Most common 2004 Ford F-650 SD problems
Share of the 10 complaints; one complaint can involve more than one system. "~" is the median mileage when the problem started.
Ford F-650 SD complaints by model year
Best F-650 SD years: 2018, 2011, 2015. Compare all years →
2004 Ford F-650 SD recalls (2)
Service brakes, air
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.
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.
Equipment › Other › Labels
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…
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.
What 2004 Ford F-650 SD owners say
Engine & cooling
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 driving at various speeds, there was a strong engine oil odor and carbon monoxide odor entering the cabin through the gap in the floorboard. The contact stated that he had headaches due to the failure. The contact notified an independent Diesel mechanic of the engine oil leak, but the mechanic declined to diagnose or repair the vehicle. The mechanic informed the contact that the vehicle was no longer safe to drive and should no longer be driven on the road. The vehicle was not repaired. The dealer and the manufacturer were not notified of the failure. The failure mileage was unknown.
Ford f650. 17,000 miles on truck, had since new. Been in shop for performance, power, and fuel economy issue`s 4 out of 6 weeks. C7 300 h.p. Caterpillar engine. Cat admits known issue with computer not able to correctly tell engine proper fuel measurements. Engine wear masks proper alignment. Down time has lost me business and money. Federal motor carrier 494973. Cat put new engine in at 23,000 miles, telling me engine was not issue, and was clearly a computer and engine combo issue. I have asked for money back on truck. They continue to say lets look at again. I have told my customers no to many times, and am now not getting the opportunity to tell them anymore. I do not want to be the beta test truck. It doesn`t pay. No compensation being offered. No calls from Ford motor co.
Frequently asked questions
Is the 2004 Ford F-650 SD a good car?
Based on 10 owner complaints filed with NHTSA, the 2004 F-650 SD rates average: 3.7× as many complaints as a typical year of the F-650 SD at the same age. 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-650 SD?
The engine & cooling — 4 complaints, 40% of all complaints for this model year, most often about exhaust system › emission control. Next are the brakes (2) and wheels & tires (2).
How many recalls does the 2004 Ford F-650 SD have?
There are 2 recalls for the 2004 Ford F-650 SD, the most recent from August 28, 2003 (service brakes, air). 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-650 SD?
The best years by complaints, compared at the same age, are 2018, 2011 and 2015. See the full Ford F-650 SD years comparison.
At what mileage do 2004 Ford F-650 SD problems happen?
The median mileage reported in complaints is about 9,000 miles; 71% 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.