2004 Ford F-650 SD recalls and problems

The 2004 Ford F-650 SD has 2 safety recalls and 10 owner complaints filed with NHTSA. Recall repairs are free at any Ford dealer.

Recalls

Complaints

Crashes / fires

0 / 0

Injuries / deaths

1 / 0

Recalls may cover only some 2004 Ford F-650 SD vehicles. Check your VIN at NHTSA ↗ to see open recalls for your exact car.

2004 Ford F-650 SD recalls

Recall 03V-319: Service Brakes, Air

Reported Aug 28, 2003 · 97 vehicles affected · FORD MOTOR COMPANY

Problem: 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.

Risk: 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.

Fix: 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.

Recall 03V-283: Equipment

Reported Aug 5, 2003 · 1,000 vehicles affected · FORD MOTOR COMPANY

Problem: 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 pressure shown in english units (Psi) is correct), and transposed tire size and rim size information.

Fix: 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.

2004 Ford F-650 SD problems reported by owners

Problem area	Reports
Engine and Engine Cooling	4
Service Brakes, Hydraulic	2
Tires	2
Suspension	1
Equipment	1
Electrical System	1
Structure	1

Most reported parts

Service Brakes, Hydraulic › Antilock/Traction Control/Electronic Limited Slip › Abs Warning Light — 1
Suspension › Rear › Springs › Air Suspension System — 1
Engine and Engine Cooling › Exhaust System › Emission Control — 1
Service Brakes, Hydraulic › Foundation Components › Disc › Caliper — 1
Engine and Engine Cooling › Engine — 1
Tires › Tread/Belt — 1

Typical mileage at the time of the problem: 9,000 miles (median of owner reports).

Problems that are not covered by a recall are paid repairs; labor rates follow local mechanic pay — see what auto mechanics earn in each state.

Recent 2004 Ford F-650 SD complaints

Owner reports filed with NHTSA, as written (personal details removed). Complaints are not verified by NHTSA.

Engine and Engine Cooling · reported Aug 8, 2024

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 driving at various speeds, there was a strong engine oil odor and carbon monoxide odor entering the cabin through the gap in the floorboard. The contact stated that he had headaches due to the failure. The contact notified an independent Diesel mechanic of the engine oil leak, but the mechanic declined…

Electrical System · at 6,000 miles · reported Aug 15, 2008

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 weeks and still no way to fit it fixed called ford in dearborn they wont do anything for me as there system is running slow. I still have no head lights that will stay on.

Tires · at 125,000 miles · reported Nov 22, 2006

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 of the highway. The failed tire was only three weeks old. When the service dealer was notified, the contact was informed the tire distributor needed to be contacted and if the distributor would provide a credit, it would be passed on to the contact.

Engine and Engine Cooling · at 71,000 miles · reported Aug 31, 2006

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.

Service Brakes, Hydraulic · at 20,341 miles · reported Aug 9, 2005

2004 f650 tow truck brakes keep eating rotor had to replace whole driver side brake system 2 times , we only got 13,8888 miles on the first brake job.

Other Ford F-650 SD years

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Compare all Ford F-650 SD years · All Ford models

Frequently asked questions

Does the 2004 Ford F-650 SD have any recalls?

Yes — NHTSA lists 2 recalls for the 2004 Ford F-650 SD: 03V-319 (service brakes, air), 03V-283 (equipment). Not every vehicle is affected, so check your VIN at nhtsa.gov/recalls.

What is the most common problem with the 2004 Ford F-650 SD?

Owners report engine and engine cooling problems most often (4 reports), followed by service brakes, hydraulic (2). The typical mileage when problems were reported is about 9,000 miles.

Are Ford recall repairs free?

Yes. Safety recall repairs are free at authorized Ford dealers, whether you are the first owner or bought the car used.