The 2004 Ford F-550 Sd has 2 NHTSA recall campaigns affecting an estimated 206,819 vehicles. Recall repairs are always free at any authorized dealer. Owners have filed 67 complaints with NHTSA, most often about the fuel system, diesel. Last updated July 5, 2026.
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…
Consequence
NON-FUNCTIONING LIGHTS COULD INCREASE THE RISK OF A CRASH.
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.
CERTAIN PICKUP TRUCKS, SPORT UTILITY VEHICLES AND VANS EQUIPPED WITH 6.0L DIESEL ENGINES MAY EXPERIENCE STALLING WITHOUT WARNING WHILE DRIVING AND MAY OR MAY NOT RESTART.
Consequence
SHOULD THE ENGINE STALL, A VEHICLE CRASH COULD OCCUR.
Remedy
DEALERS WILL UPGRADE THE FUEL INJECTION CONTROL MODULE (FICM) WIRE HARNESS OR REPLACED, AND/OR HAVE A NEW INJECTION CONTROL PRESSURE (ICP)) SENSOR CONNECTOR INSTALLED FREE OF CHARGE. THE RECALL BEGAN ON JULY 22, 2005. OWNERS MAY CONTACT FORD AT 1-800-392-3673.
Complaints by component
FUEL SYSTEM, DIESEL
19
ENGINE AND ENGINE COOLING:ENGINE:DIESEL
8
3fires
ELECTRICAL SYSTEM
5
2fires
POWER TRAIN:AUTOMATIC TRANSMISSION
5
ELECTRICAL SYSTEM:WIRING
4
ENGINE AND ENGINE COOLING
3
ENGINE AND ENGINE COOLING:COOLING SYSTEM
2
ENGINE AND ENGINE COOLING:ENGINE
2
FUEL SYSTEM, DIESEL:STORAGE:TANK ASSEMBLY
2
FUEL SYSTEM, GASOLINE
2
Total complaints67
What owners report
Verbatim reports filed with NHTSA, lightly edited for readability and with personal
information removed.
“Tl* the contact owns a 2004 ford f-550 sd. While driving approximately 55 mph, the vehicle stalled without warning. The vehicle restarted; however, the failure recurred approximately one mile later. The vehicle did not restart and was towed to the contact's job. The vehicle was taken to the dealer…”
“Tl* the contact owns a 2004 ford f-550 super duty. While the link was in the air with a worker located in the bucket, the link fractured without warning. The worker's bucket came down with force causing injury to his head, back, and pelvic area. The worker received medical attention. The vehicle…”
“The truck in question is a 2004 ford f-550 diesel. Upon depressing gas pedal, truck stalled and no longer worked properly. Truck was towed to local ford dealer where it was determined that the fuel tank was suffering from rust inside the tank. Based on the work done, rust particles that formed…”
“The truck in question is a 2004 ford f-550 diesel. Upon depressing gas pedal, truck stalled and no longer worked properly. Truck was towed to local ford dealer where it was determined that the fuel tank was suffering from rust inside the tank. Based on the work done, rust particles that formed…”
“2004 f550 diesel. Consumer states vehicle has a faulty head-gasket *tgw the consumer stated the truck would only run for 20 minutes before it overheated. The consumer was informed it cost close to 10,000 to fix the truck. *jb”
“Tl* the contact owns a 2004 ford f-550 sd. While driving approximately 5 mph, the engine stalled without prior warning. The vehicle failed to restart and it was towed to an independent mechanic who stated the failure was contributed to the high pressure oil pump. The vehicle was repaired. The…”
“Vehicle (2004 diesel f550 truck) was traveling on I-405 during rush hour traffic when the vehicle stalled. Dealer says that the paint/laminate inside the fuel tank is corroding and pieces of debris are being fed into the fuel system causing sudden stalling of vehicle. No off-road diesel has ever…”
“Tl* the contact owns a 2004 ford f-550. The contact stated that the vehicle would not start. The dealer diagnosed that the fuel injector wire was melting on the engine. The vehicle was repaired and recurred. The manufacturer was notified, but denied any assistance with repairs. The failure mileage…”
Defect investigations
InvestigationEA05003 Opened 2005-02-15 · closed 2005-11-02
ENGINE STALLING
IN A JUNE 7, 2005 LETTER, FORD NOTIFIED ODI THAT IT WOULD BE CONDUCTING A SAFETY RECALL OF APPROXIMATELY 180,000 FORD F-SUPER DUTY, EXCURSION AND E-SERIES VEHICLES EQUIPPED WITH 6.0L DIESEL ENGINES TO CORRECT TWO WIRING RELATED CONDITIONS THAT COULD RESULT IN ENGINE STALL (NHTSA RECALL NO. 05V-270, FORD NO.…
InvestigationEA05003 Opened 2005-02-15 · closed 2005-11-02
ENGINE STALLING
IN A JUNE 7, 2005 LETTER, FORD NOTIFIED ODI THAT IT WOULD BE CONDUCTING A SAFETY RECALL OF APPROXIMATELY 180,000 FORD F-SUPER DUTY, EXCURSION AND E-SERIES VEHICLES EQUIPPED WITH 6.0L DIESEL ENGINES TO CORRECT TWO WIRING RELATED CONDITIONS THAT COULD RESULT IN ENGINE STALL (NHTSA RECALL NO. 05V-270, FORD NO.…
InvestigationEA05003 Opened 2005-02-15 · closed 2005-11-02
ENGINE STALLING
IN A JUNE 7, 2005 LETTER, FORD NOTIFIED ODI THAT IT WOULD BE CONDUCTING A SAFETY RECALL OF APPROXIMATELY 180,000 FORD F-SUPER DUTY, EXCURSION AND E-SERIES VEHICLES EQUIPPED WITH 6.0L DIESEL ENGINES TO CORRECT TWO WIRING RELATED CONDITIONS THAT COULD RESULT IN ENGINE STALL (NHTSA RECALL NO. 05V-270, FORD NO.…
Recall, complaint, and investigation records from official NHTSA datasets (FLAT_RCL,
FLAT_CMPL, FLAT_INV), synced weekly. Counts reflect NHTSA records for the 2004 Ford F-550 Sd as of
July 5, 2026. Complaint narratives are consumer-submitted and unverified. This page
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