2002 Ford F-550 SD
Safety record from NHTSA: recalls, owner complaints, investigations and service bulletins.
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Vehicles › Ford › F-550 SD › 2002
These records cover every 2002 Ford F-550 SD. To see whether one car still needs a recall repair, decode its VIN or check it with NHTSA.
Recalls
5 recalls name the 2002 Ford F-550 SD. Newest first.
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…
Risk and remedy
Risk
Non-functioning lights could increase the risk of a crash.
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.
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…
Risk and remedy
Risk
A vehicle fire could occur with or without the engine running.
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.
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…
Risk and remedy
Risk
Wheel separation can result in a vehicle crash.
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.
Risk and remedy
Risk
In the event of an engine stall, a crash could result without warning.
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.
Risk and remedy
Risk
Overheating could result in smoke or burn and an underhood fire.
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)
Owner complaints
22 complaints3 involved a fire1 injuries
What owners report most
Latest complaints
- Electrical system
Connector #270B melted at central junction connector. vehicle was both in motion and parked
- Engine
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.…
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.
- Exterior lighting · Fuel system, diesel · Service brakes, hydraulic · Tires
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…
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
- Fuel system, gasoline
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…
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
- Fuel system, diesel
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
- Fuel system, diesel
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…
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
- Fuel system, diesel
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…
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
- Fuel system, diesel
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…
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
- Suspension › Rear
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…
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.
- Fuel system, diesel
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…
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
- Power train › Axle assembly
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…
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
- Service brakes, hydraulic · Steering › Hydraulic power assist system
2002 f550's power steering mechanism in engine compartment broke off and struck another vehicle on the highway. *ts a vacuum for the power steering and brakes broke. *nm
- Fuel system, diesel › Storage › Tank assembly
Fuel tank on 2002 f series ford dump trucks are coated with a substance that breaks down and causes blockage of fuel lines; original tank replaced august 2005 same problem with replacement tank, 6/06: coating breaking down; causing engine to shut off; extremely dangerous and offers no warning. *Jb updated 10/04/06. *Jb
- Fuel system, diesel
Fuel tank failure on F450 and F550 ford chassis. We have 2 F450 and 4 F550 buses with factory installed fuel tanks. The f550s have been replaced and are failing the second and third time with no recognition continued problem from ford. One of our f450s failed today. Same problem. The problem…
Fuel tank failure on F450 and F550 ford chassis. We have 2 F450 and 4 F550 buses with factory installed fuel tanks. The f550s have been replaced and are failing the second and third time with no recognition continued problem from ford. One of our f450s failed today. Same problem. The problem appears to failure of the internal coating in the tank. All failures are the same. I believe the cause IS improper application of the coating or the wrong coating IS being used. I'm sure we are not the only company in the us to experience this problem. The cost to replace the tank IS approximately $2000. *jb
- Engine and engine cooling › Engine
2002 ford F550 engine caught on fire. *ts *jb
- Fuel system, other › Storage · Suspension › Rear › Springs › Air suspension system
Bracket suspension failure allows rear end to shift over 6 - 8 inches puncturing the fuel tank and rendering the vehicle motionless.
- Electrical system · Engine and engine cooling › Engine · Service brakes, hydraulic · Steering · Wheels
2002 ford F550 has problems with oil leaks, steering, electrical shorts, brake and wheels fell off.*mr the vehicle also consumed excessive amounts of oil. *nm
- Electrical system › Alternator/generator/regulator
Myself and 3 other businesses in my area own ford f350s and f 550S all of us had alternators go bad on them at 40,000 and below miles. Seems like a big coincidence. Calling all parts stores and ford dealers we were told they were out of stock and they were getting all kinds of calls for them. *nm
- Engine and engine cooling
The vehicles engine had a hole in it. the vehicle was taken to the dealer who indicated that the oil looked bad. the consumer indicated that coolant had been leaking into the crankcase. the mechanic stated that he would void the remainder of the consumer's warranty. he then called the manufacture and they stated that they would support their dealer. *nlm
- Tires › Tread/belt
The front passenger tire experienced tread separation, which caused a tire blow out.*jb *ts
- Structure › Frame and members
Consumer states of having problems with the frame cracked all the way from the passenger side to all the way to the back shock. Dealer was contacted. ts
- Engine and engine cooling › Cooling system › Fan
The fan belt has failed (6) different times at highway speed with a/c on.dealer has thrown there hands up and the can,t repair problem .truck has been there many times and has not been repaired . When belt snaps in (two ) I have no steering or brakes .
Defect investigations
NHTSA’s Office of Defects Investigation opened these reviews into vehicles including this one.
- Engine stalling
In a december 3, 2007 letter, ford advised nhtsa that it will conduct a safety recall to replace the cam position sensor (cps) in approximately 1.2 million subject vehicles to address reports of engine stalling.a new design cps with improved performance and durability will be installed as a remedy.owner notifications…
In a december 3, 2007 letter, ford advised nhtsa that it will conduct a safety recall to replace the cam position sensor (cps) in approximately 1.2 million subject vehicles to address reports of engine stalling.a new design cps with improved performance and durability will be installed as a remedy.owner notifications will begin in december 2007. The subject vehicles are durable, full-sized, medium duty trucks commonly used for commercial purposes, rescue/emergency response, and commercial or recreational towing.cps failure IS comparable to unexpectedly turning the key off since the signal it produces IS vital to the electronic engine control system.cps signal loss terminates fuel injection resulting in an engine stall.once stalled, the engine may restart right away, or may restart after a delay (typically 5 to 10 minutes), or may not restart at all.in addition to exposing the driver and other motorists to crash risk due to loss of motive power or vehicle disablement, engine stalling also effects the power assisted steering and braking. Through consumer interviews, odi determined that cps failures occurred without any form of warning, at any vehicle speed (50% at highway speeds), and under any driving condition, such as accelerating.consumers reported that about a third of the vehicles failed to restart, with another third reporting delayed restarting.half the vehicles that did restart experienced another stall on the same or a subsequent drive cycle (before cps replacement) re-exposing those consumers to the risks associated with a stalling event.in their voq reports, half of the odi complainants described difficulty controlling the vehicle due to lose of power assist systems, especially those who were towing at the time of the incident. The one alleged injury incident occurred in an intersection when a subject vehicle stalled while turning across oncoming lanes of traffic.although unsubstantiated, the complainant alleged an injury to a child occupant during odi's interview.the other crash allegations mostly involved low speed, loss of control incidents often caused by lack of power assist; no injuries are reported in these incidents, and property damage, if any, was minimal.consumers also reported other incidents with significant safety risks, such as disablement in a lane or on a shoulder of a high-speed roadway or interstate, or extended disablement in remote areas during severe weather conditions. The population above IS ford's estimate of the 1.4 million subject vehicles produced that are currently registered.the ford complaint and warranty counts noted above are current as of ford's last submission dated june 21, 2007; they do not include F-450, F-550, or econoline counts as these products were not formally within scope of the investigation when failure information was requested.warranty data analysis indicates that about half the claims involved a stall while driving event ( ford's assessment) and that poor cps durability was a longstanding concern.ford reported that the new cps design should meet or exceed their 10 year, 150K mile life expectancy design requirement.
- Engine compartment fires
Ea05-005 IS closed with ford?s actions in recalls 05v-017, 05v-388, and 06v-286, recalling approximately 6.7 million vehicles equipped with texas instruments speed control deactivation switches (scds).the brake systems in these recalled vehicles generate a vacuum that can potentially cause the scds to fail and, in…
Ea05-005 IS closed with ford?s actions in recalls 05v-017, 05v-388, and 06v-286, recalling approximately 6.7 million vehicles equipped with texas instruments speed control deactivation switches (scds).the brake systems in these recalled vehicles generate a vacuum that can potentially cause the scds to fail and, in certain switch installation orientations, catch fire.ford IS also including the entire population of 1998 explorers.ford has informed odi that testing to determine the cause of failures in the 1998 explorers will continue after this investigation IS closed.odi believes that the vehicles exhibiting the factors causing scds failure described in this report correlate well with the observed failure rates on these vehicles by model and model year.the closing of this investigation does not constitute a finding by nhtsa that a safety-related defect does not exist in the non-recalled vehicles manufactured with scds that are not included in ford?s recalls.odi will continue to monitor the non-recalled population for incidence of engine compartment fires.the agency reserves the right to take further action if warranted by the circumstances.see attached closing report for details.
- Accelerator pedal sensor (etc)
Failure counts from odi?s analysis are stated above; see the additional problem experience discussion in the summary report.ford data contained duplicative reports for 4 odi complaints and 1 crash.three crashes were allegedly due to intermittent operation of the electronic throttle control (etc) pedal, one crash…
Failure counts from odi?s analysis are stated above; see the additional problem experience discussion in the summary report.ford data contained duplicative reports for 4 odi complaints and 1 crash.three crashes were allegedly due to intermittent operation of the electronic throttle control (etc) pedal, one crash occurred when an etc disabled vehicle was struck by another motorist, one report contained no detail.the injuries were minor.an issue involving fixed etc pedals was investigated also, however failure reports and populations are not shown above; see summary report for detail.although ford has used etc based throttle control systems for many years, the pap feature was new for my 2002.the subject etc sensor produces two output signals which the engine management system (ems) utilizes TO:1) determine fueling requirements; and 2) perform sensor diagnostics.one signal IS linearly proportional to throttle pedal position; the second IS a digital signal.by design, the detection of a sensor fault results in the engine returning to (or remaining at) the idle state.ford identified a defect in the pap etc sensor which prematurely affected an output signal; the migration of internal sensor lubricant caused a loss of proportional signal.the failure mechanism IS progressive and as the sensor deteriorates, the ems will detect a fault, store a fault code, illuminate a warning lamp, and the engine may remain at/return to idle.in the early stages, normal operation can be regained by pedal re-application.the failure progresses until the engine remains at idle.the engine does not stall, power assisted steering and braking systems are unaffected. Ford corrected the etc sensor defect and conducted field service action (fsa) 03b03 to replace etc pedals, addressing 50% of vehicles.at agency request to improve completion rate, ford extended fsa 03b03 for 6 months.based on odi's analysis of available data, ford's action has appropriately resolved the etc sensor proplem in the subject vehicles.the closing of the investigation does not constitute a finding by nhtsa that a safety-related defect does not exist, and should not be considered as having any precedential value or effect binding the agency in future defect investigations. See the attached summary report for additional information.
Service bulletins
Technical service bulletins and other communications the manufacturer sent dealers about this vehicle. Ask a dealer for the full document by its number.
- 10171326This SKU is a Spare Tire Hoist. Test results identified that the pull force parameter was not within specification, as a precautionary measure unsold inventory was requested to be returned for testing and containment. We don't have evidence that these test results have contributed to a product failure.
- 10171325This SKU is a Spare Tire Hoist. Test results identified that the pull force parameter was not within specification, as a precautionary measure unsold inventory was requested to be returned for testing and containment. We don't have evidence that these test results have contributed to a product failure.
- 10165713Some 2002-2008 F-Super Duty, F-150 and Mark LT vehicles may exhibit concern during or after programing the VSM. The programming may fail or vehicle symptoms such as inoperative door locks, dome lamps, door ajar indicators or auto lamps may occur after successful programing. To ensure the VSM is configured correctly, use the Integrated Diagnostic System (IDS) scan tool and select the blue ball and socket icon in the upper left corner. Select the utility knife in the bottom left corner. Select Update/Special Function and enter 53061 in the blue box then press the tick mark. The screen will go back to the system utilities page. Navigate to the toolbox tab and run the Programmable Module Installation (PMI) on the VSM. The procedure will prompt you to manually enter the as-built into the VSM. Obtain the as-built data from PTS > OASIS > As-Built.
- 10055648Ford: the restraint control module (rcm) when using vcm II, would have an error code 35 and diagnostic trouble code (dtc) b1035, and difficulty attempting programmable module installation (pmi). Model 2001-2004 f-super duty.
- 100236531999-2008 f250-f550 super duty 4X4 with electronic shift transfer case not engaging 4X4.
- 10018067Vacuum pump inoperative or runs continuously - climate control defaults to defrost mode.
- 10018054Service kit available for wiper motor wiring.
- 10017865Headlight adjustment - chassis cab incomplete vehicles.
- 10014138Safety belt retraction speed.
- 10014086General (pcm) power train control module programming procedures.
- 10014083Memontary return to idle during aggressive acceleration - diagnostic trouble code (dtc) p0123.
- 10013402Drive away shudder or vibration.
- 10013316A cold weather reverse engagement stall.
- 10013116Malfunction indicator lamp (mil) illuminated - system lean diagnostic trouble codes (dtc's) - service tips. Various models including 2004 f-series.
- 10013110Front hubs not engaging, not staying engaged and/or unlocking.
- 10013071Loud squealing noise from the engine area when the engine fan clutch IS under load while operated in hot dusty climates. Vehicles equipped with a 7.3L engine.
- 10012965Service tips before arc welding on the frame or body of a unit.
- 10010734Vacuum pump inoperative or runs continuously - climate control defaults to defrost. Oasis. To also include 2005 super duty f-series, excursion, and f650/750.
- 10010731Multiple vehicles - fuel level indication concerns - service tip. Various models including 2005 super duty f-series, excursion, expedition, explorer, mountaineer and aviator.
- 10008574Transfer case shift issues on vehicles with an electronic shift on the fly (esof) transfer case.
- 10008571Manual transmission fluid leak.
- 10008556Door ajar light working improperly after vehicle security module replacement.
- 10008334Engine-light tick or rattle type noise from engine after cold start.
- 10008310Engine-cylinder head deck leak-4.6 and 5.4L engines-new service-only gasket and cylinder head kits availability.
- 10008288Low power, poor fuel economy, fuel gelling cold, excessive white smoke cold, or hard start. This oasis updates previous oasis dated 12/01/03.
- 10008201Warning indicators-parking aid-reverse sensing system (rss) and forward sensing system (fss)-false activation of warning tone-service tips. Update.
- 10008166Fuel signal to instrument cluster service tip.
- 10008134Malfunction indicator lamp (mil) on with diagnostic trouble codes p0603 (powertrain control module keep alive memory error) or p0605 ( powertrain control module read only memory error).
- 10008119Oil/dust film at cac connections.
- 10007395Air bag light on with diagnostic trouble code (dtc) b1871 or b1935 following ecs/rcm replacement.
- 10004881Accessory drive belt squealing noise from the engine area when the engine fan clutch IS engaged while operated in hot dusty climates. Various models including 2003 f450/550.
- 10004025Steering wheel fight after riding over bumps/ruts. 2003, 2004 F450 and F550 models included.
- 10002783Rough idle and/or hesitation when acclerating on certain super duty vehicles equipped with a 5.4L or 6.8L engine.
- 637601Some vehicles built from 12/01/2001 to 02/08/2002 may exhibit a broken door handle rivet.
- 637591Some vehicles may exhibit steering wheel clear view condition.
- 637569Some vehicles equipped with lpg engine may exhibit the two fuel gauges displaying different fuel levels.
- 637563Some vehicles may exhibit one or both headlamps cracked at the front side of the headlamp lens area.
- 637537Some vehicles may exhibit inoperative power mirrors.
- 637517Some vehicles equipped with a 7.3L di, 4r100 transmission and built before december 10, 2001 may remain in 2ND gear with the gear shift lever in the first gear position.
- 636322Certain super duty vehicles equipped with lpg engine may exhibit a dead battery condition after leaving the vehicle parked for 2 or 3 days.
Every Ford F-550 SD model year
Bars are owner complaints, dots mark years with recalls. Select a year to open its report.