2004 FORD F-550 SD Engine And Engine Cooling Problems

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. *TR

Mileage: 36,000

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. *JB

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

Mileage: 6,500

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!!!! *TR

Mileage: 68,000

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).*CC

Mileage: 40,000

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

Mileage: 25,000

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. *TR

Mileage: 94,000

2004 FORD MODEL 5500 F SERIES DUMP TRUCK WITH 43,000 MILES DIESEL FUEL TANK DELAMINATION & DAMAGE CAUSED TO MOTOR. *TR

Mileage: 43,000

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. *LJ

Mileage: 6,000

ON JULY 7 2006 AT 8:00AM I WAS NOTIFIED BY OUR BRANCH MANAGER IN THE HARTFORD CT AREA THAT ONE OF OUR TRUCKS WAS TOTALED DUE TO FIRE THAT BURNED DOWN THE TRUCK OVERNIGHT. OUR DRIVER PARKED THE TRUCK AT HIS DRIVEWAY AT HONE AT 10:00PM, AND THE FIRE TOOK PLACE AT 2:00AM, 4 HOURS AFTER HIS ARRIVAL HOME. I WENT TO SEE THE TRUCK AND MET THE FIRE MARSHAL OF THE TOWN OF COLCHESTER CT WHERE THE DRIVER RESIDES. THE TRUCK WAS COMPLETELY BURNED, AND ACCORDING TO THE FIRE MARSHALL THE FIRE STARTED AT THE TURBO UNIT OF THE TRUCK. THIS WAS A 2004 FORD F550 CAB-CHASSIS TRUCK VIN NUMBER [XXX] WITH 28,000 MILES. IT WAS UNDER THE 3 YEARS 36,000 MILES WARRANTY OF FORD. I CONTACTED FORD AND THEY HAD AN INDEPENDENT ENGINEERING COMPANY THAT CAME TO EXAMINE THE TRUCK. A REPORT ON THEIR FINDING WAS ISSUED TO FORD. BASED ON THIS REPORT FORD ISSUED A LETTER TO ME ON AUGUST 11 2006. THEY CLAIMED THAT NO MANUFACTURING DEFECT WAS VERIFIED, AND THEREFORE FORD IS NOT RESPONSIBLE FOR THE FIRE. BASED ON THESE FINDING FORD CLOSED THIS CASE. IT IS VERY CLEAR TO ANYONE WHO LOOKED AT THE TRUCK. *NM UPDATED 07/12/2012 *JS INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

Mileage: 28,000

WHILE DRIVING A FORD F-550 THAT I BOUGHT USED ON 01-25-06 FROM HUB CITY FORD IN LAFAYETTE, LA...THE ENGINE LOST POWER AND STALLED ON A 65 MPH. HWY (HWY 90). APPARENTLY...THERE IS GOOD CAUSE TO BELIEVE THAT AN IGNORED RECALL ON THIS SPECIFIC TRUCK IS THE EXACT REASON FOR THIS DANGEROUS FAILURE. NOT TO MENTION THE NOW LOST INCOME FROM IT BEING IN THE WAITING LINE AT HUB CITY FORD...WHERE I HAD IT TOWED. I WAS PROMISED THAT ALL WAS INSPECTED AND IN GOOD WORKING ORDER PRIOR TO DRIVING THE TRUCK OFF THE LOT. WELL...IT WASN'T. I CHOSE TO SEE IF THERE WERE ANY RECALL ISSUES WITH THIS TRUCK'S VIN NUMBER AT THE FORD RECALLS WEBSITE... YES...THIS WAS WHAT I SAW: RECALLS RESULTS : BE ADVISED THAT THIS SYSTEM TRACKS SAFETY AND EMISSION RECALLS FOR WHICH VEHICLES ARE SUBJECT TO REPAIR IN THE UNITED STATES. FOR MORE INFORMATION ON FORD MOTOR COMPANY RECALLS OR CONCERNS YOU MAY BE HAVING WITH YOUR VEHICLE, PLEASE CONTACT YOUR DEALERSHIP DIRECTLY. BELOW YOU WILL FIND INFORMATION REGARDING YOUR AFFECTED VEHICLE. RECALLS LISTED 2004 FORD F-550 [XXX] 05E15 EXHAUST PRESSURE SENSOR REPLACEMENT, ON-BOARD DIAGNOSTIC SYSTEM AND ENGINE CONTROL MODULES RECALIBRATION FROM YOUR WEBSITE HERE: MAKE : FORD MODEL : F550 SUPER DUTY YEAR : 2004 MANUFACTURER : FORD MOTOR COMPANY NHTSA CAMPAIGN ID NUMBER : 05V270000 MFG'S REPORT DATE : JUN 07, 2005 COMPONENT: ELECTRICAL SYSTEM:WIRING POTENTIAL NUMBER OF UNITS AFFECTED : 180104 SUMMARY: CERTAIN PICKUP TRUCKS, SPORT UTILITY VEHICLES AND VANS EQUIPPED WITH 6.0L DIESEL ENGINES MAY EXPERIENCE STALLING WITHOUT WARNING WHILE DRIVING AND MAY OR MAY NOT RESTART. CONSEQUENCE: SHOULD THE ENGINE STALL, A VEHICLE CRASH COULD OCCUR. REMEDY: DEALERS WILL UPGRADE THE FUEL INJECTION CONTROL MODULE (FICM) WIRE HARNESS OR REPLACED, AND/OR HAVE A NEW INJECTION CONTROL PRESSURE (ICP)) SENSOR CONNECTOR INSTALLED FREE OF CHARGE. THE RECALL BEGAN ON JULY 22, 2005. FORD RECALL NO. 05S34. *NM UPDATED 07/17/2012 *JS INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORM

Mileage: 262,257

TRUCK WAS TAKEN TO DEALER FOR OVERHEATING PROBLEM. ON THE FIRST TRIP OUT WITH THE TRUCK AFTER BEING PICKED UP FROM THE DEALERSHIP, THE TRUCK OVERHEATED AND CAUGHT FIRE. EXTENSIVE DAMAGE AND NEITHER DEALERSHIP OR FORD WANT TO INVESTIGATE SOURCE OF FIRE. TRUCK WAS UNDER WARRANTY AT THE TIME OF THE INCIDENT. *NM

Mileage: 35,158

THE LOSS VEHICLE IS A 2004 FORD F-550 CHASSIS WITH A TOW BODY, WHITE IN COLOR. A 7.3 LITER POWER STROKE TURBO DIESEL ENGINE POWERS THE VEHICLE. THE VEHICLE ID NUMBER IS [XXX]. MACK TOWING OWNS THE TRUCK IN MIAMI, FLORIDA. THE VEHICLE WAS BEING DRIVEN WHEN THE OPERATOR NOTICED THE VEHICLE LOSING POWER AND THEN STALLED. HE THEN NOTICED SMOKE AND SAW FIRE UNDER THE HOOD IN THE ENGINE COMPARTMENT. EXAMINATION OF THE EXTERIOR REVEALED THAT THE FIRE ORIGINATED IN THE ENGINE COMPARTMENT, PROGRESSED TO THE EXTERIOR CAUSING FIRE DAMAGE TO THE HOOD AND BOTH FENDERS. FURTHER EXAMINATION OF THE EXTERIOR REVEALED THAT PRIOR TO THIS EVENT EXTERIOR WAS IN OVERALL GOOD CONDITION ALL WINDOW GLASS WAS BROKEN AND MELTED DUE TO THE FIRE. THE FRONT TIRES AND WHEELS WERE ALSO PRESENT AND DAMAGED BY FIRE. THE REAR TIRES AND WHEELS WERE IN GOOD CONDITION. THE TIRE TREAD DEPTH ON THE REAR TIRES WAS 7/32 WHILE THE FRONT WAS LESS. NO COMPONENTS WERE NOTED AS BEING MISSING FROM THE EXTERIOR OF THE VEHICLE. EXAMINATION OF THE INTERIOR OF THIS VEHICLE REVEALED THAT THE FIRE, WHICH ORIGINATED IN THE ENGINE COMPARTMENT, PROGRESSED INTO THE INTERIOR TOTALLY DESTROYING IT. NO COMPONENTS WERE NOTED AS MISSING. EXAMINATION OF THE ENGINE COMPARTMENT AND THE BURN PATTERNS NOTED THAT THE POINT OF ORIGIN WAS THE RIGHT SIDE FIREWALL OF THE ENGINE COMPARTMENT. EXAMINATION OF THE WIRING FOUND IN THIS AREA NOTED MANY AREAS OF DAMAGE WHICH MAY HAVE CONTRIBUTED TO OR BEEN CAUSED BY THE FIRE. THE POINT OF ORIGIN OF THE FIRE WAS AT THE POSITION WHERE THE ELECTRIC BLOWER FAN, MOTOR AND SHROUD HAD BEEN BEFORE THE FIRE, BUT WERE MISSING AT THE MOMENT OF THE EXAMINATION.. THIS SPOT WAS THE MOT HEAVILY DAMAGED POINT OF THE ENTIRE VEHICLE. EXAMINATION OF THE ENGINE AND TRANSMISSION FOUND NO SIGNS OF ANY OIL LEAKS THAT CONTRIBUTED OR TO BE CAUSED BY THE FIRE. ALL OTHER CAUSES WERE ELIMINATED AS A CAUSE FOR THIS FIRE. *JB UPDATED 07/18/2012 *JS INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

Mileage: 24,000

DT: THE CONSUMERS 2004 FORD F550 SD STALLED. THE DEALER WAS UNABLE TO DUPLICATE THE CONSUMERS CONCERN. *JB

WHILE SHIFTING, THE TRANSMISSION DOWN SHIFTED ON ITS OWN. THE TRANSMISSION SURGED, AND THE VEHICLE BLEW OUT BLUE SMOKE. THE CONSUMER DROVE VEHICLE TO THE DEALER, AND THE MECHANIC DETERMINED THAT EBP SENSOR NEEDED TO BE REPLACED. *AK THE ENGINE LOADED UP WITH FUEL, SMOKE, SURGING WHEN DOWN SHIFTED WHEN THE BRAKE WAS APPLIED, AND SEVERE MISSING WHEN GEARS WENT DOWN TO FIRST, ALL OCCURRED AS THE VEHICLE WAS IN THE TOW HAUL POSITION. WHEN THE PROBLEM OCCURRED ON ICE OR SNOW COVERED ROADS. *SC

WHILE DRIVING, THE VEHICLE STALLED. THE CONSUMER HAD THE VEHICLE TOWED. PLEASE PROVIDE MORE INFORMATION. *JB

Mileage: 12,000