In 1955, Ford made the lesser-known West Point drama The Long Gray Line for Columbia Pictures, the first of two Ford films to feature Tyrone Power, who had originally been slated to star as the adult Huw in How Green Was My Valley back in 1941. Later in 1955, Ford was hired by Warner Bros to direct the Naval comedy Mister Roberts, starring Henry Fonda, Jack Lemmon, William Powell, and James Cagney, but there was conflict between Ford and Fonda, who had been playing the lead role on Broadway for the past seven years and had misgivings about Ford's direction. During a three-way meeting with producer Leland Hayward to try and iron out the problems, Ford became enraged and punched Fonda on the jaw, knocking him across the room, an action that created a lasting rift between them. After the incident Ford became increasingly morose, drinking heavily and eventually retreating to his yacht, the Araner, and refusing to eat or see anyone. Production was shut down for five days and Ford sobered up, but soon after he suffered a ruptured gallbladder, necessitating emergency surgery, and he was replaced by Mervyn LeRoy.
Ford also made his first forays into television in 1955, directing two half-hour dramas for network TV. In the summer of 1955 he made Rookie of the Year (Hal Roach Studios) for the TV series Studio Directors Playhouse; scripted by Frank S. Nugent, it featured Ford regulars John and Pat Wayne, Vera Miles and Ward Bond, with Ford himself appearing in the introduction. In November he made The Bamboo Cross (Lewman Ltd-Revue, 1955) for the Fireside Theater series; it starred Jane Wyman with an Asian-American cast and Stock Company veterans Frank Baker and Pat O'Malley in minor roles.