Vehicle stopped working. The culprit was the Ford fuel tank that had delaminated. The tank had to be replaced. The cost: $1600.00. Additionally, there was a loss of revenue as this vehicle is used for production purposes. Ford denied responsibility for any defects of their fuel tanks. With no other choice, we had to pay for the repairs out of pocket. This is a safety issue, as these…
2007 Ford F-550 fuel system problems
moderate 9 complaints filed with NHTSA · avg repair $1,200 · see fuel system across all vehicles →
Complaints
9
Recalls
0
Avg fix
$1,200
When does it fail?
Of the 9 fuel system complaints filed for the 2007 Ford F-550, here's the actual mileage breakdown — failures cluster heaviest at 0-25,000 mi.
0-25k
25-50k
50-75k
75-100k
100-125k
125-150k
150k+
Each bar shows the share of total complaints filed at that mileage range. Peak failure window highlighted. Some owners report problems earlier; some make it well past 150,000 miles symptom-free. Maintenance habits and driving conditions shift the curve as much as mileage alone.
What stands out
Among the 5 model years of Ford F-550 in our records for fuel system problems, this one ranks #3 by owner-complaint volume.
No new NHTSA fuel system complaint has been filed on this vehicle in over 16 years — the issue may be aging out of the active population.
What owners are reporting 7 most recent
I own a 2007 Ford f550 diesel truck. The truck suddenly lost power and was on the verge of stalling. The truck was driven back at less than 40 MPH on the interstate. After taking it to the dealership they discovered that the fuel tank was delaminating. Ford is not coving the tank under warranty stating that it is was caused by the changes in the epa fuel requirements in 2009. This problem…
The diesel fuel tank had corroding and showing rust on the inside of the tank. Seems like a delamination problem. The truck is still within the warranty period but Ford refuses to cover the problem because they do not consider it a manufacturer's defect. They blame the diesel fuel companies. Ford said the tanks were manufactured for the diesel fuel specifications at that time, not now.…
Strong odor of gas noted after driving 50 miles (round trip). Upon further inspection it was discovered that a major gas leak was occurring at the rear of the truck. The dealer indicated a faulty factory installation and routing of the gas line around the air suspension. The gas line was replaced. *tr
Tl* the contact owns a 2007 Ford f550. While driving at speeds of 30 MPH, the vehicle began to decrease in speed without warrant and then stalled. The contact was unable to restart the vehicle and had it towed to the dealer. The dealer advised the failure was due to the usage of bad diesel fuel. The vehicle was repaired by the dealer. The contact stated the failure recurs intermittently. The…
Ford gas tank delamination. Loss of power. Engine missing. This has brought me extreme heartache at the worst time. I am a seasonal worker who relies solely on his truck. Without it I am out of business. It will cost me anywhere from $2,000 to $6,000 to fix it. And I simply don't have it. *tr
It started running really sluggish. Wouldn't go up hills, bogging down, etc. Second time that the dealer told me that their is flaking in the fuel tank. Need to replace the tank because Ford tells me that the diesel gas is causing the flaking in the tank. This happen before just after 3 years and at a cost of $3.000. Now the same thing, only fords seem to have this problem with the flaking…
Had fuel system trouble with your 2007 Ford F-550?
File a complaint with NHTSA → It's free, official, and how every report above got here — owner filings are the federal safety record this page is built on.
Common questions
How serious is the fuel system problem on the 2007 Ford F-550?
It's a documented issue but not catastrophic. 9 complaints have been filed. Repairs average $1,200 and most owners catch it before it causes a breakdown.
At what mileage does the fuel system typically fail?
Based on the 9 complaints filed, fuel system issues most often appear around 38,032 miles. Some report problems earlier; some make it well past 150,000 with no symptoms. Maintenance habits matter — vehicles that received timely fluid services and were not regularly overworked tend to last longer.
What does it cost to fix?
Independent shops typically charge around $1,200 for fuel system repairs on this vehicle. Dealer pricing tends to run 20-40% higher. The exact figure depends on the specific failure mode, parts availability, and your local labor rates. If you're outside factory warranty, an extended service contract often covers this category.
Are there any recalls related to fuel system?
No active recalls currently cover fuel system issues on this vehicle. The complaints filed represent owner-reported failures that haven't risen to the level of a manufacturer-issued recall — but they're still worth knowing about before you buy or budget for repairs.
Related
Complaint and recall data sourced from the National Highway Traffic Safety Administration (NHTSA)
public records database. Verify the raw federal record at
nhtsa.gov/vehicle/2007/Ford/F-550.
Severity ratings are derived from reported crashes, fires, injuries, and fatalities. Repair cost estimates are
independent-shop national averages and may differ in your area. Some links on this page are affiliate links.