuel system · 36,000 miles · CT

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. The replacement tank was made of some type of plastic not the oem metal tank that was originally used on the truck which made me question the dealer. They said they had seen this happen on tanks of this model quite often so they replaced them with a pvc model. Upon further discussions through blogs and other online resources I was able to find a few owners of the same trucks that had similar problems. These discussions prompted me to file this claim.

Filed Jul 12, 2012 · Engine · CT

2004 f550 diesel. Consumer states vehicle has a faulty head-gasket *tgw the consumer stated the truck would only run for 20 minutes before it overheated. The consumer was informed it cost close to 10,000 to fix the truck.

Filed Jun 1, 2012 · Engine · 30,000 miles · CO

Tl* the contact owns a 2004 ford f-550 sd. While driving approximately 5 MPH, the engine stalled without prior warning. The vehicle failed to restart and it was towed to an independent mechanic who stated the failure was contributed to the high pressure oil pump. The vehicle was repaired. The manufacturer was notified of the problem. The approximate failure mileage was 30,000. Updated 8/8/12 *cn updated 08/15/2012

Filed Aug 18, 2011 · Engine · 6,500 miles · OR

Tl* the contact owns a 2004 f-550 sd. While driving approximately 60 MPH, the contact noticed steam coming from the engine. The vehicle was taken to the dealer for diagnostics where the technicians advised that the turbo had over boosted and caused the engine to fail. The engine was replaced and after the repairs, the contact noticed white smoke from the exhaust pipe and an anti-freeze smell emitting from the vehicle. The vehicle was taken to an independent mechanic. The mechanic stated that the inner cooler had to be replaced and the head gasket exhibited a leak. The inner cooler was replaced. The approximate failure mileage was 6,500. Updated 10/05/11

Filed Jan 5, 2011 · Engine, Fuel system · 68,000 miles · NJ

04 ford f550 sd dump truck was bought new on 12/04.. In april 2005 transmission leaked fluid while in park and truck was towed to dealer. The dealer claimed cause of problem was due to loose bolts on trans case. Transmission continued to slip but dealer could not find problem. February 2006, approximately 16,000 miles on truck, transmission completely fails. Truck towed to dealership and new transmission installed. On june 2008 (approximately 56,000 miles) while driving on major highway, truck begins to lose power and black smoke pours out of muffler. The truck was driven to local dealership and diagnosed with a blown turbo. Ford did not cover cost of repair. I paid $4,500.00 out of pocket to replace turbo. August 2009 (approximately 68,000 miles) again while driving on major highway, truck loses power and stalls. Truck was towed to ford dealership and diagnosed with clogged injectors due to deteriorating gas tank. Dealer advised me that all 8 injectors would have to be replaced and new fuel pump installed. The total cost of repairs would be $4,300.00 and it would not be covered by ford. I was incensed to say the least...after getting a second opinion, I paid an additional $475.00 and had the truck towed to another ford dealership which made the repairs without any cost to me. The fuel tank was not replaced even though it was the cause of the problem. I replaced the tank and paid $750.00 out of pocket...december 27, 2010 (96,000 miles) without warning, transmission begins to slip. I contacted the ford dealership that made the last repairs. I was told the transmission was out of warranty and would not be covered by ford. It would cost $4,200.00 to replace. I took truck to a local transmission repair shop and paid $3,000.00 to rebuild transmission. Its obvious that ford does not back up their product. I will never buy another ford again!!!!

Filed Mar 22, 2010 · Engine, Fuel system · 40,000 miles · MD

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. This is a severe highway safety issue. Please contact me as soon as possible to resolve these problems. Thanks. [xxx] parts of this document have been redacted to protect personally identifiable information pursuant to the freedom of information act (foia), 5 u.s.c. 552(b)(6).

Filed Mar 4, 2010 · Engine, Fuel system · 25,000 miles · MD

Tl*the contact owns a 2004 ford f550 sd. The contact was driving approximately between 45- 55 MPH. The engine stalled without warning. The engine failed to restart. The vehicle was towed to an authorized dealer. The failure was contributed to the fuel injector which was replaced on three separate occasions. The failure continued with no resolutions. The failure mileage was 25,000. The current mileage was 184,602. Updated 12/08/10. *lj the radiator hose was replaced. Updated 12/13/10

Filed Sep 25, 2009 · Engine, Fuel system · 94,000 miles · PA

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. Bbb complaint filed and in search for class action law suit to cover repairs only.

Filed Feb 4, 2009 · Engine, Fuel system · 43,000 miles · NY

2004 ford model 5500 f series dump truck with 43,000 miles diesel fuel tank delamination & damage caused to motor.

Filed Aug 3, 2007 · Engine · 6,000 miles · FL

Tl*the contact owns a 2004 ford f550. The contact had the head gasket replaced in his vehicle two weeks ago. The repair cost $800. In august of 2002, while driving 55 MPH, the engine failed without warning. He stated that there have been multiple engine related failures over the four years that he has owned the vehicle such as the hoses, planetary gear, o-ring was replaced three or four times, head gaskets, wiring harness for the injectors, injectors, high pressure oil pump, clutch fan, egr cooler, oil cooler, turbo system, oxygen sensor, exhaust sensor, and lower radiator hose. The current mileage was 58,000 and failure mileage was 6,000. Updated 01/02/08.