2002 Ford F-550 SD Fuel system Problems
- Complaints
- 10about this part
- Share
- 45%of 22 total for the year
- Median mileage
- 62,754miles
- Trend
- Not enough dataFewer than 15 complaints, too few for a reliable trend.
NHTSA recorded 10 complaints about the fuel system of the 2002 Ford F-550 SD, 45% of the 22 complaints for this model year. Where a mileage was given, the median is 62,754 miles.
Fewer than 15 complaints name this part, so treat the figures as a rough indication only.
Example complaints
Selected from NHTSA records; personal details are removed. They are consumer reports, not findings.
“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.”
NHTSA complaint #10255096, filed 2009-01, 36,000 miles“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.”
NHTSA complaint #10156721, filed 2006-05, 65,000 miles“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.”
NHTSA complaint #10336451, filed 2010-06, 142,000 miles“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. Updated 10/04/06.”
NHTSA complaint #10159757, filed 2006-06, 108,000 miles“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.”
NHTSA complaint #10266445, filed 2009-04, 108,280 milesFuel system: other model years
| Year | Complaints | Share of year |
|---|---|---|
| 2022 | 1 | 11% |
| 2021 | 10 | 77% |
| 2015 | 4 | 36% |
| 2014 | 2 | 22% |
| 2008 | 4 | 15% |
| 2007 | 10 | 43% |
| 2006 | 36 | 82% |
| 2005 | 20 | 63% |
| 2004 | 26 | 53% |
| 2003 | 19 | 58% |
| 2002 | 10 | 45% |
| 2001 | 13 | 45% |
| 2000 | 7 | 10% |
| 1999 | 5 | 8% |
Other parts of the 2002 Ford F-550 SD
4 complaintsBrakes
3 complaintsElectrical system
3 complaintsSteering
2 complaintsSuspension
2 complaintsTires
2 complaintsEngine
1 complaintsExterior lighting
1 complaintsBody and structure
1 complaintsTransmission and drivetrain
1 complaintsWheels
1 complaints
← All problems reported for the 2002 Ford F-550 SD
About this data. Data from NHTSA (ODI) complaints, recalls, TSBs and investigations, updated Oct 29, 2026. Complaints are unverified consumer reports and may be duplicated or inaccurate.
To check a specific vehicle for open recalls, use its VIN at nhtsa.gov/recalls. Methodology