2020 Ford F-550 Problems

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.

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.

frame crack right behind cab. have two trucks with the same issue second vin ends in [XXX]. ford had a safety program 21B04 that expired which means they are aware of this issue and should issue a recall for it. ford has repeatedly refused to help with this issue. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

Ford Motor Company has had a known issue with the truck frames cracking on the F-550 chassis. They acknowledged it by doing a recall, which either replaced or repaired the chassis frame or installed reinforcement braces if no cracks were visible. The recall expired in September of 2023. In October 2023 we noticed a crack on the frame just outside the recall reinforcement brace that Ford-certified technicians installed. We found another in November (reinforcement brace installed) and another in January (with Ford's new and improved frame produced due to a recall issue). Ford has denied making the repairs since the original warranty expired, even though this was the same related issue. We have been dealing with Ford Motor Company since October in hopes of resolving the issue but they continue to give us any resolution. The problem has not only caused a burden on our workforce but also caused great safety concerns. With Ford avoiding responsibility, they are allowing trucks to operate daily on our highway system, which becomes a safety concern for not only the driver but for many other motorists. The problem existed, but the issue was not resolved, all we are asking is that they take responsibility for making the repairs and permanently resolving the issue for the safety of all motorists.

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.

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.

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.

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.

Ford Motor Company has had a known issue with the truck frames cracking on the F-550 chassis. They acknowledged it by doing a recall, which either replaced or repaired the chassis frame or installed reinforcement braces if no cracks were visible. The recall expired in September of 2023. In October 2023 we noticed a crack on the frame just outside the recall reinforcement brace that Ford-certified technicians installed. We found another in November (reinforcement brace installed) and another in January (with Ford's new and improved frame produced due to a recall issue). Ford has denied making the repairs since the original warranty expired, even though this was the same related issue. We have been dealing with Ford Motor Company since October in hopes of resolving the issue but they continue to give us any resolution. The problem has not only caused a burden on our workforce but also caused great safety concerns. With Ford avoiding responsibility, they are allowing trucks to operate daily on our highway system, which becomes a safety concern for not only the driver but for many other motorists. The problem existed, but the issue was not resolved, all we are asking is that they take responsibility for making the repairs and permanently resolving the issue for the safety of all motorists.

See attached document for complaint

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.

ELECTRONIC STABILITY CONTROL (ESC) LIGHT CAME ON AND STAYED ON DURING NORMAL, STRAIGHT AND LEVEL HIGHWAY DRIVING AT 60 MPH, INDICATING AN ESC SYSTEM MALFUNCTION. THE LIGHT CAME ON AFTER ABOUT 20 MILES OF HIGHWAY DRIVING AND REMAINED ON FOR THE REMAINING 12 MILES OF MY JOURNEY. AFTER BEING PARKED OVERNIGHT THE ESC LIGHT OPERATED NORMALLY WHEN THE ENGINE WAS RESTARTED WHILE PARKED.

The contact owns a 2020 Ford F-550. The contact received notification of NHTSA Campaign Number: 22V250000 (Visibility) however, the part to do the recall repair was unavailable. 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. Parts distribution disconnect.