Summary
The Ford F-550 SD has 14 recalls spanning 2006 through 2023, with the most serious being a fuel leak on 2021 diesel-equipped models where a flaw in the secondary fuel filter cap can develop into a pinhole, allowing diesel fuel to drip near ignition sources and raise the risk of fire.
Several other recalls also carry fire risk. On 2017–2019 SuperCrew Cab models with carpet flooring, sparks from a front seatbelt pretensioner deploying in a crash can ignite carpet or insulation inside the B-pillar area. On 2017 diesel models, a fuel conditioning module shield can detach and allow the drain valve to open, producing a fuel leak with the same fire potential. A separate cluster of recalls from 2009–2014 covers vehicles that were upfitted by various equipment companies and fitted with Muncie Power Products power take-off assemblies: in all of these, oil can leak from the PTO pressure switch onto a thermal blanket over the exhaust, creating a fire risk.
On the drivetrain side, 2017 F-550s can develop driveline vibration at highway speeds severe enough to fracture driveline components or the transmission itself, cutting drive power while moving. On 2015 models with 6.2L gasoline or 6.7L diesel engines and 6R140 transmissions, a transmission control error can cause the vehicle to actually be in reverse while the gear display reads drive, creating an unexpected movement hazard.
The 2021–2022 model years have a software error in the trailer brake control system, a carry-over from an earlier repair attempt that did not fully resolve the issue, which can leave a towed trailer's electric brakes non-functional and extend stopping distances considerably. The 2017 model year also has a door latch issue shared with 2015–2016 F-150s: cables can kink or latches can freeze after water intrusion, allowing doors to swing open while driving even when they appear latched.
The 2023 model year has a power window recall where a low-power reset in the door module can disable the anti-pinch function, meaning the window will not reverse if it contacts an obstruction while closing. Going back further, 2011–2015 models built with ambulance or fire engine preparation packages have a powertrain control issue that can trigger unexpected engine shutdowns. On 2006–2013 models that were modified by Farber Specialty Vehicles with Ricon wheelchair lifts, the lift platform side plates can crack and cause the platform to separate and drop against the lift door opening.
