2002 Ford F-550 SD: problems, recalls and reliability
5 recalls and 22 owner complaints on record; most reports concern fuel system, diesel.
Data updated weekly · latest recall Jul 2011
All counts are reports filed with NHTSA in the United States - US market only, not worldwide totals.
Common problems
Computed from 22 owner complaints filed with NHTSA for this exact model year.
“Tl* the contact owns a 2002 ford f-550 sd. The contact stated that while driving approximately 60 mph, thick white smoke was seen from underneath the vehicle. After inspecting the vehicle, the contact discovered flames coming from under the hood and front of the vehicle. The vehicle was destroyed. The fire department extinguished the flames. During the incident the contact sustained injuries to the back and shoulder while attempting to extinguish the fire. The manufacturer was not notified of the defect. The VIN was not available. The failure mileage was 212,000.”Owner report · Engine · May 2014
“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. *jb”Owner report · Service Brakes, Hydraulic · May 2012
“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. *tr”Owner report · Fuel System, Gasoline · Nov 2011
Show 7 more owner reports
“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. *tr”Owner report · Fuel System, Diesel · Jun 2010
“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. *tr”Owner report · Fuel System, Diesel · Oct 2009
“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. *tr”Owner report · Fuel System, Diesel · Jan 2009
“Tl*the contact owns a 2002 ford f550 super duty. The contact stated that the rear suspension system failed, which was a result of a defect repair by the fontaine modification company. The company sent notifications to the vehicles that had a defect with the rear suspension system. The rear suspension was previously repaired on the contact's vehicle and he called the fontaine modification company in regards to reimbursement. They stated that the vehicle was out of warranty. The contact has called and written letters to the company since that time, but has not received a response. The failure mileage was 125,000.”Owner report · Suspension · Oct 2008
“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. *tr”Owner report · Fuel System, Diesel · Sep 2008
“The front axle tube is broken and cracked through where the centering support rod attaches to the axle. When this occurred it fell down onto the center link of the steering which caused the steering to bind and not turn freely. This happened in our corporation yard,but had it happened on the road it would have caused an accident and very probably personal injury. There is no impact damage of any kind to this vehicle. This is a safety issue of great magnitude. I informed my local ford dealer and they are looking into it. This is a manufacturing defect. *tr”Owner report · Power Train · Apr 2008
“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. *tr”Owner report · Fuel System, Diesel · Apr 2008
When filing, owners marked a crash in 0 of these complaints and injuries in 1 - self-reported to NHTSA, not verified accident statistics.
Recalls - 5 campaigns
FORD IS RECALLING MODEL YEARS 1995-2003 WINDSTAR, 2000-2003 EXCURSION DIESEL, 1993-1997 AND 1999-2003 F-250 SD THROUGH F-550 SD DIESEL, 1992-2003 E-150 THROUGH E-550, 1995-2002 EXPLORER, 1997 AND 2002 MERCURY MOUNTAINEER, 1995-1997 AND 2001-2003 RANGER, AND 1994 F53 VEHICLES EQUIPPED WITH THE TEXAS INSTRUMENTS SPEED CONTROL DEACTIVATION SWITCH (SCDS). THE SCDS MAY LEAK INTERNALLY AND THEN OVERHEAT, SMOKE, OR BURN.
Remedy: FORD WILL NOTIFY OWNERS THAT DEALERS WILL INSTALL A FUSED WIRING HARNESS IN LINE WITH THE SCDS. ON 1999-2003 WINDSTAR VEHICLES WITH A LEAKING SCDS, DEALERS WILL ALSO INSPECT THE ABS CONTROL MODULE CONNECTOR AND REPAIR AS NECESSARY. REPAIRS WILL BE COMPLETED FREE OF CHARGE. THE SAFETY RECALL BEGAN ON OCTOBER 27, 2009. OWNERS MAY CONTACT FORD AT 1-888-222-2751.
FORD IS RECALLING CERTAIN MODEL YEAR 2011 RANGER TRUCKS BUILT FROM JANUARY 25, 2011, THROUGH APRIL 25, 2011 AT THE TWIN CITIES ASSEMBLY PLANT, AND SERVICE PARTS DISTRIBUTED TO DEALERS FOR CERTAIN 2004 THROUGH 2011 MODEL YEAR RANGER TRUCKS, 2002 THROUGH 2005 MODEL YEAR EXCURSION VEHICLES, AND 2002 THROUGH 2007 MODEL YEAR F-250, F-350, F-450, AND F-550 TRUCKS FOR FAILING TO COMPLY WITH THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 108, "LAMPS, REFLECTIVE DEVICES, AND ASSOCIATED EQUIPMENT." THE MULTI-FUNCTION SWITCH WAS SHIPPED WITH A SUBCOMPONENT (SLIDER) THAT MAY EXPERIENCE DEFORMATION. A MULTI-FUNCTION SWITCH WITH A DEFORMED SLIDER MAY MALFUNCTION CAUSING THE TURN SIGNAL, TAIL LIGHTS, HAZARD WARNING SIGNAL FLASHERS AND/OR BRAKE LIGHTS NOT TO ACTIVATE.
Remedy: DEALERS WILL REPLACE THE SWITCHES FREE OF CHARGE. THE SAFETY RECALL BEGAN ON AUGUST 15, 2011. OWNERS MAY CONTACT FORD MOTOR COMPANY CUSTOMER RELATIONSHIP CENTER AT 1-866-436-7332.
CERTAIN FEDERAL-MOGUL REPLACEMENT WHEEL HUB ASSEMBLIES WITH THE BRAND NAMES: NATIONAL, CARQUEST P/NOS. 515020, 515021, 515025, 515053, 515054, 515059, AND 515060, SHIPPED BETWEEN JANUARY 23, 2006, AND DECEMBER 20, 2007, SOLD FOR LIGHT DUTY AND MEDIUM DUTY TRUCKS. THE INBOARD RETENTION NUT USED TO MAINTAIN HUB BEARING ASSEMBLY CAN LOOSEN RESULTING IN AN ABS LIGHT INDICATION, NOISE, AND/OR WHEEL SEPARATION.
Remedy: FEDERAL-MOGUL WILL NOTIFY CUSTOMERS AND WILL REPLACE THE HUB ASSEMBLY FREE OF CHARGE. THE RECALL BEGAN ON FEBRUARY 7, 2008. OWNERS CAN CONTACT FEDERAL-MOGUL TOLL-FREE AT 877-489-6659.
ON CERTAIN HEAVY DUTY TRUCKS EQUIPPED WITH 7.3L DIESEL ENGINES, THE CAMSHAFT POSITION SENSOR LOCATED ON THE ENGINE OF THE VEHICLE MAY FUNCTION INTERMITTENTLY, POSSIBLY RESULTING IN AN ENGINE STALL.
Remedy: DEALERS WILL INSPECT THE SENSOR AND REPLACE IT WITH AN IMPROVED CAMSHAFT POSITION SENSOR FREE OF CHARGE. THE RECALL BEGAN ON DECEMBER 29, 2007. OWNERS MAY CONTACT FORD AT 1-866-436-7332.
ON CERTAIN TRUCKS EQUIPPED WITH SPEED CONTROL, GASOLINE OR NATURAL GAS ENGINES, THE SPEED CONTROL DEACTIVATION SWITCH MAY OVERHEAT.
Remedy: DEALERS WILL INSTALL A FUSED WIRING HARNESS INTO THE SPEED CONTROL SYSTEM FREE OF CHARGE. THE RECALL BEGAN ON AUGUST 7, 2006. OWNERS MAY CONTACT FORD AT 1-866-436-7332. (NOTE: ALSO SEE RECALLS 05V017 AND 05V388)
How other years compare
Check your exact F-550 SD by VIN
Recalls and equipment differ between individual vehicles. Decode your VIN to see what applies to yours.
Open VIN decoderFrequently asked questions
Is the 2002 Ford F-550 SD reliable?
NHTSA has 22 owner complaints and 5 recall campaigns on record for the 2002 Ford F-550 SD. The most complained-about area is fuel system, diesel.
Does the 2002 Ford F-550 SD have open recalls?
5 recall campaigns have been issued, the latest concerning vehicle speed control. Check your specific vehicle by VIN - recall repairs are free at franchised dealers.
Source: NHTSA recall campaigns and owner complaints (public domain). Counts reflect reports on file and are not a defect rate.