2004 Ford E-450: problems, recalls and reliability
4 recalls and 27 owner complaints on record; most reports concern engine and engine cooling; the 2002 model year looks more trouble-free.
Data updated weekly · latest recall Jun 2006
All counts are reports filed with NHTSA in the United States - US market only, not worldwide totals.
Common problems
Computed from 27 owner complaints filed with NHTSA for this exact model year.
“My box truck caught on fire, fire started at the plug in receptacle that keeps the glow plug warm and spread from there. Luckily my across the street neighbor helped put out the fire temporarily with 2 of his fire extinguisher until the fire truck arrived, otherwise it would have been a major catastrophe.”Owner report · Electrical System · Jan 2022
“Tl* the contact owns a 2004 ford e-450. The contact received notification of NHTSA campaign number: 17v782000 (equipment). The manufacturer was contacted at 1-855-262-3540 approximately two months ago. The contact left a voicemail for a call back, but did not receive a response. The contact felt that a reasonable amount of time had passed for the recall remedy. The contact had not experienced a failure. The VIN was not available.”Owner report · Equipment · Dec 2017
“Avi foodsystems vehicle # [xxx] is a danger on the road it is not federally inspected and you can see the truck is a hazard. I feel bad for the driver everytime I see her come to our account. She is risking her life driving that vehicle. This truck has ohio plates and is in erie,pa I wanted to inform d.o.t. Anonymously. Information redacted pursuant to the freedom of information act (foia), 5 u.s.c. 552(b)(6). *tr”Owner report · Service Brakes · Jun 2014
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“Bfg commercial t/a tire (215/85 r16) blew out and had total tread separation causing some vehicle damage. Tire was under 5 years old per dot date code, under 15k miles, had good tread, no indication of damage. No known impact with any road debris, blow out occurred while traveling under 55 mph. Very little warning, just slight feeling of misbalance before tire exploded. Tires had been checked for proper inflation 2-3 days before. Tires were visually inspected during travel - no signs of over/under inflation. *tr”Owner report · Tires · May 2014
“Tl* the contact owns a 2004 ford e-450. The contact stated that while driving at 30 mph, the vehicle stalled. The contact was unable to restart the vehicle. In addition, the vehicle failed to start intermittently. The vehicle was taken to a dealer multiple times. The technician diagnosed that the power control module, starter and the hop oil pressure pump needed to be replaced. The vehicle was repaired; however, the failure recurred on numerous occasions. The manufacturer was notified. The failure mileage was 119,000.”Owner report · Electrical System · Apr 2014
“The tire developed a "slow leak" at 16,500 miles since installation. The tire dealer removed the tire and found the tire to have a 2-3 inch slice in the outer skin of the sidewall which ran parallel to and closest to the rim (as opposed to the tread). It was very apparent there was total seperation of the outer sidewall from the inner ribbing yet there was only a slow leak of psi. *tr”Owner report · Tires · Jul 2012
“Tl* the contact owns a 2004 ford e450 sd. The contact stated that while driving various speeds, the brakes would seize independently. The vehicle was taken to an independent mechanic for diagnosis where both the front and rear brakes were replaced. The master cylinder was also included in the repair. The failure recurred numerous times. There had been other repairs that involved the replacement of the brakes. The manufacturer was notified of the problem. The approximate failure mileage was 26,000.”Owner report · Service Brakes · Sep 2011
“Tl* the contact owns a 2004 ford e-450. The contact stated that while driving approximately 40 mph, the brakes suddenly engaged independently. The vehicle was taken to an independent mechanic for diagnosis. The mechanic stated that the aluminum pucks in the braking system expanded when heated, causing the brakes to engage. The mechanic recommended replacing the aluminum pucks with steel ones. The manufacturer was made aware of the failure. The vehicle was not repaired. The approximate failure mileage was 30,000. Updated 3/28/14*cn”Owner report · Service Brakes · Nov 2008
“I have had three tire tread separations for tires I purchased in 2006 for my rv. The tires are cooper srm ii, lt225/75r16. The previous two were rear tires that were replaced. The most recent one happened on a front tire while traveling at highway speeds. *tr”Owner report · Tires · Jul 2008
“Unknown as to events leading up to the failure. The failure is, vehicle stalls out without warning and at times engine surges with power and loses power. Vehicle is a ford e 450 with a 6.0 lt diesel , mgf by international truck motors for ford motor co. Incident first reported oct 28, 2006 and is on going to this date, getting progressively worse, rending vehicle unreliable. Vehicle is an ambulance, modular aftermarket mfg is pl custom, owned by the pittston township ambulance association. Contact info with ford is monique - 1.800.343.5338, then select options - 3, then 7, then 4. Case id # - 41-agbdwm. *tr”Owner report · Engine And Engine Cooling · Oct 2006
Recalls - 4 campaigns
ON CERTAIN VANS, A DIODE IN THE ANTI-LOCK BRAKING SYSTEM (ABS) MODULE MAY EXPERIENCE AN ELECTRICAL SHORT.
Remedy: DEALERS WILL INSTALL A NEW FUSE IN THE ABS CIRCUIT AND INSTALL A HEAT SHIELD OVER THE ABS MODULE. THE RECALL BEGAN ON OCTOBER 15, 2004. OWNERS SHOULD CONTACT FORD AT 1-800-392-3673. ALSO FORD IS EXTENDING THE LIMITED WARRANTY (FOR A ONE TIME REPLACEMENT) OF THE ABS MODULE FOR A TOTAL OF 10 YEARS OR 150,000 MILES FROM THE WARRANTY START DATE, WHICHEVER OCCURS FIRST. IF YOUR VEHICLE HAS ALREADY ACCUMULATED MORE THAN 150,000 MILES, THIS COVERAGE WILL LAST UNTIL SEPTEMBER 30, 2005.
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 CONTACT THE AIR FILTER ELEMENT DURING CERTAIN DRIVING CONDITIONS THAT CREATE HOT PARTICLES.
Remedy: DEALERS WILL INSPECT AND REPLACE THE AIR FILTER ELEMENT. THE RECALL BEGAN SEPTEMBER 27, 2004. OWNERS SHOULD CONTACT FORD AT 1-800-392-3673. ALSO FORD IS EXTENDING THE LIMITED WARRANTY (FOR A ONE TIME REPLACEMENT) OF THE ABS MODULE FOR A TOTAL OF 10 YEARS OR 150,000 MILES FROM THE WARRANTY START DATE, WHICHEVER OCCURS FIRST. IF YOUR VEHICLE HAS ALREADY ACCUMULATED MORE THAN 150,000 MILES, THIS COVERAGE WILL LAST UNTIL SEPTEMBER 30, 2005.
CERTAIN AFTERMARKET FUEL FILTERS SOLD UNDER THE PUROLATOR BRAND NAME, P/N F65277, SHIPPED FROM JANUARY 16 THROUGH JUNE 2, 2006, FOR USE ON THE ABOVE LISTED PASSENGER VEHICLES. DUE TO INCORRECT DESIGN, THE QUICK CONNECTORS MAY NOT FULLY SEAT WITH THE TUBE INTERFACE, EVEN THOUGH THE PERSON MAKING THE CONNECTION MAY BELIEVE THAT THE QUICK CONNECTOR IS FULLY ATTACHED.
Remedy: UFI WILL NOTIFY OWNERS AND REPLACE THE FILTERS FREE OF CHARGE. THE RECALL BEGAN ON AUGUST 4, 2006. OWNERS MAY CONTACT UFI FILTERS USA AT 800-230-5876.
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.
Remedy: DEALERS WILL UPGRADE THE FUEL INJECTION CONTROL MODULE (FICM) WIRE HARNESS OR REPLACED, AND/OR HAVE A NEW INJECTION CONTROL PRESSURE (ICP)) SENSOR CONNECTOR INSTALLED FREE OF CHARGE. THE RECALL BEGAN ON JULY 22, 2005. OWNERS MAY CONTACT FORD AT 1-800-392-3673.
How other years compare
Check your exact E-450 by VIN
Recalls and equipment differ between individual vehicles. Decode your VIN to see what applies to yours.
Open VIN decoderFrequently asked questions
Is the 2004 Ford E-450 reliable?
NHTSA has 27 owner complaints and 4 recall campaigns on record for the 2004 Ford E-450. The most complained-about area is engine and engine cooling.
Does the 2004 Ford E-450 have open recalls?
4 recall campaigns have been issued, the latest concerning electrical system:wiring. Check your specific vehicle by VIN - recall repairs are free at franchised dealers.
Source: NHTSA recall campaigns and owner complaints (public domain). Counts reflect reports on file and are not a defect rate.