NHTSA vehicle safety data

2002 Ford F-550 SD Recalls & Complaints

The 2002 Ford F-550 SD has 5 NHTSA recall campaigns and 22 owner complaints on file as of November 3, 2026. Recall repairs are usually free at an authorized Ford dealer.

NHTSA recall and complaint data for the 2002 Ford F-550 SD. Recall data is refreshed daily from NHTSA.

Pre-purchase inspection checklist → Reliability & 5-year cost forecast →

2002 Ford F-550 SD owner complaints

Owners have filed 22 complaints with NHTSA about the 2002 Ford F-550 SD, describing incidents dated February 20, 2002 to December 18, 2019.

Most-cited components

Fuel/Propulsion System 10 complaints
Engine 5 complaints
Electrical System 3 complaints
Service Brakes 3 complaints
Steering 2 complaints
Suspension 2 complaints

Of the 22 complaints on file, 3 report a fire; across all 22 complaints, owners report 1 injury (owner-reported, not verified by NHTSA).

Newest complaints

ODI #11301112 · Filed January 22, 2020
CONNECTOR #270B MELTED AT CENTRAL JUNCTION CONNECTOR. VEHICLE WAS BOTH IN MOTION AND PARKED
ODI #10588420 · Filed May 14, 2014
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…
ODI #10458366 · Filed May 17, 2012
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…

Read all 22 complaints

NHTSA defect investigations

NHTSA's investigations file lists the 2002 Ford F-550 SD in 3 investigations. A listed model year means only that an investigation names it; it says nothing about any particular vehicle. An open investigation is not a finding that a safety defect exists, and NHTSA can close one without a recall.

Engineering Analysis EA06-012: ENGINE STALLING
Closed December 7, 2007
- Recall 07V-553
Engineering Analysis EA05-005: ENGINE COMPARTMENT FIRES
Closed August 2, 2006
- Recall 05V-388
- Recall 06V-286
- Recall 07V-078
- Recall 07V-336
- Recall 07V-347
- Recall 07V-488
- and 1 more on the investigation page
Engineering Analysis EA04-006: ACCELERATOR PEDAL SENSOR (ETC)
Closed February 10, 2005

Open and recently closed NHTSA defect investigations

STEERING COLUMN MULTIFUNCTION SWITCH/FMVSS 108

NHTSA #11V352000 · Exterior Lighting — Tail Lights · NHTSA notice

Reported July 13, 2011 · FORD MOTOR COMPANY

Potentially affected: 26,715 vehicles

Ford campaign 11C18 · Owners notified August 15, 2011

Defect description

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 FOR FAILING TO COMPLY WITH THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 108, "LAMPS, REFLECTIVE DEVICES, AND ASSOCIATED EQUIPMENT." THE MULTI-FUNCTION SWITCH WAS SHIPPED WITH A SUBCOMPONENT (SLIDER) THAT MAY EXPERIENCE DEFORMATION. A MULTI-FUNCTION SWITCH WITH A DEFORMED SLIDER MAY MALFUNCTION CAUSING THE TURN SIGNAL, TAIL LIGHTS, HAZARD WARNING SIGNAL FLASHERS AND/OR BRAKE LIGHTS NOT TO ACTIVATE.

Safety consequence

NON-FUNCTIONING LIGHTS COULD INCREASE THE RISK OF A CRASH.

Manufacturer 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.

Notes

FORD'S SAFETY RECALL NO. 11C18.OWNERS MAY ALSO CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S VEHICLE SAFETY HOTLINE AT 1-888-327-4236 (TTY 1-800-424-9153), OR GO TO <A HREF=HTTP://WWW.SAFERCAR.GOV>HTTP://WWW.SAFERCAR.GOV</A> .

SPEED CONTROL DEACTIVATION SWITCH/OVERHEATS

NHTSA #09V399000 · Vehicle Speed Control · NHTSA notice

Reported October 13, 2009 · FORD MOTOR COMPANY

Potentially affected: 4,500,000 vehicles

Ford campaign 09S09 · Owners notified October 27, 2009 · Recall influenced by NHTSA's Office of Defects Investigation

Defect description

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 SCDS MAY LEAK INTERNALLY AND THEN OVERHEAT, SMOKE, OR BURN.

Safety consequence

A VEHICLE FIRE COULD OCCUR WITH OR WITHOUT THE ENGINE RUNNING.

Manufacturer 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.

Notes

FORD'S RECALL CAMPAIGN NUMBER IS 09S09.OWNERS MAY ALSO CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S VEHICLE SAFETY HOTLINE AT 1-888-327-4236 (TTY 1-800-424-9153), OR GO TO <A HREF=HTTP://WWW.SAFERCAR.GOV>HTTP://WWW.SAFERCAR.GOV</A> .

REPLACEMENT WHEEL HUB ASSEMBLIES

NHTSA #07E106000 · Wheels — Hub · NHTSA notice

Reported December 17, 2007 · FEDERAL-MOGUL CORPORATION

Potentially affected: 130,000 vehicles

Owners notified February 7, 2008

Defect description

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 LIGHT INDICATION, NOISE, AND/OR WHEEL SEPARATION.

Safety consequence

WHEEL SEPARATION CAN RESULT IN A VEHICLE CRASH.

Manufacturer 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.

Notes

THIS RECALL ONLY PERTAINS TO REPLACEMENT NATIONAL, CARQUEST WHEEL HUB ASSEMBLIES AND HAS NO RELATION TO ANY ORIGINAL EQUIPMENT INSTALLED ON VEHICLES MANUFACTURED BY GENERAL MOTORS OR FORD.CUSTOMERS MAY CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S VEHICLE SAFETY HOTLINE AT 1-888-327-4236 (TTY: 1-800-424-9153); OR GO TO HTTP://WWW.SAFERCAR.GOV.

CAMSHAFT POSITION SENSOR

NHTSA #07V553000 · Engine and Engine Cooling — Engine — Diesel · NHTSA notice

Reported December 5, 2007 · FORD MOTOR COMPANY

Potentially affected: 1,176,000 vehicles

Ford campaign 07S57 · Owners notified December 29, 2007 · Recall influenced by NHTSA's Office of Defects Investigation

Defect description

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.

Safety consequence

IN THE EVENT OF AN ENGINE STALL, A CRASH COULD RESULT WITHOUT WARNING.

Manufacturer 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.

Notes

FORD RECALL NO. 07S57.CUSTOMERS MAY ALSO CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S VEHICLE SAFETY HOTLINE AT 1-888-327-4236 (TTY 1-800-424-9153), OR GO TO HTTP://WWW.SAFERCAR.GOV.

SPEED CONTROL DEACTIVATION SWITCH/SUPPLEMENT

NHTSA #06V286000 · Vehicle Speed Control · NHTSA notice

Reported August 1, 2006 · FORD MOTOR COMPANY

Potentially affected: 1,200,000 vehicles

Ford campaign 05S28 · Owners notified August 7, 2006 · Recall influenced by NHTSA's Office of Defects Investigation

Defect description

ON CERTAIN TRUCKS EQUIPPED WITH SPEED CONTROL, GASOLINE OR NATURAL GAS ENGINES, THE SPEED CONTROL DEACTIVATION SWITCH MAY OVERHEAT.

Safety consequence

OVERHEATING COULD RESULT IN SMOKE OR BURN AND AN UNDERHOOD FIRE.

Manufacturer 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)

Notes

FORD RECALL NO. 05S28.CUSTOMERS MAY ALSO CONTACT THE NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION'S VEHICLE SAFETY HOTLINE AT 1-888-327-4236 (TTY 1-800-424-9153), OR GO TO HTTP://WWW.SAFERCAR.GOV.

try.vin has no NCAP crash-test rating on file for the 2002 Ford F-550 SD. NHTSA rates some vehicles by body style — pickups by cab, vans by roof height — so check nhtsa.gov/ratings.

22 owner complaints have been filed with NHTSA for the 2002 Ford F-550 SD.

Electrical System

ODI #11301112

Fire

Incident: December 18, 2019 · Filed: January 22, 2020

CONNECTOR #270B MELTED AT CENTRAL JUNCTION CONNECTOR. VEHICLE WAS BOTH IN MOTION AND PARKED

Engine

ODI #10588420

Fire 1 injury

Incident: May 6, 2014 · Filed: May 14, 2014

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.

Service Brakes, Hydraulic; Fuel System, Diesel; Exterior Lighting; Tires

ODI #10458366

Incident: May 1, 2012 · Filed: May 17, 2012

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

ODI #10438085

Incident: November 29, 2011 · Filed: December 2, 2011

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

ODI #10336451

Incident: June 11, 2010 · Filed: June 15, 2010

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

ODI #10293021

Incident: October 28, 2009 · Filed: November 20, 2009

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

ODI #10266445

Incident: April 1, 2008 · Filed: April 23, 2009

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

ODI #10255096

Incident: January 11, 2009 · Filed: January 14, 2009

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

ODI #10249665

Incident: October 28, 2008 · Filed: November 24, 2008

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

ODI #10242387

Incident: September 13, 2008 · Filed: September 16, 2008

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

Other Ford F-550 SD model years

Check your 2002 Ford F-550 SD VIN

Not every recall applies to every VIN in a given year. Enter the 17-character VIN from your Ford F-550 SD at nhtsa.gov/recalls to see whether your specific vehicle has an unrepaired recall.

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