Summary
The Ford F-650 has 24 recalls spanning 1999 through 2022, with the most serious recent issue affecting 2021-2022 models equipped with the 7.3L gas engine, where the high-pressure fuel pump can fail due to biodiesel deposits, causing a sudden loss of drive power.
On 2021 models with the 7.3L gas engine, a transmission oil cooler line can contact the air conditioning compressor pulley, wear through, and leak fluid onto hot engine components, raising the risk of an engine compartment fire. That same model year also has a recall for missing underbody heat shields on 7.3L gas-engine trucks, where the cabin floor and seat bolt areas can become hot enough to cause burns. The 2017 model has a gear shift cable clip that may not seat fully, allowing the transmission to remain out of park even after the driver moves the shifter to park and removes the key, which can lead to unexpected rollaway.
On 2016 models with air brakes and rear air suspension, brake air lines can chafe against the rear axle housing over time, eventually leaking and triggering unintended parking brake application. The 2015 model has a parking brake connector clip that can fracture when the lever is applied, leaving the parking brake unable to hold the vehicle.
The 2012 model year has a windshield bonding issue on early-production trucks where the glass can separate from the cab structure. Going back to 2011, there are three brake-related issues: anti-lock relay valves in extremely cold conditions can leak internally, causing unintended brake application that overheats the brakes and can start a fire; separately, the anti-lock brake module on some 2011 trucks may not illuminate a trailer ABS fault warning lamp; and a steering drag link arm fastener may not have been torqued adequately during assembly, allowing the drag link to disconnect and leave the driver without steering.
The 2010 model has front and rear axle S-cam lubrication tubes that may have been assembled without grease, causing the brake to stick in the applied position and overheat. On 2009-2011 trucks built for a specific commercial outfitter, a battery separator can overheat and cause a fire. The 2008 model has a similar fire risk from a misoriented battery cable lug on a small run of specialty-built trucks.
The 2007 model has a rear drive axle housing that can crack and eventually allow the hub, axle shaft, and wheel assembly to separate from the vehicle. The 2005 model has a parking brake anchor bolt that can fail prematurely, leaving the parking brake inoperative without warning. The 2001 model has misrouted trailer brake air lines that can reduce or eliminate trailer brake effectiveness, and a separate anti-lock brake issue where chafed wheel speed sensor wiring can trigger unwanted anti-lock activation at low speeds and extend stopping distances.
Earlier production covers several issues: 2000 models have misrouted trailer air brake lines that compromise trailer brake function, a tie rod ball socket that can wear prematurely and cause partial loss of right front wheel control, and a compliance issue with the park brake warning lamp circuit. The 1999 model has two steering-related issues where tie rod and drag link ball studs can wear and separate from their sockets, and a park pawl interference problem on trucks with Allison 1000 or 2400 series transmissions that can prevent the transmission from locking in park and allow the vehicle to roll.
