CarRecallDB

2004 Ford F-550 SD recalls and problems

2 recalls and 49 owner complaints on file with NHTSA for the 2004 Ford F-550 SD.

2
recalls
49
owner complaints
1
complaints mentioning a crash
5
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-550 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.

Feb 9, 2016 · Electrical system · 155,862 miles

TL* THE CONTACT OWNS A 2004 FORD F-550 SD. WHILE DRIVING APPROXIMATELY 55 MPH, THE VEHICLE STALLED WITHOUT WARNING. THE VEHICLE RESTARTED; HOWEVER, THE FAILURE RECURRED APPROXIMATELY ONE MILE LATER. THE VEHICLE DID NOT RESTART AND WAS TOWED TO THE CONTACT'S JOB. THE VEHICLE WAS TAKEN TO THE DEALER WHERE IT WAS…

Oct 13, 2015 · Structure · crash reported

TL* THE CONTACT OWNS A 2004 FORD F-550 SUPER DUTY. WHILE THE LINK WAS IN THE AIR WITH A WORKER LOCATED IN THE BUCKET, THE LINK FRACTURED WITHOUT WARNING. THE WORKER'S BUCKET CAME DOWN WITH FORCE CAUSING INJURY TO HIS HEAD, BACK, AND PELVIC AREA. THE WORKER RECEIVED MEDICAL ATTENTION. THE VEHICLE WAS NOT DIAGNOSED. THE…

Feb 25, 2013 · Engine and engine cooling · 36,000 miles

THE TRUCK IN QUESTION IS A 2004 FORD F-550 DIESEL. UPON DEPRESSING GAS PEDAL, TRUCK STALLED AND NO LONGER WORKED PROPERLY. TRUCK WAS TOWED TO LOCAL FORD DEALER WHERE IT WAS DETERMINED THAT THE FUEL TANK WAS SUFFERING FROM RUST INSIDE THE TANK. BASED ON THE WORK DONE, RUST PARTICLES THAT FORMED INSIDE THE TANK WERE…

Aug 10, 2012 · Fuel/propulsion system · 45,000 miles

TL* THE CONTACT OWNS A 2004 FORD F-550 SD. WHILE DRIVING APPROXIMATELY 45 MPH THE VEHICLE STALLED WITHOUT WARNING. THE VEHICLE WAS TOWED TO THE DEALER FOR DIAGNOSTICS WHERE THE TECHNICIAN STATED THAT THE TURBO CHARGER WOULD HAVE TO BE REPLACED. AFTER THE REPAIR THE FAILURE CONTINUED. THE VEHICLE WAS TAKEN BACK TO THE…

Jul 12, 2012 · Engine and engine cooling

2004 F550 DIESEL. CONSUMER STATES VEHICLE HAS A FAULTY HEAD-GASKET THE CONSUMER STATED THE TRUCK WOULD ONLY RUN FOR 20 MINUTES BEFORE IT OVERHEATED. THE CONSUMER WAS INFORMED IT COST CLOSE TO 10,000 TO FIX THE TRUCK.

F-550 SD model years compared

YearRecallsComplaintsCrashesFires
2001 62903
2002 42203
2003 53315
2004 24915
2005 43200
2006 14401
2007 12302

Across all years, the 2000 F-550 SD has the most complaints (72). All Ford F-550 SD years →

Questions

Does the 2004 Ford F-550 SD have any recalls?
Yes. NHTSA lists 2 recalls for the 2004 Ford F-550 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-550 SD?
Owners have filed 49 complaints with NHTSA. The most frequently reported area is fuel system, diesel (21 complaints), followed by engine and engine cooling (16).
How many 2004 Ford F-550 SD complaints mention a crash or fire?
1 of 49 complaints report a crash and 5 a fire; 4 injuries were reported in total. Complaints are unverified reports from owners.

Source: NHTSA recall and complaint data, updated October 27, 2026. Latest complaint received February 9, 2016.