2020 Ford F-550

The Office of Defect Investigations (ODI) has received 27 complaints alleging diesel fuel leaks due to a fracture in the secondary fuel filter housing in model year (MY) 2015-2021 Ford Motor Company (Ford) F-250, 350, 450, and 550 Super Duty vehicles equipped with 6.7L diesel engines. Of these complaints, 12 describe an engine compartment fire. The proximity of the secondary fuel filter to high heat sources creates a potential for autoignition thermal events and fires. ODI has contacted the vehicle manufacturer, Ford, and the filter manufacturer, Allevard Sogefi USA (Sogefi), and learned that the low-pressure fuel system is capable of a maximum operating pressure of 8.5 Bar, while the secondary fuel filter is only tested to seven (7) Bar during the manufacturing process. Additionally, changes starting in 2022 by both Ford and Sogefi align with a lack of similar complaints on MY 2022 and newer vehicles. ODI is opening this Preliminary Evaluation (PE) to evaluate the severity of the potential problem and to fully assess the potential safety-related problems. To review the ODI reports cited in the Opening Resume ODI Report Identification Number document, go to NHTSA.gov.

The contact owns a 2020 Ford F-550. The contact stated that while the vehicle was parked, it was discovered that there was metal deposits inside the system causing the fuel pump failure. The contact associated the failure with NHTSA Campaign Number: 24V957000 (Fuel System, Diesel). The dealer was contacted but failed to retrieve the correct diagnostic trouble codes related to the recall. The vehicle was not repaired. The manufacturer was made aware of the failure. The failure mileage was approximately 150,000.

NHTSA ID

11753603

Incident

Jan 15, 2026

Mileage

150,000 mi

I had my truck serviced, engine oil and fuel filters replaced, I picked up truck and while driving home, engine loss of power came on screen, truck then stalled, I observed smoke coming from under the hood, I exited vehicle to try and open hood, but flames were already present, I called 911 fire department came and put fire out. truck is a total loss. Fire Capt observed that fire seem to have started near the fuel filter housing, I was fortunate to escape the cab along with my dog, I have read several reports about filter housing leaking and starting fires, my brother inlaw, actually had the same issue, filter split causing fuel to leak, but fortunately he had just started the truck and was not driving very long before he smelled the fuel and was able to shut down the engine before it got hot and repolace the faulty filter housing.

NHTSA ID

11730539

Incident

Apr 1, 2026

The contact owns a 2020 Ford F-550. The contact stated that while driving at 20 MPH, the fuel injector became inoperable. The check engine warning light became illuminated. The vehicle was taken to the local dealer, where it was diagnosed, and determined that the fuel injectors needed to be replaced. The vehicle was repaired. The manufacturer was contacted and confirmed that the part to repair the vehicle under NHTSA Campaign Number: 24V957000 (Fuel System, Diesel) was on back order and that a second notification would be forwarded once parts became available. The failure mileage was approximately 85,172.

NHTSA ID

11728765

Incident

Nov 26, 2025

Mileage

85,172 mi

The contact owns a 2020 Ford F-550. The contact received notification of NHTSA Campaign Number: 24V957000 (Fuel System, Diesel); however, the part to do the recall repair was not yet available. The local dealer was contacted and confirmed that the remedy was not available. The contact stated that the manufacturer had exceeded a reasonable amount of time for the recall repair. The manufacturer was made aware of the issue. The contact had not experienced a failure.

NHTSA ID

11707907

Incident

Dec 30, 2025

At ~93,000 miles, my 2020 Ford F-550 (7.3L “Godzilla” V8) suffered catastrophic engine failure due to a roller lifter bearing failure, causing internal valvetrain damage and requiring full engine replacement. Ford dealer stated they recommended 90% coverage of the repair under goodwill through corporate, but later reduced coverage to 40% without explanation. After repairs, Ford corporate recommended a 3-year/36,000-mile PremiumCare warranty, then rescinded it a week later and offered only free oil changes. The 7.3L engine in my truck shares the same design as the F-53/F-59 motorhome chassis, which have multiple Technical Service Bulletins (TSBs) for lifter bearing failure, overheating of cylinders #2–3, and low oil pressure at idle. My vehicle shows identical symptoms but was excluded from those VIN ranges, suggesting Ford is segmenting related defects to limit recall exposure. Inspection revealed a cracked and arcing spark-plug wire on cylinder #2, matching the motorhome TSB’s overheating issue. This arcing poses a fire risk and likely contributed to localized heat and mechanical failure. The truck was often driven in Eco Mode, which holds low RPMs under load. This can increase cylinder pressure, reduce oil flow, and exacerbate heat in cylinders #2–3—factors that align with the failure pattern. This combination of design-related overheating, lifter bearing failure, oil-pressure fluctuation, and spark-wire arcing presents a clear safety hazard. Engine stall or fire could occur under towing or heavy-load conditions. NHTSA investigation is warranted into Ford’s 7.3L Godzilla engine design and VIN-exclusion practices.

NHTSA ID

11692097

Incident

Aug 8, 2025

The contact owns a 2020 Ford F-550. The contact stated that while starting the vehicle, the vehicle unintentionally rolled away while the transmission was in park(P). No warning light was illuminated. Additionally, the vehicle jerked while driving uphill. The vehicle also jerked violently while downshifting from third to second gear. The vehicle was taken to the dealer, who determined that the transmission needed to be replaced. The vehicle was not repaired. The contact related the failure to NHTSA Campaign Number: 22V256000 (Power Train); however, the VIN was not included in the recall. The manufacturer was made aware of the failure and advised the contact to file a complaint with the NHTSA Hotline. The failure mileage was approximately 100,000.

NHTSA ID

11661025

Incident

May 12, 2025

Mileage

100,000 mi

There was a recall on this veh. over a year ago and they still do not have the parts to repair it. My fuel milage went from 13.8 down to 9.6 and still going down. I have called Ford about this and they say they are still waiting on parts. I reminded them it has been over a year now and should have had the parts in a long time ago.

NHTSA ID

11657747

Incident

Apr 30, 2025

The contact owns a 2020 Ford F-550. The contact received notification of NHTSA Campaign Number: 24V957000 (FUEL SYSTEM, DIESEL); however, the part to do the recall repair was not yet available. The local dealer was contacted. The contact stated that the manufacturer had exceeded a reasonable amount of time for the recall repair. The manufacturer was made aware of the issue. The contact had experienced a failure. VIN tool confirms parts not available. The contact stated that while driving on a main road at 35 MPH a message displayed on the instrument panel which stated "reduced engine power" the contact proceeded to enter into a parking lot where the vehicle was parked, and left idle for a few minutes before attempting to restart, however the engine would start back up again. The vehicle was towed to an independent mechanic where it was diagnosed and the contact was advised that the fuel pump had failed and that it would need to be replaced by a Ford Dealership, and upon the vehicle arriving at Ford it was diagnosed a second time where it was confirmed that the failure originated from fuel pump failure, and that entire fuel system would have to be replaced. The vehicle was not repaired. The approximate failure mileage was 38,239.

NHTSA ID

11650274

Incident

Sep 24, 2024

Mileage

38,239 mi

Certain 2017-2025 F-450 – F-600 Chassis Cab Upfitted with an Aerial Bucket Frame Rail Crack

The Service Awareness Newsletter is an informal communication that contains information that may not be presently available in a TSB, SSM, GSB, or other electronic communication. This article includes information on warranty, technical service tips and other service information.

Certain 2017 through 2020 Model Year F550 Equipped with Payload Plus Upgrade Package Frame Rail Crack Program Terms: Program will be extended for an additional year; Urgency/Expiration Date: Program will be extended for an additional year Owner Refunds: Refunds have been extended to December 31, 2022, for owner paid repairs completed prior to owner notification date

Certain 2017 through 2020 Model Year F550 Equipped with Payload Plus Upgrade Package Frame Rail Crack REASON FOR THIS SUPPLEMENT • Technical Instructions: Updated to clarify amount of use for Rotobroach cutter.• Attachment V: Updated list of trucks that will not require bracket installation.

Certain 2017 through 2020 Model Year F550 Equipped with Payload Plus Upgrade Package ;Frame Rail Crack In some of the affected vehicles certain second unit body (SUB) upfits could cause stress points on the frame rail. Over time this stress could cause a crack in the frame rail behind the cab.

All of the affected vehicles were built with front spring and front gross axle weight rating (FGAWR) below the customer expected value. The marketing Order Guide stated that on units equipped with Ambulance & Wrecker packages, customers would get up to 7000 lb front spring FGAWR. The front coil springs were built to match the FGAWR labels on these units. The customer did not receive the front coil spring capability they were expecting based on the data in the marketing Order Guide and their reserve capacity might be lower than expected.