2002 Ford F-550 SD problems & reliability
22 owner complaints filed with NHTSA for the 2002 Ford F-550 SD, alongside 4 safety recall campaigns. Last verified Aug 7, 2026. Complaints are unverified reports submitted by owners to the federal Office of Defects Investigation.
Each complaint is counted once (by NHTSA case number), even when it names several vehicles.
1 complaint report injuries (1 injured).
Most reported problems
| Component | Complaints | Share |
|---|---|---|
| Fuel System, Diesel | 8 | 36% |
| Engine and Engine Cooling | 4 | 18% |
| Electrical System | 3 | 14% |
| Service Brakes, Hydraulic | 3 | 14% |
| Steering | 2 | 9% |
| Suspension | 2 | 9% |
| Tires | 2 | 9% |
| Engine | 1 | 5% |
| Exterior Lighting | 1 | 5% |
| Fuel System, Gasoline | 1 | 5% |
Component groups as classified by NHTSA. A complaint can name more than one component, so shares may sum to more than 100%.
All 14 reported components →Complaints by incident year
What owners report
“Tl* the contact owns a 2002 ford f-550 sd. The contact stated that while driving approximately 60 mph, thick white smoke was seen from underneath the vehicle. After inspecting the vehicle, the contact discovered flames coming from under the hood and front of the vehicle. The vehicle was destroyed. The fire department…”
Engine · filed May 14, 2014
“2002 ford f550 flatbed truck. Consumer states vehicle is unsafe to drive *tgw the consumer stated all of the tires were dry rotted, to the point they could not be re-treaded. The rear brakes and wheel seals needed to be replaced. The fuel sending assembly failed, and had to be replaced at a cost of $ 1251.46. The…”
Fuel System, Diesel · filed May 17, 2012
“Driving vehicle, vehicle lost power. Driver just made it off the road. Had the vehicle towed to a service station. Being told that the fuel tank is de-laminating. They have to replace the whole fuel system. Total cost $3,500.00. Called ford, they are saying there is no known problem. When I do a google search several…”
Fuel System, Gasoline · filed Dec 2, 2011
Verbatim excerpts from complaints filed with NHTSA. Reports are not independently verified.
Federal defect investigations
- ENGINE STALLING
Engineering Analysis EA06012 · opened Jun 22, 2006 · closed Dec 7, 2007 · led to recall 07V553000
- ENGINE COMPARTMENT FIRES
Engineering Analysis EA05005 · opened Mar 22, 2005 · closed Aug 2, 2006 · led to recall 08V025000
- ACCELERATOR PEDAL SENSOR (ETC)
Engineering Analysis EA04006 · opened Feb 23, 2004 · closed Feb 10, 2005
Technical service bulletins
48 manufacturer communications (TSBs, service campaigns, warranty extensions) are on file with NHTSA for the 2002 Ford F-550 SD. The 10 most recent:
This SKU is a Spare Tire Hoist. Test results identified that the pull force parameter was not within specification, as a precautionary measure unsold inventory was requested to be returned for testing and containment…
DOR-U2J7Y-02 · Service Bulletin/Repair Instructions · issued Jan 13, 2020
This SKU is a Spare Tire Hoist. Test results identified that the pull force parameter was not within specification, as a precautionary measure unsold inventory was requested to be returned for testing and containment…
DOR-C2C6H-02 · Service Bulletin/Repair Instructions · issued Jan 13, 2020
Some 2002-2008 F-Super Duty, F-150 and Mark LT vehicles may exhibit concern during or after programing the VSM. The programming may fail or vehicle symptoms such as inoperative door locks, dome lamps, door ajar…
SSM 48157 · Service Bulletin/Repair Instructions · issued Sep 2, 2019
Ford: the restraint control module (rcm) when using vcm ii, would have an error code 35 and diagnostic trouble code (dtc) b1035, and difficulty attempting programmable module installation (pmi). Model 2001-2004 f-super…
ASI-44408 · Service Bulletin/Repair Instructions · issued Feb 1, 2014
1999-2008 f250-f550 super duty 4x4 with electronic shift transfer case not engaging 4x4. *nj
20052 · Service Bulletin/Repair Instructions · issued Nov 1, 2007
Vacuum pump inoperative or runs continuously - climate control defaults to defrost mode. *tt
05174 · Service Bulletin/Repair Instructions · issued Oct 7, 2005
Service kit available for wiper motor wiring. *tt
05188 · Service Bulletin/Repair Instructions · issued Oct 7, 2005
Drive away shudder or vibration. *eh
04227 · Service Bulletin/Repair Instructions · issued Oct 7, 2005
Headlight adjustment - chassis cab incomplete vehicles. *tt
18735 · Service Bulletin/Repair Instructions · issued Jul 1, 2005
Safety belt retraction speed. *tt
042421 · Service Bulletin/Repair Instructions · issued Jun 7, 2005
TSBs are repair guidance manufacturers send to dealers — they are not recalls and repairs are not automatically free. Full documents are available on NHTSA’s site.
Safety recalls
The 2002 Ford F-550 SD has 4 NHTSA recall campaigns — recall repairs are free at franchised dealers regardless of the vehicle’s age.
Check whether your specific vehicle is affected
Recall campaigns often cover only certain VIN ranges. Enter your VIN on the official NHTSA site to confirm whether your vehicle is included and whether the repair is still open.
Check VIN on NHTSA →Buying a used 2002 Ford F-550 SD?
- · Decode the seller’s VIN with our free VIN decoder to confirm the exact year, engine and trim.
- · Check for unrepaired recalls by VIN on NHTSA’s official lookup — recall repairs are free.