2004 Ford F-550 SD: fuel pump failure

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 Aug 10, 2012 · Fuel system · 45,000 miles · NY

Tl* the contact owns a 2004 ford f-550 sd. While driving approximately 45 MPH the vehicle stalled without warning. The vehicle was towed to the dealer for diagnostics where the technician stated that the turbo charger would have to be replaced. After the repair the failure continued. The vehicle was taken back to the dealer a second time where the fuel pump was replaced but to no avail. The vehicle was taken to an independent mechanic for diagnostic testing. The mechanic stated that the lamination of the fuel tank was peeling and entering the fuel system and the engine. The vehicle was not repaired. The approximate failure mileage was 45,000.

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 Aug 6, 2010 · Fuel system · 27,120 miles · CT

Tl* the contact owns a 2004 ford f-550 sd. The contact stated the vehicle would intermittently lose power when driving at various speeds. On one occasion that the failure occurred, the contact shut off the engine and when restarting, he was able to drive a very short distance before the failure recurred. The vehicle would not accelerate past 5 MPH. The vehicle was taken to an authorized dealer where the contact was informed that the fuel pump, filters, fuel tank and eight fuel injectors would need to be replaced because the fuel tank was rusted. The manufacturer advised the failure occurred because the contact failed to keep the fuel tank full. The vehicle was not repaired. The failure mileage was 27,120 and the current mileage was approximately 46,000.

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.