The 2004 Ford E-450 has 3 NHTSA recall campaigns affecting an estimated 648,029 vehicles. Recall repairs are always free at any authorized dealer. Owners have filed 45 complaints with NHTSA, most often about the electrical system. Last updated July 5, 2026.
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.
Consequence
SHOULD THE ENGINE STALL, A VEHICLE CRASH COULD OCCUR.
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.
ON CERTAIN VANS, A DIODE IN THE ANTI-LOCK BRAKING SYSTEM (ABS) MODULE MAY EXPERIENCE AN ELECTRICAL SHORT.
Consequence
THE ELECTRICAL SHORT MAY CAUSE AN ABS MALFUNCTION THAT WOULD ILLUMINATE THE ABS WARNING LIGHT, OR THE MODULE MAY OVERHEAT RESULTING IN A BURNING ODOR, SMOKE, AND/OR FIRE. THIS CONDITION MAY OCCUR WHILE THE VEHICLE IS BEING DRIVEN OR UNATTENDED.
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…
ENGINE AND ENGINE COOLING04V4450002004-09-13253,076 affected
Defect
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…
Consequence
THESE HOT PARTICLES MAY IGNITE THE AIR FILTER ELEMENT WITH THE POTENTIAL FOR AIR INDUCTION SYSTEM DAMAGE OR UNDERHOOD FIRE.
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…
Verbatim reports filed with NHTSA, lightly edited for readability and with personal
information removed.
“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…”
“I was driving my rv down the freeway when the inside dual blew out on the passenger side of the vehicle. Before the tire blew out I noticed a vibration on the passenger side of the rv. A few moments later the tire blew out and the tread came off completely leaving only the side walls. I do not…”
“The component system addressed, which is available for inspection, is the propane line routed through a jagged torched hole in the vehicle main frame; location is left-rear frame extension. Pictures are available. If piping is allowed to remain, the propane line will sustain a propane leak with…”
“Tl* the contact owns a 2004 ford e-450. The contact received notification of nhtsa campaign number: 17v782000 (equipment). The manufacturer was contacted at [REDACTED] approximately two months ago. The contact left a voicemail for a call back, but did not receive a response. The contact felt that…”
“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…”
“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…”
“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.…”
“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…”
Defect investigations
InvestigationPE09055 Opened 2009-12-07 · closed 2010-04-21
HVAC Switch Failures
ODI has received 1 complaint and reports from 4 transportation fleets alleging 182 switch failures.Each fleet operates mini buses built on a Ford E350 or E450 cutaway chassis.The OEM HVAC blower switches have melted, smoked, burned or experienced open flame and become inoperable on vehicles in each fleet.Some drivers…
Recall, complaint, and investigation records from official NHTSA datasets (FLAT_RCL,
FLAT_CMPL, FLAT_INV), synced weekly. Counts reflect NHTSA records for the 2004 Ford E-450 as of
July 5, 2026. Complaint narratives are consumer-submitted and unverified. This page
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