The 2004 Ford F-650 Sd has 2 NHTSA recall campaigns affecting an estimated 1,097 vehicles. Recall repairs are always free at any authorized dealer. Owners have filed 12 complaints with NHTSA, most often about the engine and engine cooling. Last updated July 5, 2026.
Recall campaigns
SERVICE BRAKES, AIR03V3190002003-08-2897 affected
Defect
CERTAIN MEDIUM DUTY CHASSIS CABS FAIL TO COMPLY TO THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 121, "AIR BRAKE SYSTEMS." THE AIR BRAKE LINES MAY BE MISROUTED BETWEEN THE PRIMARY AND SECONDARY RESERVOIR TANKS OF THE AIR BRAKE SYSTEM.
Consequence
IF THE AIR BRAKE LINES ARE MISROUTED, AND THE AIR BRAKE SYSTEM EXPERIENCES A LOSS OF AIR FROM THE PRIMARY AIR TANK, THE VEHICLE WILL NOT HAVE SERVICE AIR BAKE FUNCTION, INCREASING THE RISK OF A CRASH.
Remedy
FORD WILL INSPECT THE AIR BRAKE LINE ROUTING AND IF NECESSARY, REPAIR THE VEHICLE. OWNER NOTIFICATION BEGAN ON SEPTEMBER 12, 2003. OWNERS SHOULD CONTACT FORD AT 1-800-248-0186.
EQUIPMENT03V2830002003-08-051,000 affected
Defect
CERTAIN MEDIUM DUTY CHASSIS CABS FAIL TO COMPLY WITH THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 120, "TIRE SELECTION AND RIMS FOR MOTOR VEHICLES OTHER THAN PASSENGER CARS." THE TIRE PLACARD LABEL AND INCOMPLETE VEHICLE LABEL MAY HAVE INCORRECT METRIC (KPA) TIRE PRESSURE INFORMATION (TIRE INFLATION…
Remedy
OWNERS WILL BE SENT CORRECTED LABELS WITH INSTRUCTIONS FOR INSTALLATION. OWNER NOTIFICATION BEGAN AUGUST 8, 2003. OWNERS SHOULD CONTACT FORD AT 1-800-392-3673.
Complaints by component
ENGINE AND ENGINE COOLING
2
1injuries
ELECTRICAL SYSTEM
1
ENGINE AND ENGINE COOLING:ENGINE
1
ENGINE AND ENGINE COOLING:EXHAUST SYSTEM:EMISSION CONTROL
1
EQUIPMENT
1
SERVICE BRAKES, HYDRAULIC:ANTILOCK/TRACTION CONTROL/ELECTRONIC LIMITED SLIP:ABS WARNING LIGHT
1
SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS:DISC:CALIPER
1
STRUCTURE
1
1injuries
SUSPENSION:REAR:SPRINGS:AIR SUSPENSION SYSTEM
1
TIRES
1
Total complaints12
What owners report
Verbatim reports filed with NHTSA, lightly edited for readability and with personal
information removed.
“The contact works for a trucking company that owns a 2004 ford f-650 sd 3-ton commercial vehicle. The contact stated that the gear shifter rubber boot was not securely mounted onto the floorboard, resulting in a gap that allowed the driver to see underneath the vehicle. The contact stated while…”
“The contact works for a trucking company that owns a 2004 ford f-650 sd 3-ton commercial vehicle. The contact stated that the gear shifter rubber boot was not securely mounted onto the floorboard, resulting in a gap that allowed the driver to see underneath the vehicle. The contact stated while…”
“Lights on the unit will just shut of randomly I bought this new aug 24 2007 dealer looked at it said its a ford issue I contacted ford to get repaired ford says it is out of warranty. The dealer had to send in a form on line to get warranty started takes 7 working days they said. I have waited 2…”
“Dt*: the contact stated while driving 60 mph, the rear left inside tire blew out. The road was clear of debris. The vehicle was driven off to the side of the road, then driven to an independent tire shop where a used tire replaced the failed tire. Most of the separated tread was left on the side…”
“Dt*: the contact stated while exiting a driveway between 5 -15 mph the engine started smoking and making a knocking sound. The service dealer determined that the engine's o-ring pistons were defective and the engine may need to be replaced. The check engine light was not illuminated.”
“Hankook tires are being installed on vehicles which require a load range higher than a passenger tire p235/r16 sl. These vehicles weigh in at 24,000 lbs gvw and at times can be overloaded. They also do not take into account the 5% safety factor since the rears are on duals. Tires were wearing…”
“Hankook tires are being installed on vehicles which require a load range higher than a passenger tire p235/r16 sl. These vehicles weigh in at 24,000 lbs gvw and at times can be overloaded. They also do not take into account the 5% safety factor since the rears are on duals. Tires were wearing…”
“Vehicle stalled on 2 separate occasions while driving. Dealership was unable to indicate the cause of the failure. Vehicle was at the dealership for the last 2 weeks due to the failure.*ak *bf *nm”
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 F-650 Sd as of
July 5, 2026. Complaint narratives are consumer-submitted and unverified. This page
contains ads and affiliate links. Full methodology.