2003 Ford E550 Problems

What owners report

Most complaints in this sample describe other 2003 Ford F-Series trucks, many with 6.0-liter diesel engines, rather than the E-550 specifically. The most common reports are engines that stall, shut off or lose power while driving, followed by airbags that did not deploy in crashes, low power linked to turbo charge hoses, diesel injector failures and tire sidewall or tread separation. Several stalls are tied to camshaft position sensor problems, and many owners describe the power loss as sudden and without warning.

1. 1
   Engine cooling

   Engine stalls, shuts off or loses power while driving

   • 26 complaints (39%)
   • median 14,400 mi at 1.3 yrs old (21 state mileage)
   • 1 mention a crash, fire or injury
   • filed 2003–2015

   Owners describe the engine shutting off or losing power without much warning, sometimes on the freeway, at stops, or while climbing a grade. Several connect it to a failed camshaft position sensor, and in some cases the engine restarted after shutting off. A separate report traces the power loss to tank lining that flaked and clogged the fuel lines, pump and filter. According to complaints, in some cases no fix was found and the truck was replaced with a newer engine version. Where mileage is recorded, reports range from under 1,000 miles to about 86,000 miles, with a cluster between about 35,000 and 49,000 miles.

   What to check: Ask whether the camshaft position sensor, ignition coils and fuel system parts have been checked or replaced, and whether any stall history is on record. On a test drive, check how the engine idles, restarts and responds to the throttle, and ask for any stored diagnostic trouble codes.

   2 excerpts from owner complaints in NHTSA records

   “I have a Ford 250 superduty with a 6.0l engine. Twice the engine quit, once when I was in heavy traffic on the interstate, needless to say it left me with limited bracking and once when I was coming to a stop. Both times I was able to start the engine. I found a recall on this problem #05s34 but it was only for years 2004 and 2005 models. I call and I was told to file a complaint and to give refferance #o5v270000 when fileing the complaint.”

   NHTSA complaint #10127835, filed 2005-07, 39,250 miles

   “No warning/symptom camshaft position sensor failed -10* outside with icy roads 7:00 pm moderate traffic on freeway engine shut down this is a 1ton pickup going 55 MPH with very little steering control with lack of power steering. My understanding this is a common occurrence with the Ford 7.3 diesel poor design this is also a dealer only part that cost $175.00 I was just glad I was able to get the vehicle on the side of the road and avoid an accident.”

   NHTSA complaint #10173793, filed 2006-11, 48,950 miles
2. 2
   Air bags

   Airbags did not deploy in crashes

   Mentioned in 5 of 56 sampled complaints

   Owners describe airbags that did not deploy, or did not operate as expected, in crashes that included rear-end, head-on and quarter-panel impacts. A report notes the passenger airbag switch was set to on, and the bag still did not deploy. Some describe injuries they attribute to the missing airbag, and some say the seat belt did not restrain them either. Recorded mileage runs from very low figures to about 50,000 miles.

   What to check: Ask the dealer to confirm the airbag system has no stored fault codes and that the passenger airbag switch and sensors were checked. During a test drive, check that the airbag warning light comes on at startup and then goes out, since a light that stays on can indicate a fault.

   2 excerpts from owner complaints in NHTSA records

   “Air bags failed to deploy in an accident. Woman pulled out in front of me and I hit her left front quarter panel. Her saturn and my f-150 were totaled at about 30 MPH. My air bags did not deploy nor did my seat belt hold. I sustained moderate facial and leg injuries. Had the bags deployed, I would be hurting a lot less!”

   NHTSA complaint #10140947, filed 2005-10, 47,000 miles

   “The passenger side airbag on our 2003 Ford ranger xlt failed to operate in such a manner, during a collision, to prevent a head injury to my wife. Neither the airbag nor the seat belt retarder kept her from striking her head on the rear view mirror and dislodging the mirror from the window.”

   NHTSA complaint #10047295, filed 2003-11, 10 miles
3. 3
   Engine cooling

   Low power and turbo charge-hose problems

   • 11 complaints (17%)
   • median 14,150 mi at 1.5 yrs old (8 state mileage, few)
   • 1 mention a crash, fire or injury
   • filed 2003–2007

   Owners describe power dropping after the hose between the turbo and the intercooler, or the cold air tube, came loose, sometimes with black smoke. Other reports describe weak power at low engine speeds, with a delay before power returns when pulling into traffic. A few say the hose kept coming loose or the turbo was replaced, and the fix did not last. Where mileage is recorded, these reports range from about 1,000 miles to about 41,500 miles, and some occur early in ownership.

   1 related service bulletin

   What to check: Ask whether the turbo hoses, clamps and cold air tube were inspected or upgraded, and whether any turbo or low-power service tip was applied. On a test drive, check for hesitation or weak power at low engine speeds when pulling away or climbing a hill.

   2 excerpts from owner complaints in NHTSA records

   “Turbo charger hose keeps blowing off pull a horse trailer w/f350 diesel 2003 Ford & on nov. 19,2003 I got my right hand burned trying to put turbo hose back on, to get truck & trailer off road Ford dealer would not come out. Ilgot to a deler in gerstown ,maryland & got new hose & clamps after being on the road for over 12 hours to go 175 miles. …”

   NHTSA complaint #10100532, filed 2004-11, 10,000 miles

   “The cold air tube to the turbo blew loose on a uphill pull. I experienced a severe loss of power and lots of black smoke. I am pulling a 5th wheel trailer and had this been on a mountain pass I feel I could have lost control, thus resulting in a deadly accident. Country Ford at las vegas re-attached the hose b ut gave no guarantee that it would not happen again. I believe Ford should re-engineer the tube with a more severe flange that could be better secured.”

   NHTSA complaint #10141352, filed 2005-10, 38,500 miles
4. 4
   Fuel system

   Injector failures and fuel leaking into the oil

   • 7 complaints (11%)
   • median 5,700 mi at 0.9 yrs old (5 state mileage, few)
   • filed 2003–2006

   Owners describe diesel injectors that failed, leaked or broke, sometimes with fuel getting into the oil or filling the oil pan. A report links a leak to a seized turbocharger, and some describe a loss of power in traffic with no warning. Some describe further injector failures after the warranty expired, and some say the same symptom came back after a repair. Where mileage is recorded, these reports range from about 2,500 miles to about 10,700 miles, and some failures came after the warranty expired.

   What to check: Ask whether the injectors were replaced, whether the oil was checked for fuel, and request the repair records for any injector work. On a test drive, check for rough running or sudden power loss under load.

   2 excerpts from owner complaints in NHTSA records

   “Purchased a new 2003 Ford f-350 super duty with the 6.0 diesel on sept.9-15. At 10,000 miles troubles began. At 20,000 2 injectors failed. Between then and the warranty expiration, another 12 failed. Since then, another 16 have failed. From day one, I've tried to get relief from the dealer and Ford. The dealer has filed for bankruptcy and Ford doesn't care.”

   NHTSA complaint #10146540, filed 2005-12, 10,708 miles

   “On labor day weekend 2003 a fuel injector failed and filled the oil pan with fuel. The engine shut down and I had to be towed in. It took Ford road service 3 hrs to find a tow service. The truck had 5700 miles on it. Now on march 20, 2004 the truck will be going back to the dealer with what acts like the same problem. If Ford knows they have a problem with a certain batch of injectors they should replace them all.”

   NHTSA complaint #10062698, filed 2004-03, 5,700 miles
5. 5
   Tires

   Tire sidewall or tread separation

   • 6 complaints (9%)
   • median 53,000 mi at 3.0 yrs old (3 state mileage, few)
   • 1 mention a crash, fire or injury
   • filed 2003–2007

   Owners describe tires whose sidewalls cracked or separated, or whose tread separated from the sidewall, sometimes ending in a blowout or a loss of control. Some say the same damage appeared on several tires at once, and others noticed the separation before the tire failed. A report describes a trailer tire that blew out while being towed. Where mileage is recorded, these tire failures fall between about 42,000 and 53,000 miles.

   What to check: Ask whether the tires were inspected for sidewall cracks or separation and whether any replacement was done under a tire warranty. On a used-vehicle check, look for cracks, bulges or lifted lettering on the sidewalls, since owners describe separation that was visible before the failure.

   2 excerpts from owner complaints in NHTSA records

   “I have had two carlisle tire failures on my weekend warrior 3705 slc 5th wheel trialer. On the first one I noticed the tread separating from the side wall before it actually blew out. Carlisle replaced it at10% cost to me. The second blew out while I was pulling. They are 22575r15's.”

   NHTSA complaint #10037003, filed 2003-09

   “Firestone steeltex lt265/75/r16 r4s tires - sidewalls are separated at the raised letters. This issue was identicle on all 4 tires. Tires were original equipment on a Ford excursion - 2003 2wd diesel. Tires currently have 48000 miles with good tread remaining. I can lift up the lettering and see the sidewall fibers on the sidewalls. This vehicle is never used off road and specifically used for long distance travel. I am going to replace these tires tomorrow, 3/21/2007. …”

   NHTSA complaint #10185672, filed 2007-03

Buying note. For a 2003 Ford truck, ask whether the camshaft position sensor, turbo hoses and injectors were inspected or replaced, and whether the airbags and tires were checked before buying. Some owners say the stalls, power loss or injector problems returned after repairs, so review the repair history and consider a pre-purchase inspection.

Summary written with AI from a sample of 56 NHTSA complaints for this model year (picked at random, with complaints that state a mileage and recent ones taken first), then checked automatically against the source records. Where a problem shows a complaint count, every complaint for this model year was matched with fixed keyword rules (written with AI and tested against the sample), and the mileage, age and repair figures are calculated from those complaints; owners' figures are as stated, not verified. Other counts refer to the sample. The excerpts come from NHTSA's public complaint records and are unverified; capitalisation is normalised, NHTSA staff notes are removed, and shortened text ends with “…”. Something wrong? Request a correction.