VehicleVerdict

2004 Ford F-450 Sd problems

Verdict · NHTSA data

One of the years to avoid

With 43 complaints filed to NHTSA — about 8.6 times the median F-450 Sd year — the 2004 model ranks #6 of 36 F-450 Sd years for complaint volume. It lands on the years-to-avoid list.

The trouble concentrates in one system: fuel system issues account for 47% of all reports (20 of 43), far ahead of engine at 8.

43

NHTSA complaints

3

Recalls

1

Investigations

1

Crash-involved

1

Fires reported

0

Injuries

0

Deaths

—

NCAP overall

How does 2004 compare to other F-450 Sd years?

F-450 Sd NHTSA complaints by model year, 2004 highlighted105 complaints1991: 19 complaints1992: 3 complaints1993: 5 complaints1994: 3 complaints1995: 2 complaints1996: 5 complaints1997: 9 complaints1998: 1 complaints1999: 76 complaints2000: 59 complaints2001: 28 complaints2002: 15 complaints2003: 18 complaints2004: 43 complaints2005: 47 complaints2006: 44 complaints2007: 19 complaints2008: 105 complaints2009: 5 complaints2010: 4 complaints2011: 11 complaints2012: 5 complaints2013: 2 complaints2014: 2 complaints2015: 2 complaints2016: 1 complaints2017: 1 complaints2018: 0 complaints2019: 5 complaints2020: 0 complaints2021: 26 complaints2022: 37 complaints2023: 9 complaints2024: 14 complaints2025: 2 complaints2026: 1 complaints
F-450 Sd NHTSA complaints by model year, 2004 highlighted. Red bars are years to avoid.

See all F-450 Sd years to avoid →

What are the most common 2004 Ford F-450 Sd problems?

ComponentComplaintsShare
Fuel System2047%
Engine819%
Electrical System37%
Transmission37%
Brakes25%
Other25%
Tires & Wheels25%
Body & Structure12%
Speed Control12%
Steering12%

Does the 2004 Ford F-450 Sd have recalls?

3 NHTSA recall campaigns on file. Recall repairs are free at franchised dealers.

11V352000LightingJuly 13, 2011 · 26,715 units

Defect

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.

Consequence

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.

07E066000Electrical SystemAugust 28, 2007 · 175 units

Defect

CERTAIN CEQUENT 90 DEGREE 7-WAY RIGHT ANGLE ADAPTORS SOLD BY DISTRIBUTORS IN TOW PACKAGES FOR AFTERMARKET SALES TO TOW 5TH WHEEL RV TRAVEL TRAILERS. DUE TO INCORRECT WIRING OF THE HARNESS, THE TRAILER LIGHTS MAY NOT OPERATE PROPERLY.

Consequence

IF THE TRAILER LIGHTS ARE NOT WORKING PROPERLY, A VEHICLE CRASH CAN OCCUR.

Remedy

ALL OF THE DEFECTIVE TOW PACKAGES ARE STILL AT THE DISTRIBUTOR LEVEL AND HAVE NOT BEEN SOLD TO ANY CONSUMERS.

05V270000Electrical SystemJune 10, 2005 · 180,104 units

Defect

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.

Consequence

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.

Consumer complaints filed with NHTSA

Representative excerpts, cleaned of personal information. These are consumer statements, not verified defects.

“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…”

Complaint filed with NHTSA · Fuel System · March 21, 2010

“DT*: THE CONTACT STATED THE VEHICLE OVERHEATED AND CONSUMED EXCESSIVE AMOUNTS OF WATER. THE ENGINE HAS BEEN REPLACED ONCE. THERE HAVE ALSO BEEN NUMEROUS PROBLEMS WITH THE VEHICLE'S TRANSMISSION WHICH HAS BEEN ALSO REPLACED DUE TO A BOLT COMING LOOSE RESULTING IN THE ENGINE BLOWING TWO HEAD GASKETS.…”

Complaint filed with NHTSA · Engine · July 10, 2006

“2004 F-450 6.0 DIESEL IN SHOP 15 TIMES, HOSES BURN REPLACE AND BURNS AGAIN ,TRUCK SHAKES REAL BAD . OIL LEAKS , RADIATOR HOSES LEAKS ,GLOW PLUGS,BAD INJECTORS ,WIRES RUBS MOTOR SHUTS TRUCK OFF,INSTRUMENT PANEL BATTERY LIGHT COMES ON AND OFF AND THEN STAYS ON. LOSES POWER. *JB”

Complaint filed with NHTSA · Transmission · December 8, 2003

“DT: CONSUMER STATES HER 2004 FORD F450 CAUGHT ON FIRE WHILE IN OPERATION. SMOKE WAS COMING FROM UNDER THE HOOD BEFORE THE FIRE. THE VEHICLE WAS LAST SERVICED ON APRIL 11, 2005. THE FIRE DEPARTMENT DID RESPOND. THE ENGINE COMPARTMENT AND CAB MELTED. THEREFORE, THERE WAS NO INVESTIGATION AS TO WHY…”

Complaint filed with NHTSA · Electrical System · June 30, 2005 · fire

“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…”

Complaint filed with NHTSA · Other · October 17, 2013

2004 Ford F-450 Sd — common questions

Is the 2004 Ford F-450 Sd reliable?

NHTSA data argues against it: 43 complaints put the 2004 model at #6 of 36 F-450 Sd years. It is one of the F-450 Sd years to avoid.

What are the most common 2004 F-450 Sd problems?

According to NHTSA complaint data, the leading problem areas are fuel system (20 complaints), engine (8 complaints), electrical system (3 complaints).

Does the 2004 Ford F-450 Sd have recalls?

Yes — NHTSA lists 3 recall campaigns affecting the 2004 Ford F-450 Sd. Recall repairs are free at franchised dealers; check the VIN at nhtsa.gov/recalls to confirm the work was done.

Is the 2004 Ford F-450 Sd under NHTSA investigation?

NHTSA opened one investigation into this model year; all are now closed.

Which Ford F-450 Sd years should you avoid?

Based on complaint rates and open investigations, the F-450 Sd years to avoid are 2008, 1999, 2000, 2005, 2006, 2004, 2022, 2021, 2019, 2015, 2016, 2017, 2020, 2018. The cleanest record among F-450 Sd years belongs to 2026.

Related

Based on NHTSA ODI data through June 2026. Complaints are consumer-reported and unverified. Updated July 5, 2026.

Compiled by Sharon Ben-Moshe, Founder.