2004 FORD DIESEL OVERHEATS AND STALLS. *TR
2004 Ford E-450
Owner reports · Recalls · Investigations
Limited comparison data
There is not enough comparable history to draw a useful model-year comparison.
About this comparison →How this year compares
Owner complaints by model year
Compare all E-450 years →Counts vary with age, sales and reporting. They are not failure rates.
What owners reported most
All reported categories
Tap a category to read its complaints. One report may name several components.
When problems were reported
Mileage at the reported incident
Limited mileage data: 19 of 27 reports include usable mileage. There isn’t enough coverage to show a useful chart.
NHTSA’s mileage field refers to the reported incident, not necessarily the filing date. This shows report counts, not the likelihood of a failure.
What to inspect
Issues worth paying extra attention to based on owner reports.
- Engine And Engine Cooling. Review the 10 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
- Electrical System. Review the 5 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
- Power Train. Review the 5 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
NHTSA owner reports · September 18, 2026 snapshot.
Engine And Engine Cooling complaints
10 reportsUNKNOWN AS TO EVENTS LEADING UP TO THE FAILURE. THE FAILURE IS, VEHICLE STALLS OUT WITHOUT WARNING AND AT TIMES ENGINE SURGES WITH POWER AND LOSES POWER. VEHICLE IS A FORD E 450 WITH A 6.0 LT DIESEL , MGF BY INTERNATIONAL TRUCK MOTORS FOR FORD MOTOR CO. INCIDENT FIRST REPORTED OCT 28, 2006 AND IS ON GOING TO THIS DATE, GETTIN…
Read full complaint
UNKNOWN AS TO EVENTS LEADING UP TO THE FAILURE. THE FAILURE IS, VEHICLE STALLS OUT WITHOUT WARNING AND AT TIMES ENGINE SURGES WITH POWER AND LOSES POWER. VEHICLE IS A FORD E 450 WITH A 6.0 LT DIESEL , MGF BY INTERNATIONAL TRUCK MOTORS FOR FORD MOTOR CO. INCIDENT FIRST REPORTED OCT 28, 2006 AND IS ON GOING TO THIS DATE, GETTING PROGRESSIVELY WORSE, RENDING VEHICLE UNRELIABLE. VEHICLE IS AN AMBULANCE, MODULAR AFTERMARKET MFG IS PL CUSTOM, OWNED BY THE PITTSTON TOWNSHIP AMBULANCE ASSOCIATION. CONTACT INFO WITH FORD IS MONIQUE - 1.800.343.5338, THEN SELECT OPTIONS - 3, THEN 7, THEN 4. CASE ID # - 41-AGBDWM. *TR
FORD E450 DOORS POP OPEN WHILE DRIVING. CONSUMER STATES THAT THE BODY IS TWISTED, THE DOORS POP OPEN WHILE DRIVING. THE MOTOR AND TRANSMISSION HAVE BEEN REPLACED. PLUS THIS VEHICLE HAS EXPERIENCED EVEN MORE SEVERE PROBLEMS. *KB THE CONSUMER STATED THE BOLTS SHEARED OFF THE BODY OF THE VEHICLE, THE ROOF LEAKED, THE VEHICLE WOUL…
Read full complaint
FORD E450 DOORS POP OPEN WHILE DRIVING. CONSUMER STATES THAT THE BODY IS TWISTED, THE DOORS POP OPEN WHILE DRIVING. THE MOTOR AND TRANSMISSION HAVE BEEN REPLACED. PLUS THIS VEHICLE HAS EXPERIENCED EVEN MORE SEVERE PROBLEMS. *KB THE CONSUMER STATED THE BOLTS SHEARED OFF THE BODY OF THE VEHICLE, THE ROOF LEAKED, THE VEHICLE WOULD JUST SHUT OFF WITH NO WARNING AND THE OVERHEAD OF THE CAB WAS COMING OFF OVER THE WINDSHIELD. *JB ODI NOTE: THIS IS A ROCKPORT BODY ON AN E450 FORD CHASSIS - GTB 5-2-08
ENGINE WAS REPLACED 3 TIMES BY FORD DEALERSHIP, BUT PROBLEM NEVER FIXED , EVERY RE-BUILD ENGINE THAT WAS INSTALLED HAD DIFF. ISSUE , THEN THE LAST ONE JUST CAUGHT IN FIRE FROM LEAKING OIL AND ALSO FROM THE WAY THEY INSTALLED 11-01-07 DATE CAUGHT IN FIRE. *TR
(1) DRIVING VEHICLE. (2) INTERMITTENT POWER LOSS AND STALLING. AFTER STALLING CRANK/NO START (3) TOOK VEHICLE TO DEALER FOR REPAIR, UNABLE TO DUPLICATE PROBLEM NO REPAIRS MADE. REPEATED THIS PROCESS MANY TIMES WITH NO REPAIRS FIXING THE PROBLEM. *TR
WE HAD A MAJOR PROBLEM WITH THE VEHICLE NOT STARTING WHEN IT WAS DISPATCHED TO A CALL. INTERNAL OIL COOLER DISENTIGRATED, AND LEAKED OIL INTO THE COOLING SYSTEM. THE CAM SENSORS, AND INJECTORS HAVE BEEN REPLACED SEVERAL TIMES. THE TRANSMISSION HAD TO BE REPAIRED SHORTLY AFTER PURCHASE, AND HAS HAD ALL OF THE INTERNAL GEARS REPLA…
Read full complaint
WE HAD A MAJOR PROBLEM WITH THE VEHICLE NOT STARTING WHEN IT WAS DISPATCHED TO A CALL. INTERNAL OIL COOLER DISENTIGRATED, AND LEAKED OIL INTO THE COOLING SYSTEM. THE CAM SENSORS, AND INJECTORS HAVE BEEN REPLACED SEVERAL TIMES. THE TRANSMISSION HAD TO BE REPAIRED SHORTLY AFTER PURCHASE, AND HAS HAD ALL OF THE INTERNAL GEARS REPLACED SINCE. ALL OF THE WIRING HARNESSES HAVE BEEN REPLACED.THIS PARTICULAR UNIT HAS SPENT MANY MONTHS THIS YEAR IN A SHOP BEING WORKED ON. *JB
PARAMEDIC PLUS DBA SUNSTAR PARAMEDIC, IN PINELLAS COUNTY, FLORIDA, PURCHASED 54 AMBULANCES, FORD E-450, 6.0 LITER, IN AUGUST OF 2004. FOR THE PAST TWO YEARS OF USING THESE AMBULANCES IN ONE OF THE COUNTRIES BUSIEST EMS AGENCIES, WE'VE INCURRED A MULTITUDE OF ISSUES, WHICH HAVE HAMPERED OUR ABILITY TO PUT AMBULANCES ON THE STREE…
Read full complaint
PARAMEDIC PLUS DBA SUNSTAR PARAMEDIC, IN PINELLAS COUNTY, FLORIDA, PURCHASED 54 AMBULANCES, FORD E-450, 6.0 LITER, IN AUGUST OF 2004. FOR THE PAST TWO YEARS OF USING THESE AMBULANCES IN ONE OF THE COUNTRIES BUSIEST EMS AGENCIES, WE'VE INCURRED A MULTITUDE OF ISSUES, WHICH HAVE HAMPERED OUR ABILITY TO PUT AMBULANCES ON THE STREET. THESE PROBLEMS INCLUDE, BUT ARE NOT LIMITED TO: EGR VALVES, EGR COOLERS, OIL COOLERS, INJECTORS, AC COMPRESSORS, RADIATORS, WIRING HARNESSES, SEVERAL ENGINES. EVERY AMBULANCE IN OUR FLEET HAS BEEN AFFECTED BY ONE OR MORE OF THE ABOVE PROBLEMS. IN SPEAKING WITH EMS AGENCY REPRESENTATIVES ACROSS THE UNITED STATES, I HAVE FOUND THAT THIS IS NOT AN ISOLATED PROBLEM. WE ARE SPENDING COUNTLESS HOURS OF LABOR AND COST OF REPAIRS OVER TWO YEARS WITH 54 OF THESE VEHICLES. WE HAVE MAINTAINED ALL RECORDS OF REPAIR AND CAN DEMONSTRATE THE IMPACT THIS HAS ON OUR EMERGENCY 911 SERVICE. PLEASE FEEL FREE TO CONTACT ME AT YOUR CONVENIENCE SO WE CAN DISCUSS MORE OF THIS IN DETAIL. *JB
I BOUGHT A FORD 2004 E450 WITH A6. 0 ENGINE AND HAVE HAD TRANSMISSION PROBLEMS TWICE, ALSO REPLACED 2 HEATER CORES. THE VEHICLE ALSO STALLS AT HIGH SPEEDS ON THE HIGHWAY . I HAVE HAD NO LUCK WITH FORD CUSTOMER SUPPORT TO SELL BACK VIA LEMON LAW. *NM
WHILE DRIVING AT VARIOUS SPEEDS OR TURNING THE ENGINE STALLED. WHEN THIS OCCURRED THE VEHICLE COASTED TO A COMPLETE STOP. DEALERSHIP REPROGRAMMED THE COMPUTER TWICE, REPLACED THE SENSOR ON CRANK SHAFT, AND CHECKED THE WIRING IN THE ENGINE COMPARTMENT. BUT, PROBLEM RECURRED. VEHICLE IS CURRENTLY AT THE DEALERSHIP. THE CHASSIS IS…
Read full complaint
WHILE DRIVING AT VARIOUS SPEEDS OR TURNING THE ENGINE STALLED. WHEN THIS OCCURRED THE VEHICLE COASTED TO A COMPLETE STOP. DEALERSHIP REPROGRAMMED THE COMPUTER TWICE, REPLACED THE SENSOR ON CRANK SHAFT, AND CHECKED THE WIRING IN THE ENGINE COMPARTMENT. BUT, PROBLEM RECURRED. VEHICLE IS CURRENTLY AT THE DEALERSHIP. THE CHASSIS IS CONNECTED TO A BIG FOOT MH30BB 2004 MOTOR HOME. *AK WHEN THE ENGINE SHOT DOWN IT CHIMED AND THE LIGHTS CAME ON INDICATING THAT WATER WAS IN THE FUEL. CHECK ENGINE LIGHT COMES ON THEN THE ENGINE DIED. *TC
THE VEHICLE WILL NOT START. THE VEHICLE WAS TOWED TO DEALER AND THEY CANNOT FIND DEFECTS. THE MANUFACTURE HAS STATED THAT THEY WILL HELP. THE CONSUMER STATED "THIS IS AN EMERGENCY VEHICLE, AND HAS BEEN OUT OF SERVICE FOR THIRTEEN DAYS". *NM
Official recalls
305V270000 · Electrical System:wiring
Jun 10, 2005
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.
Consequence & remedy
Consequence: SHOULD THE ENGINE STALL, A VEHICLE CRASH COULD OCCUR.
Remedy: 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.
04V444000 · Electrical System:wiring
Sep 13, 2004
ON CERTAIN VANS, A DIODE IN THE ANTI-LOCK BRAKING SYSTEM (ABS) MODULE MAY EXPERIENCE AN ELECTRICAL SHORT.
Consequence & remedy
Consequence: 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.
Remedy: 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.
04V445000 · Engine And Engine Cooling
Sep 13, 2004
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.
Consequence & remedy
Consequence: THESE HOT PARTICLES MAY IGNITE THE AIR FILTER ELEMENT WITH THE POTENTIAL FOR AIR INDUCTION SYSTEM DAMAGE OR UNDERHOOD FIRE.
Remedy: 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.
Model-level recall history does not show whether a particular VIN is affected or has received a repair. Check a VIN with NHTSA ↗
NHTSA investigations
1PE09055 · Hvac Switch Failures
Opened Dec 7, 2009 · Closed Apr 21, 2010
Status: closed (inferred from source dates) · Electrical System:wiring:interior/under Dash
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.
Illustration