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2004 Ford E-150 Recalls & Complaints

6

open safety recalls on record

Critical

36 owner complaints filed · Severity Index 0.33 · updated 2026-08-07

The recalls

Critical11E047000

Fuel System, Gasoline:Storage:Tank Assembly

FUEL LEAK IN THE PRESENCE OF AN IGNITION SOURCE MAY RESULT IN A FIRE.

Remedy & full details

FORD WILL NOTIFY OWNERS, AND DEALERS WILL REPLACE THE FUEL TANKS FREE OF CHARGE. THE SAFETY RECALL BEGAN ON NOVEMBER 28, 2011. OWNERS MAY CONTACT FORD MOTOR COMPANY CUSTOMER RELATIONSHIP CENTER AT 1-800-232-5952.

FORD IS RECALLING CERTAIN REPLACEMENT FUEL TANKS THAT COULD BE INSTALLED INTO MODEL YEAR 2004 THROUGH 2008 E-150, E-250, AND E-350 VANS AND WAGONS. THE AFFECTED FUEL TANKS HAVE AN EXTRA OBDII SENSOR HOLE ON THE TOP OF THE TANK THAT MAY NOT BE PROPERLY SEALED AND MAY LEAK FUEL.

Critical06E056000

Fuel System, Gasoline

FAILURE OF THIS CONNECTION COULD LEAD TO FUEL SPILLAGE AND, IN THE PRESENCE OF AN IGNITION SOURCE, A FIRE COULD OCCUR.

Remedy & full details

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 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.

Critical04V445000

Engine And Engine Cooling

THESE HOT PARTICLES MAY IGNITE THE AIR FILTER ELEMENT WITH THE POTENTIAL FOR AIR INDUCTION SYSTEM DAMAGE OR UNDERHOOD FIRE.

Remedy & full details

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.

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.

Critical04V444000

Electrical System:Wiring

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.

Remedy & full details

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, A DIODE IN THE ANTI-LOCK BRAKING SYSTEM (ABS) MODULE MAY EXPERIENCE AN ELECTRICAL SHORT.

Serious09V102000

Equipment Adaptive/Mobility

THE USER OF THE LIFT COULD BE INJURED SHOULD THE LIFT MOVE UNINTENTIONALLY.

Remedy & full details

VAN CONVERSIONS IS WORKING WITH RICON TO CORRECT THE WHEELCHAIR LIFTS FREE OF CHARGE (PLEASE SEE 07E095). OWNERS MAY CONTACT RICON AT 1-818-267-3000 OR VAN CONVERSIONS AT 610-837-0707.

VAN CONVERSIONS IS RECALLING 74 MY 2004-2007 FORD E-150, E-250 E-350 AND MY 2006 GM SAVANNA 3500 VANS BUILT ON FORD AND GM CHASSIS AND EQUIPPED WITH RICON PLATFORM STYLE WHEELCHAIR LIFTS. THESE VEHICLES FAIL TO COMPLY WITH THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 404, "PLATFORM LIFT INSTALLATIONS IN MOTOR VEHICLES." THE THRESHOLD WARNING SYSTEM MAY NOT DETECT THE PRESENCE OF A WHEELCHAIR OR MOBILITY AID USER IN A CERTAIN SPOT WITHIN THE DEFINED THRESHOLD AREA.

Serious09V100000

Equipment Adaptive/Mobility

LIFT OCCUPANT CAN BE INJURED SHOULD THE LIFT BEGIN TO STOW UNINTENTIONALLY.

Remedy & full details

VAN CONVERSIONS IS WORKING WITH RICON TO CORRECT THE WHEELCHAIR LIFTS FREE OF CHARGE (PLEASE SEE 07E097). OWNERS MAY CONTACT RICON AT 1-818-267-3000 OR VAN CONVERSIONS AT 610-837-0707.

VAN CONVERSIONS IS RECALLING 52 MY 2004-2007 FORD E-150, E-250 E-350 AND MY 2006 GM SAVANNA 3500 VANS BUILT ON FORD AND GM CHASSIS AND EQUIPPED WITH RICON PLATFORM STYLE WHEELCHAIR LIFTS. THESE LIFTS FAIL TO COMPLY WITH THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 403, "PLATFORM LIFT SYSTEM ACCESSIBLE FOR MOTOR VEHICLES," THE ANTI-STOW INTERLOCK MAY NOT DETECT THE PRESENCE OF A WHEELCHAIR OR MOBILITY AID USER. THE PRESSURE SENSING SWITCH THAT DETECTS THE PRESENCE OF WEIGHT ON THE PLATFORM WAS NOT ADJUSTED TO THE NECESSARY SENSITIVITY LEVEL. THE LIFT COULD STOW EVEN THOUGH SOMEONE OR SOMETHING IS STILL ON THE LIFT.

Complaint volume

36 this model-year 6 median, same year

Volume alone is not a fault rate — popular vehicles attract more reports. Read it next to the severity mix below.

What owners reported happened

2Crashes
0Fires
2Injuries
0Deaths

Across 36 complaints. Severity Index 0.33.

Severity Index weights each complaint's reported outcome (death ×10, injury ×4, fire ×3, crash ×2) and divides by total complaints. It measures how severe reports are, not how often faults occur.

What owners report most

Service Brakes, Hydraulic4 · 11%Power Train4 · 11%Latches/Locks/Linkages · …2 · 6%Wheels · Lugs/Nuts/Bolts/…2 · 6%Vehicle Speed Control2 · 6%Visibility · Power Window…2 · 6%Engine2 · 6%Engine And Engine Cooling1 · 3%
  1. Service Brakes, Hydraulic — 4 reports
  2. Power Train — 4 reports
  3. Latches/Locks/Linkages:Doors:Latch — 2 reports
  4. Wheels:Lugs/Nuts/Bolts/Studs — 2 reports
  5. Vehicle Speed Control — 2 reports
  6. Visibility:Power Window Devices And Controls — 2 reports
  7. Engine — 2 reports
  8. Engine And Engine Cooling — 1 reports
  9. Fuel System, Gasoline:Delivery:Fuel Pump — 1 reports
  10. Service Brakes, Hydraulic:Foundation Components:Hoses, Lines/Piping, And Fittings — 1 reports

What to do

  1. Find your 17-character VIN on the driver's door jamb or the base of the windscreen.
  2. Check it against NHTSA's official lookup at nhtsa.gov/recalls — the authoritative record for your exact car.
  3. Book the repair with any franchised dealer. Safety recall work is free, with no time limit and regardless of who owns the car now.

Other model years

1995 (3) · 1996 (3) · 1997 (5) · 1998 (4) · 1999 (5) · 2000 (5) · 2001 (4) · 2002 (3) · 2003 (6) · 2004 · 2005 (4) · 2006 (15) · 2007 (18) · 2008 (17) · 2009 (13) · 2010 (8) · 2011 (12) · 2012 (7) · 2013 (5) · 2014 (6) · 2015 (1) · 2016 (1)

Numbers in brackets are open recall campaigns for that year.

Questions

Does an open recall mean the car is unsafe to drive?

Not usually. NHTSA issues a "do not drive" or "park outside" advisory when a defect is dangerous enough to keep you out of the car — those are flagged Critical above. Everything else should be repaired promptly but is not an immediate stop-driving order.

Do I pay for recall repairs?

No. Federal law requires the manufacturer to fix a safety recall free of charge, including parts and labour, whether or not you are the original owner.

Why are there complaints but no recalls?

Complaints are unverified reports filed by owners. They can prompt an investigation, but many never become recalls — either the fault isn't safety-related or it isn't widespread.