Ford F-550 SD fuel pump problems

Filed Jun 25, 2026 · Fuel system · PA

High pressure fuel pump failed damaging/ contaminating fuel system

Filed Feb 16, 2025 · Fuel system, Transmission · OR · crash

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. However, prior warnings from the FordPass app indicated powertrain malfunctions since October 2024. A subsequent recall notice (24S78/24V957) in January 2025 highlighted potential high-pressure fuel pump issues leading to power loss. After multiple attempts coming after multiple attempts to call the dealership and corporate with no answer was forced to leave a bad survey and then someone they’ve let me leave the dealership twice now saying that there was nothing wrong with my truck and then to find out that there’s a recall a couple weeks later Safety Concerns: The unexpected power loss and control failure pose significant safety risks. The recurrence of issues post-recall raises concerns about the effectiveness of the initial repair and overall vehicle safety. Requested Action: I urge the federal safety agency to investigate this matter to ensure driver safety and hold the manufacturer accountable for providing a reliable remedy.

Filed Feb 3, 2025 · Fuel system · 150,000 miles · SC

The contact owns a 2022 Ford F-550 SD. The contact stated that while driving on the highway at 60 MPH, the vehicle experienced a loss of automotive power, with the check engine warning light illuminated. The contact proceeded to pull over onto the side of the highway to safely park the vehicle. The contact attempted to restart the vehicle however, the vehicle failed to restart. The vehicle was towed to a local independent mechanic to be diagnosed. The contact was informed that the fuel pump was faulty and needed to be replaced. The vehicle was repaired. The manufacturer was not notified of the failure. The approximate failure mileage was 150,000.

Filed Nov 19, 2014 · Engine, Fuel system · 101,445 miles · MD

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. This is a well known , widespread problem (google it on the internet ) and I think ford should issue a recall and reimburse owners for all expenses , including rentals while repairs were made.

Filed Jul 24, 2014 · Fuel system · 42,608 miles · NY

Tl* the contact owns a 2009 ford 550 super duty. The contact stated that while driving 30 MPH, there was a loud rattling sound as then the vehicle stalled. The vehicle was restarted and taken to the dealer where the mechanic diagnosed that the fuel pump, filters and sensors needed to be replaced. The vehicle was repaired and the manufacturer was notified of the failure, who advised the contact that the problem was not covered under the warranty. The approximate failure mileage was 42,608. Updated 9/24/14

Filed Sep 23, 2013 · Fuel system · 31,010 miles · NC

I have a 2007 ford f-550 with only 31000 miles and the vehicle lost power and stalled out on side of road. When ford dealership checked the vehicle it was found that the fuel tank liner had deteriorated and rusted causing debris to enter into the fuel system which damaged the fuel pump, injectors and other parts of the fuel system. After talking with other ford dealerships we found out that this has been a problem with other vehicles that have this same tank. If ford would have recalled the tank or at least made it known to the owners that there was a problem all the damage would not have happened. This has cost us already $2658 to the ford dealership and we have about $1500 more to spend to correct the problem----all because ford would not even let us know there was a problem that could have been fixed for a lot less.

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 Feb 20, 2013 · Fuel system · 20,000 miles · NY

Tl* the contact owns a 2008 ford f-550. The contact stated that while driving at various speeds, the vehicle stalled without warning. The vehicle was taken to the dealer and the technician diagnosed that the fuel pump was clogged due to the fuel tank delaminating. As a result, both the fuel pump and the fuel tank needed to be replaced. The manufacturer was made aware of the failure and offered to pay the repair costs for the fuel pump and a percentage of the fuel tank repair expense. The vehicle was not repaired. The failure mileage was 20,000 and the current mileage was 32,000.

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 Nov 15, 2011 · Electrical, Fuel system · 55,050 miles · TN

Truck stalled I check it fuel pump had stop working took to dealer, next time the ficm went bad I replaced it drove good for 1500 or so miles then problems again ford said fuel tank rusting causing ficm to go bad and clog injectors ford fixed I asked about use of coolent they could not find any problem but I have to add one galion every week and truck is starting to smoke!