2009 Ford F-550 Super Duty

The 2009 Ford F-550 Super Duty is a heavy-duty work truck known for its robust capabilities and towing capacity. Engine options for this year include the 6.4L Power Stroke diesel V8, which produces 350 horsepower and 650 lb-ft of torque, and the 6.8L Triton V10 gasoline engine, which produces 362 horsepower and 457 lb-ft of torque. Both engines are typically paired with a 5-speed TorqShift automatic transmission. Owners often appreciate the F-550 for its raw power and ability to handle demanding tasks, but some common complaints revolve around fuel economy, maintenance costs associated with the diesel engine, and overall ride quality.

Engine

6.4L Power Stroke Diesel V8

• EGR Cooler Failure
  • Description/Symptoms: The EGR cooler cracks, leading to coolant leaks, white smoke from the exhaust, and potential overheating. Coolant may also enter the intake, causing further issues.
  • Solution: Replace the EGR cooler. Upgraded aftermarket coolers are available.
  • Estimated Cost to Fix: $800 - $1500+
  • Recalls: None Found
• Fuel Injector Failure
  • Description/Symptoms: Rough running engine, misfires, black smoke from the exhaust, and poor fuel economy. In severe cases, fuel dilution of the engine oil can occur.
  • Solution: Replace the failed fuel injector(s). It’s often recommended to replace all injectors at the same time to ensure balanced performance.
  • Estimated Cost to Fix: $400 - $800+ per injector (parts and labor)
  • Recalls: None Found
• High Pressure Oil Pump (HPOP) Failure
  • Description/Symptoms: Difficulty starting the engine, stalling, and loss of power. Diagnostic codes related to HPOP pressure are usually present.
  • Solution: Replace the HPOP.
  • Estimated Cost to Fix: $1200 - $2500+
  • Recalls: None Found
• Turbocharger Failure
  • Description/Symptoms: Loss of power, excessive black smoke, and a whistling noise from the engine.
  • Solution: Replace the turbocharger. Sometimes, cleaning and inspection can resolve the issue if it’s due to carbon buildup.
  • Estimated Cost to Fix: $2000 - $4000+
  • Recalls: None Found

6.8L Triton V10

• Spark Plug Blowout
  • Description/Symptoms: A spark plug is ejected from the cylinder head, often accompanied by a loud popping noise and a sudden loss of power. This is due to weak threads in the cylinder head.
  • Solution: Repair the cylinder head by installing thread inserts or replacing the entire head.
  • Estimated Cost to Fix: $500 - $2000+
  • Recalls: None Found

Transmission

5R110W TorqShift Automatic Transmission

• Torque Converter Failure
  • Description/Symptoms: Shuddering during acceleration, especially at lower speeds. Can also manifest as a complete loss of power transfer.
  • Solution: Replace the torque converter. Flushing the transmission is recommended during replacement.
  • Estimated Cost to Fix: $1500 - $3000+
  • Recalls: None Found
• Valve Body Issues
  • Description/Symptoms: Erratic shifting, harsh shifting, or failure to shift into certain gears.
  • Solution: Replace or rebuild the valve body.
  • Estimated Cost to Fix: $800 - $2000+
  • Recalls: None Found

Suspension

• Leaf Spring Sagging/Failure
  • Description/Symptoms: The rear of the truck sits lower than the front, leading to poor handling and reduced load capacity. Can also cause clunking noises over bumps.
  • Solution: Replace the leaf springs. Consider upgrading to heavier-duty springs if the truck is frequently used for heavy hauling.
  • Estimated Cost to Fix: $500 - $1500+ per spring (parts and labor)
  • Recalls: None Found

Electrical

• Alternator Failure
  • Description/Symptoms: Dimming headlights, warning lights on the dashboard, and difficulty starting the engine.
  • Solution: Replace the alternator.
  • Estimated Cost to Fix: $300 - $600+
  • Recalls: None Found
• Glow Plug Issues (Diesel Only)
  • Description/Symptoms: Hard starting, especially in cold weather. Diagnostic codes related to glow plugs are usually present.
  • Solution: Replace the faulty glow plug(s).
  • Estimated Cost to Fix: $100 - $400+
  • Recalls: None Found

Exterior

• Rust on Body Panels
  • Description/Symptoms: Rust forming on the lower body panels, especially around the wheel wells and rocker panels.
  • Solution: Repair or replace the rusted body panels. Prevention includes regular washing and waxing.
  • Estimated Cost to Fix: $300 - $2000+ (depending on severity and location)
  • Recalls: None Found

Interior

• HVAC Blend Door Actuator Failure
  • Description/Symptoms: Inability to control the temperature of the air coming from the vents. One side may blow hot air while the other blows cold. Clicking noises behind the dashboard are often present.
  • Solution: Replace the blend door actuator.
  • Estimated Cost to Fix: $200 - $500+
  • Recalls: None Found

Summary

The 2009 Ford F-550 Super Duty, while a capable workhorse, has potential issues that buyers should be aware of. The most concerning issues revolve around the 6.4L Power Stroke diesel engine, which can be prone to expensive problems like EGR cooler, fuel injector, HPOP, and turbocharger failures. The 6.8L V10 is prone to spark plug blowouts. The transmission can experience torque converter and valve body problems. Suspension issues like leaf spring sagging can also affect performance. While the F-550 is built for heavy-duty work, potential buyers should carefully inspect the vehicle’s maintenance history and be prepared for potentially high repair costs, especially if the truck is equipped with the 6.4L diesel.