2004 Ford E-450 Problems
- Complaints
- 27filed with NHTSA
- Median mileage
- 28,010miles, 19 complaints with mileage
- Recalls
- 6campaigns on record
- Trend
- StableComplaints filed in the last 3 full calendar years are within 25% of the 3 years before.
Sources: NHTSA records for the 2004 Ford E-450 (complaints, recalls, investigations). Report an error
NHTSA recorded 27 consumer complaints for the 2004 Ford E-450. The part named most often is engine cooling, with 10 complaints (37% of the total), followed by electrical system (5) and fuel system (5). 19 of the complaints include a mileage, and 68% of those were filed for vehicles with under 50,000 miles; the median is 28,010 miles. Of all complaints, 3 a fire, according to the filers. NHTSA lists 6 recall campaigns and 47 technical service bulletins for this model year. Engine cooling complaints overlap with 1 recall campaign and 25 technical service bulletins filed under the same part. Electrical system complaints overlap with 3 recall campaigns covering the fuses and circuit breakers and 9 technical service bulletins filed under the same part.
Not compared (before 2008). Model years 2008–2023 of the same vehicle that have at least 25 complaints are compared, and a model needs at least 3 of them.
Which parts are reported most
Complaints can name more than one part, so the counts add up to more than the total. Select a part to see its complaints, recalls and bulletins.
- Engine cooling10 37%
- Electrical system5 19%
- Fuel system5 19%
- Brakes4 15%
- Tires4 15%
- Equipment3 11%
- Body and structure2 7.4%
- Exterior lighting1 3.7%
Also reported: Latches, locks and linkages (1), Other or unknown (1), Vehicle speed control (1).
Example complaints
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.”
NHTSA complaint #10208724, filed 2007-11, 81,250 milesElectrical system: “We had a major problem with the vehicle not starting when it was dispatched to a call. Internal oil cooler disentigrated, and leaked oil into the cooling system. The cam sensors, and injectors have been replaced several times. The transmission had to be repaired shortly after purchase, and has had all of the internal gears replaced since. All of the wiring harnesses have been replaced.this particular unit has spent many months this year in a shop being worked on.”
NHTSA complaint #10172849, filed 2006-11, 62,199 milesFuel system: “April 2005 was the first time the truck started to stall while driving. Syosset Ford's diagnosis was r&r cam shaft position sensor. The second incident may 2005. Truck stalling intermittently again. Syosset Ford unable to duplicate the problem. July 2005 a recall notice is sent from Ford stating the icp sensors may have been improperly manufactured causing the vehicle to stall. Third incident truck is still stalling intermittently on august 15, 2005 icp connectors are replaced. …”
NHTSA complaint #10254808, filed 2009-01, 15,578 milesTransmission and drivetrain: “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. …”
NHTSA complaint #10380259, filed 2011-01, 28,010 milesMileage when problems were reported
68% of the 19 complaints with a mileage were filed for vehicles with under 50,000 miles; the middle half falls between 17,350 and 68,000 miles.
Complaints by year filed
Trend: stable. Complaints filed in the last 3 full calendar years are within 25% of the 3 years before.
Recalls and investigations
- 08V524000Oct 8, 2008Equipment adaptive/mobilityCovers: Ford E-450 2004, Dodge Sprinter 2007, Blue Bird TC2000 1998
Matthews is recalling 8 my 1998 bluebird, my 2004 ford e450, my 2005-2006 thomas built buses, my 2006 international bus, my 2007 chevrolet 5500, freightliner and dodge sprinter trucks, transit buses, and specialty vehicles equipped with ricon platform style…
- 08V526000Oct 8, 2008Equipment adaptive/mobilityCovers: Ford E-450 2004, Dodge Sprinter 2007, Blue Bird TC2000 1998
Matthews is recalling 8 my 1998 bluebird, my 2004 ford e450, my 2005-2006 thomas built bus, my 2006 international bus, my 2007 chevrolet 5500, freightliner and dodge sprinter trucks, transit buses, and specialty vehicles equipped with ricon platform style…
- 07V569000Dec 15, 2007Electrical system › Wiring › Fuses and circuit breakersCovers: Ford E-450 2004–2007, E-350 2004–2007
On certain ambulances originally sold in or currently registered in the states of connecticut, delaware, illinois, indiana, iowa, maine, maryland, massachusetts, michigan, minnesota, missouri, new hampshire, new jersey, new york, ohio, pennsylvania, rhode…
- 05V270000Jun 10, 2005Electrical system › WiringCovers: Ford E-450 2004–2005, Excursion 2004–2005, E-350 2004–2005 +4 more
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.
- 04V444000Sep 13, 2004Electrical system › WiringCovers: Ford E-450 2003–2004, E550 2003–2004, E-350 2003–2004 +2 more
On certain vans, a diode in the anti-lock braking system (abs) module may experience an electrical short.
- 04V445000Sep 13, 2004Engine and engine coolingCovers: Ford E-450 2003–2004, E550 2003–2004, E-350 2003–2004 +2 more
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…
Recall details for the 2004 Ford E-450 → · Check a VIN at nhtsa.gov/recalls
Technical service bulletins
TSBs are manufacturer notes to dealers about known repair procedures. They are not recalls and do not by themselves mean a vehicle has a fault. 47 on record; the latest 10 are shown.
- 10243490Sep 7, 2023Transmission and drivetrain. When performing any transmission fluid changes or topoffs involving MERCON SP, MERCON LV has replaced all versions of MERCON SP and can be used going forward. Mixing MERCON LV and MERCON SP in the…
- 10056196May 1, 2014Transmission and drivetrain. Ford: when shifting between park, reverse and/or during 2-3 shift, an intermittent clunk occurs with a torqshift transmission. Model 2003-2014 f-super duty, e series, excursion, f-53 motorhome…
- 10055629Feb 1, 2014Engine cooling, Transmission and drivetrain. Ford: on some trucks, there is a no crank situation and if voltage on transmission range sensor at pin 21, is less than 5 volts, disconnect the engine cooling fan clutch, electronically, and recheck…
- 10034571Jun 11, 2010Fuel system. Ford: runs rough, lacks power, hard start, no start. Some vehicles and trucks equipped with 6.0l engine may exhibit a runs rough, lacks power, hard to start, no start concern with or without…
- 10028826Jun 1, 2009Engine cooling, Fuel system. Ford: some vehicles with diesel engines may experience no starts, hard starts or rough running when cold and may be accompanied with diagnostic trouble codes (dtcs) p0611, p1378 and/or all 8…
- 10028730May 1, 2009Engine cooling. Ford: some vehicles equipped with 6.0l diesel engine may exhibit any one or combination of the following concerns-lack of power, white/black smoke or a surge.
- 10028284Mar 20, 2009Engine cooling. Ford trucks: misfire, lack of power, buck/jerk, excessive smoke, crank/no start-diagnostics for fuel system. There are several potential causes for these symptoms.
- 10024325Mar 1, 2008Engine cooling. 6.0l turbocharger carbon deposit diagnostics and service tips. *nj updated 5/29/08.
- 10023855Oct 1, 2007Engine cooling. 6.0l--mil on--p0401, p0402, p0404, p1335--lack of power or surge with some 2003-2007 f-super duty, 2003-2005 excursion and 2004-2008 e-series vehicles.
- 10019810Apr 29, 2006Electrical system. Lack of power or mil on - turbocharger sticking - revised diagnostics.
Other model years of the Ford E-450
| Year | Complaints | Median mi | Recalls | Crash ★ | MPG | Score (50 = typical) | Trend |
|---|---|---|---|---|---|---|---|
| 2022 | 13 | 4,000 | 3 | — | — | — | Not enough data |
| 2021 | 27 | 9,508 | 6 | — | — | Not compared (fewer than 3 comparable model years) | Stable |
| 2019 | 5 | 111,059 | 0 | — | — | — | Not enough data |
| 2018 | 5 | 3,514 | 4 | — | — | — | Not enough data |
| 2017 | 11 | 6,000 | 3 | — | — | — | Not enough data |
| 2016 | 17 | 7,206 | 5 | — | — | — | Falling |
| 2015 | 6 | 50,878 | 2 | — | — | — | Not enough data |
| 2014 | 5 | 13,257 | 3 | — | — | — | Not enough data |
| 2013 | 12 | 25,900 | 2 | — | — | — | Not enough data |
| 2011 | 7 | 33,750 | 8 | — | — | — | Not enough data |
| 2010 | 5 | 23,652 | 6 | — | — | — | Not enough data |
| 2008 | 6 | 13,926 | 8 | — | — | — | Not enough data |
| 2007 | 12 | 30,477 | 13 | — | — | — | Not enough data |
| 2006 | 20 | 35,000 | 13 | — | — | — | Falling |
| 2005 | 34 | 21,000 | 8 | — | — | Not compared (before 2008) | Stable |
| 2004 | 27 | 28,010 | 6 | — | — | Not compared (before 2008) | Stable |
| 2003 | 18 | 38,270 | 4 | — | — | — | Rising |
| 2002 | 13 | 38,750 | 2 | — | — | — | Not enough data |
| 2001 | 16 | 54,200 | 2 | — | — | — | Falling |
| 2000 | 42 | 34,350 | 3 | — | — | Not compared (before 2008) | Stable |
| 1999 | 73 | 34,323 | 2 | — | — | Not compared (before 2008) | Stable |
| 1998 | 5 | 22,008 | 2 | — | — | — | Not enough data |
| 1997 | 18 | 54,000 | 2 | — | — | — | Stable |
All Ford E-450 model years · Best and worst years by complaints
Frequently asked questions
How many NHTSA complaints does the 2004 Ford E-450 have?
NHTSA recorded 27 consumer complaints for the 2004 Ford E-450 as of Oct 28, 2026. Complaints are unverified consumer reports and may be duplicated or inaccurate.
What part of the 2004 Ford E-450 is reported most often?
Engine cooling is named most often, in 10 complaints (37% of the total), followed by electrical system with 5.
Has the 2004 Ford E-450 been recalled?
NHTSA lists 6 recall campaigns for this model year. To check a specific vehicle, enter its VIN at nhtsa.gov/recalls.
At what mileage are problems with the 2004 Ford E-450 reported?
Among the 19 complaints that include a mileage, the median is 28,010 miles and the middle half falls between 17,350 and 68,000 miles; 68% were filed for vehicles with under 50,000 miles.
About this data. Data from NHTSA (ODI) complaints, recalls, TSBs and investigations, updated Oct 28, 2026. Complaints are unverified consumer reports and may be duplicated or inaccurate.
Complaint counts come from NHTSA’s public complaint database; we count each complaint once. The source records for this vehicle are on nhtsa.gov. Scores and trends are our own summaries of that data, described in the methodology. This page is not legal, safety or repair advice: for a specific vehicle, check its VIN at nhtsa.gov/recalls and ask a qualified mechanic. See an error? Tell us.