Which parts fail
Components named in complaints (fuel pump, injectors, fuel tank, hybrid and EV propulsion).
Mileage when the problem started
Owner reports
Selected complaints filed with NHTSA by 2004 Ford F-450 SD owners, lightly cleaned up (personal details are redacted by NHTSA).
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! …
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.
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.
Our 2004 Ford f450 diesel truck lost power when driving on the highway. We took it to Ford and they told us the liner in the fuel tank was coming apart and they wanted $2100 to replace the tank. I saw on several web sites that this is a common problem that Ford is well aware and refuses to take responsibility for. I saw over 1,000 blogs from people who have had the same problem and Ford tells them it is the fuel they are getting and not a default in the tank design. I believe they should own up to their mistake and recall these tanks instead of making money off of replacing them.
I have 2 2005 Ford f450's that both have had fuel tank delamination. I have talked with the dealer at length about the situation. Off the record the service advisor acknowledged that this is a huge problem and there is no promise the new tanks will not have the same problems. After searching online message boards I have found that the problem is widespread. Basically the fuel tank that the manufacturer chose to use when building the truck will not hold up to the fuel type that the manufacturer requires to be used in the truck.
Dt: the vehicle stalled intermittently at idling speeds . This sometimes occurred 20 minutes after driving. When vehicle stalled all power was lost, including brakes and power steering. To vehicle to dealer, who is unable to resolve any concerns, but blamed this issue on the faulty fuel injection programming. There was a recall on this vehicle concerning the fuel injection system. Vehicle was included in the recall, and recall repair work has been performed twice without success.
The diesel fuel tank on my 2004 Ford f450 is delaminating on the inside of the tank and causing fuel contamination with metalic particles. If this condition had gone undiscovered it would have resulted in failure of the injector pump and ultimatly the engine itself. This is a serious factory defect with driver/passenger safety implications for all late model Ford super duty trucks. Ford should be forced to recall these trucks and replace the defective tanks reengineered fuel tanks.
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 contact owns a 2004 Ford f-450. While the contact was driving 65 MPH he noticed thick white smoke coming from the exhaust pipe and moments later the vehicle suddenly shut off. The vehicle was taken to the dealership where they replaced the egv valve, computer, and 6 injectors; however, the failure continued to occur. There were no prior warnings. The current and failure mileages were 69,122. Updated 04/01/10 updated 10/05/10
Fuel System complaints in other F-450 SD years
Frequently asked questions
How common are fuel system problems on the 2004 Ford F-450 SD?
NHTSA has 20 complaints about the fuel & propulsion system of the 2004 Ford F-450 SD, 61% of the model year's 33 complaints. The component named most often is fuel injection system (3 mentions).
Is there a recall for 2004 Ford F-450 SD fuel system problems?
No. NHTSA lists no fuel & propulsion system recall for the 2004 Ford F-450 SD, though it has 2 recalls for other components. If the problem is widespread, a repair may still be covered by an extended warranty or a manufacturer service bulletin — ask a dealer.
At what mileage do 2004 Ford F-450 SD fuel system problems start?
Half of the complaints with a recorded mileage happened before about 71,000 miles, and 13% before 25,000 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.