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 the federal safety agency campaign number 05v270000 (electrical system). The failure mileage was approximately 71,000.
The worst 2004 Ford F-450 SD problems
Ranked by number of owner complaints. Mileage and cost come from what owners wrote.
Problems by type
Tap a problem to see which part fails, at what mileage and in which other years.
- Fuel system20
- Engine8
- Electrical3
- Transmission3
- Brakes2
- Acceleration1
- Body1
- Steering1
- Tires1
- Wheels1
Specific symptoms reported on the 2004 Ford F-450 SD
Recalls 2
Exterior lighting: brake lights
- What is wrong
- 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.
- Risk
- Non-functioning lights could increase the risk of a crash.
- Remedy
- 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.
Recall number 11V352000 · Recall details
Electrical system: wiring
- What is wrong
- 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.
- Risk
- Should the engine stall, a vehicle crash could occur.
- Remedy
- 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.
Recall number 05V270000 · Recall details
See all 2 recalls for the 2004 Ford F-450 SD
Defect investigations
Engine stalling
In a june 7, 2005 letter, ford notified odi that it would be conducting a safety recall of approximately 180,000 ford f-super duty, excursion and e-series vehicles equipped with 6.0l diesel engines to correct two wiring related conditions that could result in engine stall (the federal safety agency recall no. 05v‑270, ford no. 05s34).the affected vehicles were built between september 29, 2003 and may 31, 2004.according to ford, vehicles with the conditions may stall without warning and may or may not restart.ford will instruct owners of vehicles included in the recall to take their vehicles to a dealer to have the fuel injector control module wire harness upgraded or replaced and or have a new injection control pressure sensor connector installed.during a may 2005 presentation to odi, ford identified a number of potential failure mechanisms that could affect engine performance in various segments of the subject vehicle population, including the wiring conditions addressed by 05v‑270.the wiring conditions, which both affect engine fueling, were the most likely conditions to result in engine stall.the recalled vehicles comprise approximately 43% of the subject vehicle population and account for 75 of the 113 odi reports that have a valid VIN (66%).the voq complaint rate for the recall population is 45/100k while the rate for vehicles outside the recall population is 17/100k and their trend (by date of receipt) is declining.based on the analysis, odi believes ford?s actions are sufficient to address the current safety risks and the investigation is thus closed.the closing of this investigation does not constitute a finding by the federal safety agency that a safety related defect does not exist.further action will be taken if warranted by future circumstances.
EA05003
Technical service bulletins for the 2004 Ford F-450 SD 128
Bulletins tell dealers how to fix known problems. A warranty extension means the manufacturer pays for that repair for longer.
- When performing any transmission fluid changes or topoffs involving MERCON SP, MERCON LV has replaced all...
- This SKU is a Transmission Line
- This SKU is a Spare Tire Hoist
- Concern during or after programing the VSM. The programming may fail or vehicle symptoms such as...
- Ford: when shifting between park, reverse and/or during 2-3 shift, an intermittent clunk occurs with a...
- Ford: on some trucks, there is a no crank situation and if voltage on transmission range sensor at pin 21,...
- Ford: the restraint control module (RCM) when using vcm II, would have an error code 35 and diagnostic...
- Dtc's P006A or P132B - lacks power, surge, or flutter after field service action 06E17
- Repeat turbocharger or vgt replacement
- Exhaust pressure sensor input no longer used if PCM is reprogrammed - service tip
What 2004 Ford F-450 SD owners say
Most recent owner complaints, unedited.
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 apart now it messed up my injectors, and I think ford should have a recall on something like that before someone gets killed or severly hurt!!!! It is in the shop now and I think ford should pay something on this.
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 collision at freeway speeds and was very dangerous to pull over when there was no shoulder. Ford dealer states the cost to repair is over $3,500.00 and open ended depending on whether the fuel tank coating entered the motor or injectors. They want to start by replacing the harness, fuel tank and fuel pump and go from there. Ford refuses to honor this clear manufacturing defect.
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 and was declined.
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 causing particles to clog the fuel system. As we haul a large trailer with this vehicle (as I'm sure other consumers do as well) this can result in a catastrophic outcome as stalling results in lack of steering abilities and can leave vehicle vulnerable in traffic. Ford needs to recognize this issue immediately and correct vehicles currently on the road at their cost.
Tl* the contact owns a 2004 ford f-450. The contact stated that the vehicle stalled while driving 55 MPH. The check engine light illuminated after the failure occurred. The vehicle was towed to the dealer where the dealer performed a diagnostic that located the failure as the fuel liner delaminating. The dealer replaced the fuel tank and the manufacturer was notified of the failure. The failure and the current mileage was 200,000. Updated 01/11/12
Tl* the contact owns a 2004 f-450 sd. While driving, the contact stated that the vehicle would loose power and would stall intermittently. The dealer diagnosed that there was delamination found in the fuel tank lining, which was flaking off and causing a leak in the fuel filter and fuel pump. The manufacturer was not notified of the failure. The vehicle was repaired. The failure mileage was unavailable and the current mileage was 34,000.
2004 ford f450 ambulance. Consumer states defective of the fuel tank *tgw the consumer stated as a result of a serious structural defect of the fuel tank, the vehicle stalled during several emergency calls. The coating in the interior diesel fuel tank corroded and collected as sediment, which extracted into the fuel system. The fuel line became clogged and damaged the fuel pump and valves. *jb updated 03/01/12 *bf updated 03/16/12 updated 04/18/12
Tl* the contact owns a 2004 ford f-450. She stated that while driving at unknown speeds, the engine stalled. The vehicle was towed to a local repair facility where it was diagnosed for injector control pressure, sensor connector failure. The contact believed the failure was associated with the federal safety agency recall campaign id number: 05v270000 (electrical system: wiring). The manufacturer advised that the information she had found was a technical service bulletin and not a recall. The manufacturer would not provide any assistance. The vehicle was not repaired. The failure and current mileages were 41,498.
Fuel tank delamination. Trucks started running bad, would eventually stop. Has left me and my employees stranded several times, sometimes in unsafe traffic areas. New fuel tanks installed, fuel pumps injectors put in new. Entire fuel system cleaned. Just under $5000.00 each time. Ford says biofuel is the cause. Never have used biofuel in anything.
Compare the 2004 Ford F-450 SD
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Questions about the 2004 Ford F-450 SD
Is the 2004 Ford F-450 SD reliable?
Owners have filed 33 complaints about the 2004 Ford F-450 SD, 5.5 times a typical F-450 SD model year.
What is the most common problem with the 2004 Ford F-450 SD?
Fuel and propulsion system, with 20 complaints, typically around 71,000 miles. Next is engine (8).
How many recalls does the 2004 Ford F-450 SD have?
2 recalls, covering exterior lighting and electrical system.
What year does the Ford F-450 SD have the most fuel system problems?
The Ford F-450 SD model years with the most fuel system complaints are 2006 (26 complaints), 2005 (24 complaints) and 2004 (20 complaints).
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Check its historyFord F-450 SD in the news
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- Ford recalls 2025-2027 Expedition, 2026 F-250 SD and 2026 F-350 SD and other models over exterior lighting headlights problem (41,748 vehicles)