2004 Ford F-450 SD Fuel system Problems
- Complaints
- 20about this part
- Share
- 61%of 33 total for the year
- Median mileage
- 71,000miles
- Trend
- StableComplaints filed in the last 3 full calendar years are within 25% of the 3 years before.
NHTSA recorded 20 complaints about the fuel system of the 2004 Ford F-450 SD, 61% of the 33 complaints for this model year. Where a mileage was given, the median is 71,000 miles.
Example complaints
Selected from NHTSA records; personal details are removed. They are consumer reports, not findings.
“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“My 2004 Ford f-450 has a fuel tank corrosion/delamination problem. Ford refuses to fix the defect. The delamination is causing a clogging of the fuel system which causes the engine to shut down while driving. I have changed the injectors and change/clean the fuel filters regularly I have read online the complaints of numerous other owners of the same types of truck.”
NHTSA complaint #10292330, filed 2009-11, 98,479 miles“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.”
NHTSA complaint #10254967, filed 2009-01, 67,818 miles“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. …”
NHTSA complaint #10445180, filed 2012-01, 80,000 miles“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. …”
NHTSA complaint #10317140, filed 2010-03, 109,240 milesRelated service bulletins
- 10019075Jan 1, 2006Fuel conditioner. Low power, poor fuel economy, fuel gelling in cold weather, excessive white smoke on cold start, hard start, or coking of components exposed to exhaust.
Fuel system: other model years
| Year | Complaints | Share of year |
|---|---|---|
| 2024 | 1 | 11% |
| 2022 | 1 | 4% |
| 2021 | 3 | 17% |
| 2011 | 2 | 33% |
| 2008 | 19 | 28% |
| 2007 | 12 | 75% |
| 2006 | 26 | 74% |
| 2005 | 24 | 60% |
| 2004 | 20 | 61% |
| 2003 | 6 | 38% |
| 2002 | 7 | 50% |
| 2001 | 7 | 30% |
| 2000 | 7 | 16% |
| 1999 | 2 | 3% |
| 1993 | 1 | 20% |
Other parts of the 2004 Ford F-450 SD
7 complaintsElectrical system
3 complaintsTransmission and drivetrain
3 complaintsBrakes
2 complaintsEngine
1 complaintsEquipment
1 complaintsSteering
1 complaintsBody and structure
1 complaintsTires
1 complaintsVehicle speed control
1 complaintsWheels
1 complaints
← All problems reported for the 2004 Ford F-450 SD
About this data. Data from NHTSA (ODI) complaints, recalls, TSBs and investigations, updated Oct 30, 2026. Complaints are unverified consumer reports and may be duplicated or inaccurate.
To check a specific vehicle for open recalls, use its VIN at nhtsa.gov/recalls. Methodology