Most common 2004 Ford E-450 problems
Share of the 27 complaints; one complaint can involve more than one system. "~" is the median mileage when the problem started.
Ford E-450 complaints by model year
Best E-450 years: 2009, 2012, 2010. Years to avoid: 2021, 2022, 1999, 2000, 2005. Compare all years →
2004 Ford E-450 recalls (3)
Electrical system › Wiring
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.
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.
Electrical system › Wiring
On certain vans, a diode in the anti-lock braking system (ABS) module May experience an electrical short.
Remedy: Dealers will install a new fuse in the ABS circuit and install a heat shield over the ABS module. The recall began on October 15, 2004. Owners should contact Ford at 1-800-392-3673.
Engine and engine cooling
On certain vans, the air filter element material process resulted in an air filter paper element that can smolder or burn. This change in filter paper composition combined with the configuration of the air induction system, May allow hot carbon particles to contact the air filter element during certain driving conditions that…
Remedy: Dealers will inspect and replace the air filter element. The recall began September 27, 2004. Owners should contact Ford at 1-800-392-3673.
NHTSA defect investigations
Federal safety investigators have looked into a possible defect involving the 2004 Ford E-450:
HVAC Switch Failures
ODI has received 1 complaint and reports from 4 transportation fleets alleging 182 switch failures.Each fleet operates mini buses built on a Ford E350 or E450 cutaway chassis.The OEM HVAC blower switches have melted, smoked, burned or experienced open flame and become inoperable on vehicles in each fleet.Some drivers have reported a burning smell or smoke coming from the dash.One fleet reported a vehicle fire.No…
What 2004 Ford E-450 owners say
Engine & cooling
Engine was replaced 3 times by Ford dealership, but problem never fixed , every re-build engine that was installed had diff. Issue , then the last one just caught in fire from leaking oil and also from the way they installed 11-01-07 date caught in fire.
Unknown as to events leading up to the failure. The failure is, vehicle stalls out without warning and at times engine surges with power and loses power. Vehicle is a Ford e 450 with a 6.0 lt diesel , mgf by international truck motors for Ford motor co. Incident first reported oct 28, 2006 and is on going to this date, getting progressively worse, rending vehicle unreliable. Vehicle is an ambulance, modular aftermarket mfg is pl custom, owned by the pittston township ambulance association. Contact info with Ford is monique - [phone], then select options - 3, then 7, then 4. Case id # - 41-agbdwm.
Transmission & drivetrain
Engine was replaced 3 times by Ford dealership, but problem never fixed , every re-build engine that was installed had diff. Issue , then the last one just caught in fire from leaking oil and also from the way they installed 11-01-07 date caught in fire.
Problem: hesitation on acceleration, rough idles, loss of power upon acceleration. Injector found clogged on 12-2006. Replaced turbo assembly and cold air boot on 12/20/2006. Filed written complaint to Ford in April 2006 for recurring engine issues. Ford never answered. On 1/30/09 truck not running and Ford replaced the transmission. Asked Ford service to check rough running and engine power loss but computer showed no codes. Took truck into Ford on 1/21/20011 for brakes and vehicle not running properly even after warm up. Diagnosis from Ford --- found rust in the fuel filter, was told fuel tank needed replaced as well as injectors and injector pump and fuel lines. Cost to replace $5000 or more. Warranty ran out November 2010. Ford is now requiring vehicle owners to replace their fuel tanks and any ancillary parts at their own cost. …
Electrical system
My box truck caught on fire, fire started at the plug in receptacle that keeps the glow plug warm and spread from there. Luckily my across the street neighbor helped put out the fire temporarily with 2 of his fire extinguisher until the fire truck arrived, otherwise it would have been a major catastrophe.
Tl* the contact owns a 2004 Ford e-450. The contact stated that while driving at 30 MPH, the vehicle stalled. The contact was unable to restart the vehicle. In addition, the vehicle failed to start intermittently. The vehicle was taken to a dealer multiple times. The technician diagnosed that the power control module, starter and the hop oil pressure pump needed to be replaced. The vehicle was repaired; however, the failure recurred on numerous occasions. The manufacturer was notified. The failure mileage was 119,000.
Frequently asked questions
Is the 2004 Ford E-450 a good car?
Based on 27 owner complaints filed with NHTSA, the 2004 E-450 rates use caution: 1.5× as many complaints as a typical year of the E-450 at the same age. It is one of the E-450 years we suggest avoiding. Complaint counts don't account for sales volume or individual maintenance, so have any used car inspected before buying.
What is the most common problem with the 2004 Ford E-450?
The engine & cooling — 10 complaints, 37% of all complaints for this model year, most often about engine › diesel. Next are the transmission & drivetrain (5) and electrical system (5).
How many recalls does the 2004 Ford E-450 have?
There are 3 recalls for the 2004 Ford E-450, the most recent from June 10, 2005 (wiring). Recall repairs are free at any authorized dealer — check whether yours has been done with the VIN recall check.
What are the best and worst years of the Ford E-450?
The best years by complaints, compared at the same age, are 2009, 2012 and 2010. Years to avoid or approach with caution: 2021, 2022, 1999, 2000 and 2005. See the full Ford E-450 years comparison.
At what mileage do 2004 Ford E-450 problems happen?
The median mileage reported in complaints is about 28,000 miles; 68% of problems with a recorded mileage started before 50,000 miles.
Source: U.S. National Highway Traffic Safety Administration (NHTSA) — owner complaints through October 20, 2026, recalls and defect investigations; fuel economy from the EPA. Complaints are unverified reports and are not proof of a defect. How we rate model years.