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2004 Ford E-450 Recalls & Complaints

4

open safety recalls on record

Critical

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

The recalls

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.

Critical05V270000

Electrical System:Wiring

SHOULD THE ENGINE STALL, A VEHICLE CRASH COULD OCCUR.

Remedy & full details

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.

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.

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.

Complaint volume

45 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

0Crashes
5Fires
0Injuries
0Deaths

Across 45 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

Engine And Engine Cooling4 · 9%Engine And Engine Cooling…4 · 9%Tires4 · 9%Electrical System4 · 9%Power Train · Automatic T…3 · 7%Service Brakes3 · 7%Visibility · Defroster/De…2 · 4%Power Train2 · 4%
  1. Engine And Engine Cooling — 4 reports
  2. Engine And Engine Cooling:Engine:Diesel — 4 reports
  3. Tires — 4 reports
  4. Electrical System — 4 reports
  5. Power Train:Automatic Transmission — 3 reports
  6. Service Brakes — 3 reports
  7. Visibility:Defroster/Defogger/Hvac System:Heater Core — 2 reports
  8. Power Train — 2 reports
  9. Fuel System, Diesel — 2 reports
  10. Vehicle Speed Control:Cruise Control — 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

1996 (2) · 1997 (2) · 1998 (2) · 1999 (2) · 2000 (2) · 2001 (2) · 2002 (3) · 2003 (5) · 2004 · 2005 (7) · 2006 (12) · 2007 (11) · 2008 (8) · 2009 (10) · 2010 (7) · 2011 (10) · 2012 (4) · 2013 (2) · 2014 (3) · 2015 (1) · 2016 (4) · 2017 (2) · 2018 (4) · 2019 · 2021 (6) · 2022 (3) · 2023 (3) · 2024 · 2025 · 2026 (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.