FORD F-650 SD · model year

2004 FORD F-650 SD

12 NHTSA complaints, and 2 active recalls for this specific cohort.

NHTSA overall rating

Not crash-tested

New Car Assessment Program

The 2004FORDF-650 SD carries 12 consumer safety complaints in NHTSA's Office of Defects Investigation database for this specific model-year cohort. Within that volume, owners reported 0 crashes, 0 fires, 2 injuries, and 0 fatalities. No NCAP 5-star crash-test rating is available for this model year in the federal database.

Component-level analysis is where model-year complaints become actionable: the top complaint category for the 2004 F-650 SD is engine and engine cooling with 2 filings, followed by service brakes, hydraulic:antilock/traction control/electronic limited slip:abs warning light (1) and suspension:rear:springs:air suspension system (1). Concentration in one or two component groups is the classic signature of a systemic defect; a flat distribution usually reflects normal aging, warranty complaints, or isolated build-plant variability. This model year has 2 active recall campaigns, which means the manufacturer is obligated to remedy the covered defect at no charge for the life of the vehicle — the full NHTSA campaign numbers are listed below.

NHTSA currently has 177 investigation files overlapping the 2004 F-650 SD, and 8 remain open. Owners comparing this cohort against neighboring years should pair the counters above with the complaint-by-year trend on the parent model page — a spike in a single year often tracks to a platform refresh, a new transmission supplier, or an updated ECU calibration. Use the related-complaint feed below to read raw owner narratives before deciding whether any pattern here affects your specific use case.

12
Complaints
0
Crashes
0
Fires
2
Injuries
0
Deaths

Total Complaints

12 filings

Crashes Reported

0 reports

Source

NHTSA ODI

Federal complaints database

Complaints vs. fleet median (215)

At or below the fleet median complaint volume.

Complaints by Component

ComponentCount
ENGINE AND ENGINE COOLING2
SERVICE BRAKES, HYDRAULIC:ANTILOCK/TRACTION CONTROL/ELECTRONIC LIMITED SLIP:ABS WARNING LIGHT1
SUSPENSION:REAR:SPRINGS:AIR SUSPENSION SYSTEM1
ENGINE AND ENGINE COOLING:EXHAUST SYSTEM:EMISSION CONTROL1
SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS:DISC:CALIPER1
ENGINE AND ENGINE COOLING:ENGINE1
TIRES:TREAD/BELT1
TIRES1
EQUIPMENT1
ELECTRICAL SYSTEM1
STRUCTURE1

Recalls (2)

03V31900028/08/2003

SERVICE BRAKES, AIR

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.

03V28300005/08/2003

EQUIPMENT:OTHER:LABELS

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 INFORMATI

Recent Complaints

20240808ENGINE AND ENGINE COOLING

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 to diagnose or repair the vehicle. The mechanic informed the contact that the vehicle was no longer safe to drive and should no longer be driven on the road. The vehicle was not repaired. The dealer and the manufacturer were not notified of the failure. The failure mileage was unknown.

20240808STRUCTURE

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 to diagnose or repair the vehicle. The mechanic informed the contact that the vehicle was no longer safe to drive and should no longer be driven on the road. The vehicle was not repaired. The dealer and the manufacturer were not notified of the failure. The failure mileage was unknown.

20080815ELECTRICAL SYSTEM

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. *TR

Mileage: 6,000

20070205TIRES

HANKOOK TIRES ARE BEING INSTALLED ON VEHICLES WHICH REQUIRE A LOAD RANGE HIGHER THAN A PASSENGER TIRE P235/R16 SL. THESE VEHICLES WEIGH IN AT 24,000 LBS GVW AND AT TIMES CAN BE OVERLOADED. THEY ALSO DO NOT TAKE INTO ACCOUNT THE 5% SAFETY FACTOR SINCE THE REARS ARE ON DUALS. TIRES WERE WEARING EXTREMELY FAST AND SOME WERE DEVELOPING SEPARATIONS IN THE TREAD AND SIDEWALL AREAS AS WELL AS A NUMBER OF THEM BLEW OUT. IT WAS RECOMMENDS THEY MOVE TO A RADIAL TRUCK TIRE LR E AND THEY WERE CONVINCED THIS WAS THE WAY TO GO SINCE THEY WOULD HAVE A RETREADABLE CASING AND MORE CARRYING CAPACITY. I INSTALLED GOODYEAR RADIAL LT ON ALL SIX POSITIONS. I WAS CHASTISED ALONG WITH MY ASSISTANT FOR DOING SO BY (SHAWNEE MISSION FORD) FOR PUTTING RADIAL TRUCK TIRES ON WHICH WOULD LAST THREE TIMES AS LONG AND CUT INTO THEIR PURCHASES WHICH THEY HAD A QUOTA BASED ON A FORD MOTOR COMPANY PROGRAM THAT PUSHED TIRE SALES. FAILURE TO MEET THE OBJECTIVE CREATED CONSTERNATION WITHIN THE LOCAL DEALER AS THEY SOL

20070205EQUIPMENT

HANKOOK TIRES ARE BEING INSTALLED ON VEHICLES WHICH REQUIRE A LOAD RANGE HIGHER THAN A PASSENGER TIRE P235/R16 SL. THESE VEHICLES WEIGH IN AT 24,000 LBS GVW AND AT TIMES CAN BE OVERLOADED. THEY ALSO DO NOT TAKE INTO ACCOUNT THE 5% SAFETY FACTOR SINCE THE REARS ARE ON DUALS. TIRES WERE WEARING EXTREMELY FAST AND SOME WERE DEVELOPING SEPARATIONS IN THE TREAD AND SIDEWALL AREAS AS WELL AS A NUMBER OF THEM BLEW OUT. IT WAS RECOMMENDS THEY MOVE TO A RADIAL TRUCK TIRE LR E AND THEY WERE CONVINCED THIS WAS THE WAY TO GO SINCE THEY WOULD HAVE A RETREADABLE CASING AND MORE CARRYING CAPACITY. I INSTALLED GOODYEAR RADIAL LT ON ALL SIX POSITIONS. I WAS CHASTISED ALONG WITH MY ASSISTANT FOR DOING SO BY (SHAWNEE MISSION FORD) FOR PUTTING RADIAL TRUCK TIRES ON WHICH WOULD LAST THREE TIMES AS LONG AND CUT INTO THEIR PURCHASES WHICH THEY HAD A QUOTA BASED ON A FORD MOTOR COMPANY PROGRAM THAT PUSHED TIRE SALES. FAILURE TO MEET THE OBJECTIVE CREATED CONSTERNATION WITHIN THE LOCAL DEALER AS THEY SOL

20061122TIRES:TREAD/BELT

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.

Mileage: 125,000

20060831ENGINE AND ENGINE COOLING:ENGINE

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.

Mileage: 71,000

20050809SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS:DISC:CALIPER

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. *JB

Mileage: 20,341

20050405ENGINE AND ENGINE COOLING

VEHICLE STALLED ON 2 SEPARATE OCCASIONS WHILE DRIVING. DEALERSHIP WAS UNABLE TO INDICATE THE CAUSE OF THE FAILURE. VEHICLE WAS AT THE DEALERSHIP FOR THE LAST 2 WEEKS DUE TO THE FAILURE.*AK *BF *NM

Mileage: 9,000

20041014ENGINE AND ENGINE COOLING:EXHAUST SYSTEM:EMISSION CONTROL

FORD F650. 17,000 MILES ON TRUCK, HAD SINCE NEW. BEEN IN SHOP FOR PERFORMANCE, POWER, AND FUEL ECONOMY ISSUE`S 4 OUT OF 6 WEEKS. C7 300 H.P. CATERPILLAR ENGINE. CAT ADMITS KNOWN ISSUE WITH COMPUTER NOT ABLE TO CORRECTLY TELL ENGINE PROPER FUEL MEASUREMENTS. ENGINE WEAR MASKS PROPER ALIGNMENT. DOWN TIME HAS LOST ME BUSINESS AND MONEY. FEDERAL MOTOR CARRIER 494973. CAT PUT NEW ENGINE IN AT 23,000 MILES, TELLING ME ENGINE WAS NOT ISSUE, AND WAS CLEARLY A COMPUTER AND ENGINE COMBO ISSUE. I HAVE ASKED FOR MONEY BACK ON TRUCK. THEY CONTINUE TO SAY LETS LOOK AT AGAIN. I HAVE TOLD MY CUSTOMERS NO TO MANY TIMES, AND AM NOW NOT GETTING THE OPPORTUNITY TO TELL THEM ANYMORE. I DO NOT WANT TO BE THE BETA TEST TRUCK. IT DOESN`T PAY. NO COMPENSATION BEING OFFERED. NO CALLS FROM FORD MOTOR CO.*AK

Mileage: 8,500

20040513SUSPENSION:REAR:SPRINGS:AIR SUSPENSION SYSTEM

THIS TRUCK HAS A TERRIBLE VIBRATION STARTING AT 53 AND GOING THRU 65 THEN THE INTENSITY LESSONS BUT CONTINUES. SHIFT OF TRANSMISSION IS ALMOST IMPOSSIBLE AT TIME, FRONT END HAS PROBLEMS INCLUDING WEARING OF TIRED IN 29960 MILES. *AK

Mileage: 3

20030923SERVICE BRAKES, HYDRAULIC:ANTILOCK/TRACTION CONTROL/ELECTRONIC LIMITED SLIP:ABS WARNING LIGHT

CONSUMER STATED THAT FOR THE LAST SIX MONTHS ABS INDICATOR LIGHT HAS BEEN FLASHING. DEALER HAS BEEN CONTACTED.*AK

Compare 2004FORDF-650 SD to Similar Vehicles

NHTSA Investigations 8 Open

View all investigations

Frequently Asked Questions

How many complaints does the 2004 FORD F-650 SD have?
The 2004 FORD F-650 SD has 12 NHTSA complaints, 0 crashes, 0 fires, 2 injuries, and 0 deaths reported.
Are there any recalls for the 2004 FORD F-650 SD?
Yes, the 2004 FORD F-650 SD has 2 recall(s). The most common affected component is SERVICE BRAKES, AIR. Recalls are issued by NHTSA and manufacturers must provide a free remedy.
What are the most common problems with the 2004 FORD F-650 SD?
The most-complained component for the 2004 FORD F-650 SD is ENGINE AND ENGINE COOLING with 2 complaints. Other frequently reported areas include SERVICE BRAKES, HYDRAULIC:ANTILOCK/TRACTION CONTROL/ELECTRONIC LIMITED SLIP:ABS WARNING LIGHT and SUSPENSION:REAR:SPRINGS:AIR SUSPENSION SYSTEM.
Is the 2004 FORD F-650 SD safe to buy?
Review the complaint history, crash and fire reports, safety ratings, and recall status on this page to make an informed decision. No NHTSA crash test rating is available for this model year. Compare with other model years using the links above.
Where does this data come from?
All complaint, recall, and safety rating data is sourced from the National Highway Traffic Safety Administration (NHTSA). Complaints are filed by vehicle owners through NHTSA's Office of Defects Investigation.

Vehicle Safety Guides

Data as of 2025. Sources: NHTSA Office of Defects Investigation (ODI) complaints database, NHTSA recall campaign API, NHTSA NCAP crash-test ratings, and NHTSA FARS for fatality cross-reference.