CarRecallDB

2004 Ford F-450 SD recalls and problems

2 recalls and 33 owner complaints on file with NHTSA for the 2004 Ford F-450 SD.

2
recalls
33
owner complaints
1
complaints mentioning a crash
1
mentioning a fire

Recalls apply to specific production ranges. To see whether a particular car still has an open recall, enter its VIN at nhtsa.gov/recalls. Repairs for safety recalls are free at authorised dealers.

2004 Ford F-450 SD recalls

Exterior lighting: brake lights · Exterior lighting: tail lights

NHTSA campaign 11V352000 · reported July 13, 2011 · FORD MOTOR COMPANY · 26,715 vehicles potentially affected

The problem
Ford is recalling certain model year 2011 ranger trucks built from january 25, 2011, through april 25, 2011 at the twin cities assembly plant, and service parts distributed to dealers for certain 2004 through 2011 model year ranger trucks, 2002 through 2005 model year excursion vehicles, and 2002 through 2007 model year f-250, f-350, f-450, and f-550 trucks for failing to comply with the requirements of federal motor vehicle safety standard no. 108, "lamps, reflective devices, and associated equipment." the multi-function switch was shipped with a subcomponent (slider) that may experience deformation. A multi-function switch with a deformed slider may malfunction causing the turn signal, tail lights, hazard warning signal flashers and/or brake lights not to activate.
The risk
Non-functioning lights could increase the risk of a crash.
The fix
Dealers will replace the switches free of charge. The safety recall began on august 15, 2011. Owners may contact ford motor company customer relationship center at 1-866-436-7332.

Electrical system: wiring

NHTSA campaign 05V270000 · reported June 10, 2005 · FORD MOTOR COMPANY · 180,104 vehicles potentially affected

The problem
Certain pickup trucks, sport utility vehicles and vans equipped with 6.0l diesel engines may experience stalling without warning while driving and may or may not restart.
The risk
Should the engine stall, a vehicle crash could occur.
The fix
Dealers will upgrade the fuel injection control module (ficm) wire harness or replaced, and/or have a new injection control pressure (icp)) sensor connector installed free of charge. The recall began on july 22, 2005. Owners may contact ford at 1-800-392-3673.

Most reported problems

Areas named in owner complaints to NHTSA. One complaint can name several areas.

What owners report

Recent complaints filed with NHTSA, shortened. These are unverified accounts from owners, not findings.

Jan 6, 2014 · Fuel system, gasoline · 71,000 miles

TL* THE CONTACT OWNS A 2004 FORD F-450 SD. THE CONTACT STATED THAT THE VEHICLE SUDDENLY STALLED. THE VEHICLE WAS TAKEN TO THE DEALER WHERE IT WAS FOUND THAT THE FUEL TANK LINING HAD FAILED. THE VEHICLE WAS BEING REPAIRED. THE MANUFACTURER WAS CONTACTED AND INFORMED THE CONTACT THAT THE VEHICLE WAS NOT INCLUDED IN…

Nov 3, 2013 · Fuel system, diesel

10/17/13 I WAS DRIVING ON THE INTERSTATE WITH A LOAD OF CATTLE RUNNING FINE AND JUST LOST POWER GOING ON THE INTERSTATE GOING FROM 65 TO 10 MILES AN HOUR. TRAFFIC ZIPPING BY. I THOUGHT IT WAS THE FUEL FILTERS BUT IT DONE THE SAME AFTER I CHANGED THEM. I TOOK IT TO A GARAGE AND HE SAID HE THE TANK LINER WAS COMING…

Nov 3, 2012 · Power train · 59,000 miles

VEHICLE LOOSES POWER, NO ACCELERATION, OCCURS MOST FREQUENTLY UNDER HEAVY LOAD OR HIGH ACCELERATION DEMAND, TOLD BY FORD DEALER THE PROBLEM IS CAUSED BY DE-LAMINATING FUEL TANK RESULTING IN FUEL TANK COATING ENTERING THE FUEL SYSTEM AND OBSTRUCTING DIESEL FUEL FLOW TO MOTOR WHEN HIGH DEMAND FOR DUEL OCCURS. NEAR…

Feb 21, 2012 · Fuel system, diesel · 80,000 miles

AT APPX. 80,000 MILES ON OUR 2004 F450 SD FUEL TANK DELAMINATED CAUSING FUEL SYSTEM FAILURE WHICH RESULTED IN SUDDEN LOSS OF POWER. WE HAVE ALWAYS PURCHASED HIGH QUALITY DIESEL FROM REPUTATABLE GAS STATIONS (CHEVRON, SHELL). VEHICLE REPAIRED AT FORD AND HAD CONTACTED FORD MOTOR COMPANY REGARDING REIMBURSEMENT OF COST…

Jan 25, 2012 · Fuel system, gasoline · 80,000 miles

TRUCK FAILS TO MAINTAIN SPEED (ACTS FUEL STARVED) AND IS AT RISK OF STALLING IN TRAFFIC. VEHICLE HAS BEEN MAINTAIN COMPLETELY AT FORD DEALERSHIP AND HAS HAD NO AFTERMARKET ADJUSTMENTS. AFTER TAKING THIS TRUCK TO THE FORD DEALER (PARR FORD IN BREMERTON, WA) WE HAVE BEEN NOTIFIED THAT THE FUEL TANK IS DELAMINATING AND…

F-450 SD model years compared

YearRecallsComplaintsCrashesFires
2001 72322
2002 41400
2003 51600
2004 23311
2005 44000
2006 13520
2007 11600

Across all years, the 2008 F-450 SD has the most complaints (68). All Ford F-450 SD years →

Questions

Does the 2004 Ford F-450 SD have any recalls?
Yes. NHTSA lists 2 recalls for the 2004 Ford F-450 SD, the most recent reported on July 13, 2011 (Exterior lighting: brake lights, Exterior lighting: tail lights). Check a specific car by its VIN at nhtsa.gov/recalls.
What are the most common problems with the 2004 Ford F-450 SD?
Owners have filed 33 complaints with NHTSA. The most frequently reported area is fuel system, diesel (14 complaints), followed by engine and engine cooling (7).
How many 2004 Ford F-450 SD complaints mention a crash or fire?
1 of 33 complaints report a crash and 1 a fire; 0 injuries were reported in total. Complaints are unverified reports from owners.

Source: NHTSA recall and complaint data, updated October 27, 2026. Latest complaint received January 6, 2014.