VehicleVerdict

2004 Ford F-650 Sd problems

Verdict · NHTSA data

Limited data — recalls on file

NHTSA has just 12 complaints on file for the 2004 Ford F-650 Sd — too few to judge reliability from owner reports alone — but 2 recall campaigns apply to this year, so any used example should have its VIN checked for completed recall work.

12

NHTSA complaints

2

Recalls

0

Investigations

0

Crash-involved

0

Fires reported

2

Injuries

0

Deaths

—

NCAP overall

How does 2004 compare to other F-650 Sd years?

F-650 Sd NHTSA complaints by model year, 2004 highlighted12 complaints2004: 12 complaints2005: 6 complaints2006: 3 complaints2007: 5 complaints2008: 2 complaints2009: 1 complaints2010: 0 complaints2011: 1 complaints2012: 0 complaints2013: 0 complaints2015: 1 complaints2016: 6 complaints2018: 0 complaints2019: 8 complaints2021: 1 complaints2023: 4 complaints2025: 4 complaints
F-650 Sd NHTSA complaints by model year, 2004 highlighted. Red bars are years to avoid.

See all F-650 Sd years to avoid →

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

ComponentComplaintsShare
Engine433%
Brakes217%
Tires & Wheels217%
Suspension18%
Other18%
Electrical System18%
Body & Structure18%

Does the 2004 Ford F-650 Sd have recalls?

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

03V319000BrakesAugust 28, 2003 · 97 units

Defect

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.

Consequence

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.

Remedy

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.

03V283000OtherAugust 5, 2003 · 1,000 units

Defect

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.

Remedy

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.

Consumer complaints filed with NHTSA

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

“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.”

Complaint filed with NHTSA · Engine · August 17, 2006

“2004 F650 TOW TRUCK BRAKES KEEP EATING ROTOR HAD TO REPLACE WHOLE DRIVER SIDE BRAKE SYSTEM 2 TIMES , WE ONLY GOT 13,8888 MILES ON THE FIRST BRAKE JOB. *JB”

Complaint filed with NHTSA · Brakes · February 1, 2005

“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…”

Complaint filed with NHTSA · Tires & Wheels · November 20, 2006

“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…”

Complaint filed with NHTSA · Body & Structure · May 31, 2024

“THIS TRUCK HAS A TERRIBLE VIBRATION STARTING AT 53 AND GOING THRU 65 THEN THE INTENSITY LESSONS BUT CONTINUES. SHIFT OF TRANSMISSION IS ALMOST IMPOSSIBLE AT TIME, FRONT END HAS PROBLEMS INCLUDING WEARING OF TIRED IN 29960 MILES. *AK”

Complaint filed with NHTSA · Suspension · August 15, 2003

2004 Ford F-650 Sd — common questions

Is the 2004 Ford F-650 Sd reliable?

The record is thin — 12 NHTSA complaints — so owner-report data can't strongly confirm reliability either way, though 2 recalls should be verified as completed.

What are the most common 2004 F-650 Sd problems?

According to NHTSA complaint data, the leading problem areas are engine (4 complaints), tires & wheels (2 complaints), brakes (2 complaints).

Does the 2004 Ford F-650 Sd have recalls?

Yes — NHTSA lists 2 recall campaigns affecting the 2004 Ford F-650 Sd. Recall repairs are free at franchised dealers; check the VIN at nhtsa.gov/recalls to confirm the work was done.

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.