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Ford F550 SD

2002–2006 only

106 classified complaints 1 recall

2002–2006 Ford F550 SD models have 106 classified complaints on record for these years specifically, plus 1 recall. The most common issue in this range is Tank, lines and filler, typically surfacing around 75,000 miles.

Computed directly from stored federal records for 2002–2006 model years only — not blended with the rest of this vehicle's production run. See the full Ford F550 SD report for every year combined.

Where this range fits

2002–2006

2007–2011

2012–2016

Complaints filed per 5-year model-year window — highlighted bars link to their own dedicated page.

What breaks, and when — 2002–2006 only

Tank, lines and filler · Fuel system 59 complaints

Median onset: 75,000 miles. 1.7% of these reported an injury, a death, or a crash with fire.

Tends to show up later than this model's other issues. · More common in older model years.

Injectors and high-pressure fuel system · Fuel system 10 complaints

Median onset: 64,127 miles.

Tends to show up later than this model's other issues. · More common in older model years. · Typical repair: $720–$2,150 nationally.

Stalling and no-start · Engine 6 complaints

Median onset: 53,000 miles.

More common in older model years.

Fuel pump and sending unit · Fuel system 4 complaints

Median onset: 74,145 miles.

Tends to show up later than this model's other issues. · More common in older model years. · Typical repair: $630–$1,700 nationally.

Head gasket and cylinder head · Engine 3 complaints

Median onset: 23,250 miles.

Tends to show up earlier than this model's other issues. · More common in older model years. · Typical repair: $1,620–$3,010 nationally.

Turbocharger and intercooler · Engine 3 complaints

Median onset: 34,519 miles.

More common in older model years. · Typical repair: $1,520–$2,820 nationally.

Tire wear and premature wear patterns · Wheels and tires 3 complaints

Median onset: 36,000 miles.

Body control and other modules · Electrical 3 complaints

Median onset: 27,544 miles.

Tends to show up earlier than this model's other issues. · More common in newer model years.

From owner-filed complaints to NHTSA, not independently verified. Federal mileage reporting on recent complaints is sparse — see how it works. Cost ranges are national estimates from book labor hours and parts pricing, not this vehicle's actual repair history — they don't account for your location or shop type.

Cost estimator: what will this one cost you?

Enter the car's year and mileage. See which known problems are due in your next 3 years, what each costs at your state's labor rates, which ones to ask the seller about, and routine maintenance to budget for.

Sources: NHTSA Office of Defects Investigation — complaints and recalls, scoped to 2002–2006 model years. See the full Ford F550 SD report for every year and full specs/safety data.