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Ford F-450 SDModel year report

2004 Ford F-450 SD Problems

Complaints
33filed with NHTSA
Median mileage
48,101miles, 25 complaints with mileage
Recalls
2campaigns 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 F-450 SD (complaints, recalls, investigations). Report an error

NHTSA recorded 33 consumer complaints for the 2004 Ford F-450 SD. The part named most often is fuel system, with 20 complaints (61% of the total), followed by engine cooling (7) and electrical system (3). 25 of the complaints include a mileage, and 52% of those were filed for vehicles with under 50,000 miles; the median is 48,101 miles. Of all complaints, 1 involved a crash, 1 a fire, according to the filers. NHTSA lists 2 recall campaigns and 68 technical service bulletins for this model year. Fuel system complaints overlap with 1 technical service bulletin filed under the same part. Engine cooling complaints overlap with 27 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.

Also reported: Vehicle speed control (1), Wheels (1).

Example complaints

Fuel system: “At appx. 80,000 miles on our 2004 f450 sd fuel tank delaminated causing fuel system failure which resulted in sudden loss of power. We have always purchased high quality diesel from reputatable gas stations (chevron, shell). Vehicle repaired at Ford and had contacted Ford motor company regarding reimbursement of cost and was declined.”

NHTSA complaint #10448794, filed 2012-02, 80,000 miles

Engine cooling: “2004 Ford f-450 had rotting oil pan. It was determined by Ford that the cause was from environmental issues. Vehicle was only used on-road at all times and there was no reason after four years that the oil pan should have rotted out because of environmental issues. We are located in connecticut, nowhere near salt water. It cost our company $1,500 to replace the pan and related items. We did have a three-year extended warranty on the vehicle; however, we feel an oil pan should not rot after four years of normal wear and tear on the vehicle.”

NHTSA complaint #10290826, filed 2009-11, 27,200 miles

Electrical system: “Dt: consumer states her 2004 Ford f450 caught on fire while in operation. Smoke was coming from under the hood before the fire. The vehicle was last serviced on april 11, 2005. The fire department did respond. The engine compartment and cab melted. Therefore, there was no investigation as to why this occurred. This was not the consumers personal vehicle, but it belonged to her employer, and they were aware that she was filing the complaint. Gem air distributors leased the vehicle. The mileage was not exact, the maintenance log was inside the vehicle when it caught on fire.”

NHTSA complaint #10127604, filed 2005-07, 28,000 miles

Transmission and 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. …”

NHTSA complaint #10483254, filed 2012-11, 59,000 miles

Mileage when problems were reported

52% of the 25 complaints with a mileage were filed for vehicles with under 50,000 miles; the middle half falls between 17,573 and 80,000 miles.

20%0–108%10–2524%25–5016%50–7516%75–10012%100–1504%150+
Share of complaints by mileage when the problem was reported, in thousands of miles (25 complaints with mileage). Red bars: under 50,000 miles. Bucket widths differ. Median: 48,101 miles.

Complaints by year filed

Trend: stable. Complaints filed in the last 3 full calendar years are within 25% of the 3 years before.

2004920062008201020122014
Complaints by year the complaint was filed with NHTSA. Red bars: the last 3 full calendar years used for the trend. The current year (2026) is partial.

Recalls and investigations

Recall details for the 2004 Ford F-450 SD → · 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. 68 on record; the latest 10 are shown.

See all 68 bulletins →

Other model years of the Ford F-450 SD

YearComplaintsMedian miRecallsCrash ★MPGScore (50 = typical)Trend
202499,7073———Too new
20235—13———Too new
20222475,00014———Rising
2021182,76312———Rising
2011658,2508———Not enough data
20086834,0903——Not compared (fewer than 3 comparable model years)Rising
20071653,0001———Stable
20063549,7911——Not compared (before 2008)Stable
20054051,6504——Not compared (before 2008)Falling
20043348,1012——Not compared (before 2008)Stable
20031655,2215———Stable
20021455,0004———Not enough data
20012360,3517———Stable
20004361,1355——Not compared (before 2008)Stable
19996676,0009——Not compared (before 2008)Stable
19935—3———Not enough data
19916—0———Not enough data

All Ford F-450 SD model years · Best and worst years by complaints

Frequently asked questions

How many NHTSA complaints does the 2004 Ford F-450 SD have?

NHTSA recorded 33 consumer complaints for the 2004 Ford F-450 SD as of Oct 27, 2026. Complaints are unverified consumer reports and may be duplicated or inaccurate.

What part of the 2004 Ford F-450 SD is reported most often?

Fuel system is named most often, in 20 complaints (61% of the total), followed by engine cooling with 7.

Has the 2004 Ford F-450 SD been recalled?

NHTSA lists 2 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 F-450 SD reported?

Among the 25 complaints that include a mileage, the median is 48,101 miles and the middle half falls between 17,573 and 80,000 miles; 52% were filed for vehicles with under 50,000 miles.

About this data. Data from NHTSA (ODI) complaints, recalls, TSBs and investigations, updated Oct 27, 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.