Does the 2004 Ford F-650 SD have any recalls?

Yes. NHTSA lists 2 recalls for the 2004 Ford F-650 SD, the most recent reported on August 28, 2003 (Service brakes, air). Check a specific car by its VIN at nhtsa.gov/recalls.

What are the most common problems with the 2004 Ford F-650 SD?

Owners have filed 10 complaints with NHTSA. The most frequently reported area is engine and engine cooling (4 complaints), followed by service brakes, hydraulic (2).

How many 2004 Ford F-650 SD complaints mention a crash or fire?

0 of 10 complaints report a crash and 0 a fire; 1 injuries were reported in total. Complaints are unverified reports from owners.

2004 Ford F-650 SD recalls and problems

2 recalls and 10 owner complaints on file with NHTSA for the 2004 Ford F-650 SD.

recalls

owner complaints

complaints mentioning a crash

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-650 SD recalls

Service brakes, air

NHTSA campaign 03V319000 · reported August 28, 2003 · FORD MOTOR COMPANY · 97 vehicles potentially affected

The problem: Certain medium duty chassis cabs fail to comply to the requirements of federal motor vehicle safety standard no. 121, "air brake systems." the air brake lines may be misrouted between the primary and secondary reservoir tanks of the air brake system.
The risk: If the air brake lines are misrouted, and the air brake system experiences a loss of air from the primary air tank, the vehicle will not have service air bake function, increasing the risk of a crash.
The fix: Ford will inspect the air brake line routing and if necessary, repair the vehicle. Owner notification began on september 12, 2003. Owners should contact ford at 1-800-248-0186.

Equipment: other, labels

NHTSA campaign 03V283000 · reported August 5, 2003 · FORD MOTOR COMPANY · 1,000 vehicles potentially affected

The problem: Certain medium duty chassis cabs fail to comply with the requirements of federal motor vehicle safety standard no. 120, "tire selection and rims for motor vehicles other than passenger cars." the tire placard label and incomplete vehicle label may have incorrect metric (kpa) tire pressure information (tire inflation pressure shown in english units (psi) is correct), and transposed tire size and rim size information.
The fix: Owners will be sent corrected labels with instructions for installation. Owner notification began august 8, 2003. Owners should contact ford at 1-800-392-3673.

Most reported problems

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

Engine and engine cooling4
Service brakes, hydraulic2
Tires2
Electrical system1
Equipment1
Structure1
Suspension1

What owners report

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

Aug 8, 2024 · Engine and engine cooling
The contact works for a trucking company that owns a 2004 Ford F-650 SD 3-Ton Commercial Vehicle. The contact stated that the gear shifter rubber boot was not securely mounted onto the floorboard, resulting in a gap that allowed the driver to see underneath the vehicle. The contact stated while driving at various…

Aug 15, 2008 · Electrical system · 6,000 miles
LIGHTS ON THE UNIT WILL JUST SHUT OF RANDOMLY I BOUGHT THIS NEW AUG 24 2007 DEALER LOOKED AT IT SAID ITS A FORD ISSUE I CONTACTED FORD TO GET REPAIRED FORD SAYS IT IS OUT OF WARRANTY. THE DEALER HAD TO SEND IN A FORM ON LINE TO GET WARRANTY STARTED TAKES 7 WORKING DAYS THEY SAID. I HAVE WAITED 2 WEEKS AND STILL NO WAY…

Feb 5, 2007 · Tires
HANKOOK TIRES ARE BEING INSTALLED ON VEHICLES WHICH REQUIRE A LOAD RANGE HIGHER THAN A PASSENGER TIRE P235/R16 SL. THESE VEHICLES WEIGH IN AT 24,000 LBS GVW AND AT TIMES CAN BE OVERLOADED. THEY ALSO DO NOT TAKE INTO ACCOUNT THE 5% SAFETY FACTOR SINCE THE REARS ARE ON DUALS. TIRES WERE WEARING EXTREMELY FAST AND SOME…

Nov 22, 2006 · Tires · 125,000 miles
DT*: THE CONTACT STATED WHILE DRIVING 60 MPH, THE REAR LEFT INSIDE TIRE BLEW OUT. THE ROAD WAS CLEAR OF DEBRIS. THE VEHICLE WAS DRIVEN OFF TO THE SIDE OF THE ROAD, THEN DRIVEN TO AN INDEPENDENT TIRE SHOP WHERE A USED TIRE REPLACED THE FAILED TIRE. MOST OF THE SEPARATED TREAD WAS LEFT ON THE SIDE OF THE HIGHWAY. THE…

Aug 31, 2006 · Engine and engine cooling · 71,000 miles
DT*: THE CONTACT STATED WHILE EXITING A DRIVEWAY BETWEEN 5 -15 MPH THE ENGINE STARTED SMOKING AND MAKING A KNOCKING SOUND. THE SERVICE DEALER DETERMINED THAT THE ENGINE'S O-RING PISTONS WERE DEFECTIVE AND THE ENGINE MAY NEED TO BE REPLACED. THE CHECK ENGINE LIGHT WAS NOT ILLUMINATED.

F-650 SD model years compared

Year	Recalls	Complaints	Fires
2004	2	10	0
2005	2	6	0
2006	0	3	0
2007	1	5	1

All Ford F-650 SD years →

Questions

Does the 2004 Ford F-650 SD have any recalls?: Yes. NHTSA lists 2 recalls for the 2004 Ford F-650 SD, the most recent reported on August 28, 2003 (Service brakes, air). Check a specific car by its VIN at nhtsa.gov/recalls.
What are the most common problems with the 2004 Ford F-650 SD?: Owners have filed 10 complaints with NHTSA. The most frequently reported area is engine and engine cooling (4 complaints), followed by service brakes, hydraulic (2).
How many 2004 Ford F-650 SD complaints mention a crash or fire?: 0 of 10 complaints report a crash and 0 a fire; 1 injuries were reported in total. Complaints are unverified reports from owners.

Source: NHTSA recall and complaint data, updated October 27, 2026. Latest complaint received August 8, 2024.