Most common 2004 Ford F-450 SD problems
Share of the 33 complaints; one complaint can involve more than one system. "~" is the median mileage when the problem started.
Ford F-450 SD complaints by model year
Best F-450 SD years: 2018, 2020, 2014. Years to avoid: 2022, 2021, 2008, 1999, 2000. Compare all years →
2004 Ford F-450 SD recalls (2)
Exterior lighting › Brake lights
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,…
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.
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.
NHTSA defect investigations
Federal safety investigators have looked into a possible defect involving the 2004 Ford F-450 SD:
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 (NHTSA recall no. 05v-270, Ford no.
What 2004 Ford F-450 SD owners say
Fuel & propulsion system all 20 →
2004 Ford f-450 super duty. Truck was running as if it was running out of fuel, got to a stop light and the truck stalled. Got the truck to restart. That evening I had the fuel filters changed thinking that was the problem, then the truck ran fine. Two days later the truck did the same thing, and I was driving at 25mph, truck would not run any faster, then the truck stalled in the middle of a two lane road. The truck at this time did not restart. I had to get the truck towed. I got advice from a mechanic and he drained the tank and he found silver flakes in the tank. I called universal Ford in richmond virginia and they had it towed there to look at the truck, and the technician verified that the tank was contaminated from the tank due to delamination of the interior of the tank. …
I have a complaint about the fuel tank in my 2004 f-450, the truck was losing power and driving like a plugged fuel filter and after changing fuel filters many times I had found a "grey flake like" materials in both filters. I decided to take truck to Ford dealer in Lincoln, ne to have looked at and fixed. They called back telling me the fuel tank lining was bad in the fuel tank and needed to be replaced at my expense. It also caused one injector to go bad(hopefully not more) and a "nozzle assembly". They charged me to dispose of the 25(or so) gallons of fuel, and charged me for new fuel. The total bill was $2066.23. They said they talked to Ford and Ford would not warranty anything. In looking on internet there are many people with same problem. The tank has a liner in it that has dissolved causing the problems. I am the original owner, truck has 32000 miles and should not! …
Engine & cooling
Purchased 2004 Ford f-450 deisel truck 5/31/04 - first had at dale jarrett Ford in monroe, nc in July regarding problem with turbo but have no documentation for first visit - 8/12/04 dale jarrett Ford examined truck for loss of power and problem with turbo - result: operating to specs according to service dept. 8/27/04 examined by dale jarrett Ford again for lack of power and problem with turbo - result: replaced turbo kit and core return, truck operating to specs according to service record 8/31/04 examined by harrelson Ford, charlotte, nc for loss of power - result: PCM reprgrammed 9/2/04 harrelson Ford examined truck for lack of power on acceleration, power comes back up to some extent after period of time has lapsed - result: replaced exhaust back pressure sensor and vgt control valve 9/21/04 exmained by harrelson Ford for complete loss of power while driving, will restart after …
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.
Transmission & drivetrain
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.
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.
Frequently asked questions
Is the 2004 Ford F-450 SD a good car?
Based on 33 owner complaints filed with NHTSA, the 2004 F-450 SD rates avoid: 6.0× as many complaints as a typical year of the F-450 SD at the same age. It is one of the F-450 SD 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 F-450 SD?
The fuel & propulsion system — 20 complaints, 61% of all complaints for this model year, most often about fuel injection system. Next are the engine & cooling (8) and transmission & drivetrain (3).
How many recalls does the 2004 Ford F-450 SD have?
There are 2 recalls for the 2004 Ford F-450 SD, the most recent from July 13, 2011 (brake lights). 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 F-450 SD?
The best years by complaints, compared at the same age, are 2018, 2020 and 2014. Years to avoid or approach with caution: 2022, 2021, 2008, 1999 and 2000. See the full Ford F-450 SD years comparison.
At what mileage do 2004 Ford F-450 SD problems happen?
The median mileage reported in complaints is about 48,000 miles; 52% 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.