Model year record

2004 Ford E-450 recalls & problems

The 2004 Ford E-450 has 6 safety recalls and 27 owner complaints on file with NHTSA. The most-reported problem area is engine and engine cooling (10 complaints).

Recalls6safety recalls

Complaints27filed by owners

Crashes · fires0 · 3reported in complaints

Injuries · deaths0 · 0reported in complaints

Safety recalls

Equipment adaptive/mobilityOct 8, 2008

Equipment adaptive/mobility

Recall 08V5260008 vehiclesopened after NHTSA action (ODI)

Problem: MATTHEWS IS RECALLING 8 MY 1998 BLUEBIRD, MY 2004 FORD E450, MY 2005-2006 THOMAS BUILT BUS, MY 2006 INTERNATIONAL BUS, MY 2007 CHEVROLET 5500, FREIGHTLINER AND DODGE SPRINTER TRUCKS, TRANSIT BUSES, AND SPECIALTY VEHICLES 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.
Risk: A LIFT OCCUPANT CAN BE INJURED SHOULD THE LIFT BEGIN TO STOW UNINTENTIONALLY.
Fix: MATTHEWS 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 MATTEWS SPECIALTY AT 336-297-9600.

Equipment adaptive/mobilityOct 8, 2008

Equipment adaptive/mobility

Recall 08V5240008 vehiclesopened after NHTSA action (ODI)

Problem: MATTHEWS IS RECALLING 8 MY 1998 BLUEBIRD, MY 2004 FORD E450, MY 2005-2006 THOMAS BUILT BUSES, MY 2006 INTERNATIONAL BUS, MY 2007 CHEVROLET 5500, FREIGHTLINER AND DODGE SPRINTER TRUCKS, TRANSIT BUSES, AND SPECIALTY VEHICLES EQUIPPED WITH RICON PLATFORM STYLE WHEELCHAIR LIFTS. THESE BUSES FAIL TO COMPLY WITH THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 404, "PLATFORM LIFT INSTALLATION 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.
Risk: THE USER OF THE LIFT COULD BE INJURED SHOULD THE LIFT MOVE UNINTENTIONALLY.
Fix: MATTHEWS 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 MATTHEWS SPECIALTY AT 336-297-9600.

Fuel system, gasolineJun 13, 2006

Fuel system, gasoline

Recall 06E05600058,640 vehicles

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

Electrical systemJun 10, 2005

Wiring

Recall 05V270000180,104 vehiclesopened after NHTSA action (ODI)

Problem: 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.
Risk: SHOULD THE ENGINE STALL, A VEHICLE CRASH COULD OCCUR.
Fix: 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.

Electrical systemSep 13, 2004

Wiring

Recall 04V444000214,849 vehicles

Problem: ON CERTAIN VANS, A DIODE IN THE ANTI-LOCK BRAKING SYSTEM (ABS) MODULE MAY EXPERIENCE AN ELECTRICAL SHORT.
Risk: 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.
Fix: 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.

Engine and engine coolingSep 13, 2004

Engine and engine cooling

Recall 04V445000253,076 vehicles

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

Recall repairs are free at any authorised dealer. A recall listed here may already have been fixed on a particular car: enter its 17-character VIN at nhtsa.gov/recalls to see open recalls.

What owners report

Problem area	Complaints	Fires	Typical mileage*
Engine and engine coolingEngine › Diesel; Engine	10	1	28,462 mi
Electrical systemIgnition; Wiring › Front underhood	6	2	90,599 mi
Power trainAutomatic transmission	5	1	45,104 mi
Tires	4	0	28,385 mi
EquipmentAppliance › Air conditioner; Recreational vehicle/trailer › Lpg systems › Water heater	3	0	—
Service brakes	3	0	—
VisibilityDefroster/defogger/hvac system › Heater core	2	0	—
Fuel system, otherFuel injection system	2	1	—
StructureBody	2	0	—
Fuel system, diesel	2	0	—
Vehicle speed controlCruise control	1	0	—
Exterior lightingBrake lights › Switch	1	0	—

*Median odometer reading when the problem happened, where owners gave one. One complaint can name several problem areas.

Recent owner complaints

Equipment › Recreational vehicle/trailer › Lpg systems › Water heater
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 constant rubbing against the hole going through the frame. Our safety, and the safety of many others across the nation is at risk, specifically with the reports of motorhome fires to date. THE existing problem has not been confirmed by a dealer or independent service center at this time. THE existing problem has not been confirmed by the manufacturer, police, insurance representatives or others. NO…
Jun 1, 2018
Electrical systemFire
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 catastrophe.
Jan 13, 2022
Tires
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 REMEMBER RUNNING OVER ANY OBJECTS IN THE FREEWAY AND HAD NOT HIT ANY POT HOLES. THIS TIRE WAS THREE YEARS OLD WITH LESS THAN 5,000 MILES ON IT. I HAD CHECKED AND VERIFIED THE TIRE PRESSURE BEFORE LEAVING AND ENSURED THAT I HAD INFLATED THE TIRES TO THE RECOMMENDED TIRE PRESSURE PER THE VEHICLES OWNER MANUAL 80 PSI. THESE TIRES WERE THE DEFINITY DAKOTA LT225/75/16 TIRE. THE TIRE WAS REPLACED BY PEP…
Nov 25, 2018 · 23,425 miles
Equipment
TL* THE CONTACT OWNS A 2004 FORD E-450. THE CONTACT RECEIVED NOTIFICATION OF NHTSA CAMPAIGN NUMBER: 17V782000 (EQUIPMENT). THE MANUFACTURER WAS CONTACTED AT 1-855-262-3540 APPROXIMATELY TWO MONTHS AGO. THE CONTACT LEFT A VOICEMAIL FOR A CALL BACK, BUT DID NOT RECEIVE A RESPONSE. THE CONTACT FELT THAT A REASONABLE AMOUNT OF TIME HAD PASSED FOR THE RECALL REMEDY. THE CONTACT HAD NOT EXPERIENCED A FAILURE. THE VIN WAS NOT AVAILABLE.
Dec 1, 2017
Electrical system
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 POWER CONTROL MODULE, STARTER AND THE HOP OIL PRESSURE PUMP NEEDED TO BE REPLACED. THE VEHICLE WAS REPAIRED; HOWEVER, THE FAILURE RECURRED ON NUMEROUS OCCASIONS. THE MANUFACTURER WAS NOTIFIED. THE FAILURE MILEAGE WAS 119,000.
Apr 2, 2014 · 119,000 miles
Structure › Body
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 INFORM D.O.T. ANONYMOUSLY. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6). *TR
Jun 18, 2014
Tires
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. VERY LITTLE WARNING, JUST SLIGHT FEELING OF MISBALANCE BEFORE TIRE EXPLODED. TIRES HAD BEEN CHECKED FOR PROPER INFLATION 2-3 DAYS BEFORE. TIRES WERE VISUALLY INSPECTED DURING TRAVEL - NO SIGNS OF OVER/UNDER INFLATION. *TR
May 11, 2014
Service brakes
TL* THE CONTACT OWNS A 2004 FORD E-450. THE CONTACT STATED THAT WHILE DRIVING APPROXIMATELY 40 MPH, THE BRAKES SUDDENLY ENGAGED INDEPENDENTLY. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC FOR DIAGNOSIS. THE MECHANIC STATED THAT THE ALUMINUM PUCKS IN THE BRAKING SYSTEM EXPANDED WHEN HEATED, CAUSING THE BRAKES TO ENGAGE. THE MECHANIC RECOMMENDED REPLACING THE ALUMINUM PUCKS WITH STEEL ONES. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE VEHICLE WAS NOT REPAIRED. THE APPROXIMATE FAILURE MILEAGE WAS 30,000. UPDATED 3/28/14*CN
Nov 22, 2008 · 30,000 miles

Owner complaints are submitted to NHTSA by the public and are not verified. Shown as filed (NHTSA removes personal details); long reports are shortened.

NHTSA defect investigations

HVAC Switch FailuresClosed
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 have reported a burning smell or smoke coming from the dash.One fleet reported a vehicle fire.No injuries were sustained.However, the bus was carrying special needs children when the driver noticed smoke coming from the dash.The driver was able to evacuate the children prior to the vehicle becoming engulfed in flames.This PE has been upgraded to an Engineering Analysis (EA) to determine if the blower motor switch failures create a situation where a vehicle fire is possible and presents a safety risk to the driver and other passengers.
PE09055 · opened Dec 7, 2009 · closed Apr 21, 2010