IllustrationMy 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.
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.
0 crash reports3 fire reports0 injury reports
Electrical System complaints
5 reportsTL* 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 AN…
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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.
FORD E450 FRONT BLOWER MOTOR SWITCH FAILURE ON TRANSIT BUSES USED FOR PUBLIC TRANSPORTATION. *NJ THE CONSUMER STATED THE PROBLEM IS NOT ISOLATED TO ONE VEHICLE AND IS BEING FOUND ROUTINELY IN ALL THE VEHICLES OF THIS TYPE IN HIS FLEET AS THE SWITCHES ROUTINELY OVERHEAT. ONE OF THE VEHICLES CAUGHT FIRE AS A RESULT OF THE FAULTY…
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FORD E450 FRONT BLOWER MOTOR SWITCH FAILURE ON TRANSIT BUSES USED FOR PUBLIC TRANSPORTATION. *NJ THE CONSUMER STATED THE PROBLEM IS NOT ISOLATED TO ONE VEHICLE AND IS BEING FOUND ROUTINELY IN ALL THE VEHICLES OF THIS TYPE IN HIS FLEET AS THE SWITCHES ROUTINELY OVERHEAT. ONE OF THE VEHICLES CAUGHT FIRE AS A RESULT OF THE FAULTY SWITCH. *JB
TL*THE CONTACT OWNS A 2004 FORD E-450. WHILE DRIVING VARIOUS SPEEDS, THE VEHICLE SPONTANEOUSLY STALLED. THE VEHICLE USUALLY RESTARTS ITSELF AFTER THE FAILURE OCCURS. THE VEHICLE WAS TAKEN TO THE DEALER ON FIVE OCCASIONS AND ALL THE FUEL INJECTORS WERE REPLACED. A MECHANIC STATED THAT THE FUEL INJECTION CONTROL MODULE (FICM) …
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TL*THE CONTACT OWNS A 2004 FORD E-450. WHILE DRIVING VARIOUS SPEEDS, THE VEHICLE SPONTANEOUSLY STALLED. THE VEHICLE USUALLY RESTARTS ITSELF AFTER THE FAILURE OCCURS. THE VEHICLE WAS TAKEN TO THE DEALER ON FIVE OCCASIONS AND ALL THE FUEL INJECTORS WERE REPLACED. A MECHANIC STATED THAT THE FUEL INJECTION CONTROL MODULE (FICM) WIRE HARNESS WAS THE CAUSE OF THE FAILURE. THE DEALER STATED THAT THE VIN WAS EXCLUDED FROM NHTSA CAMPAIGN ID NUMBER 05V270000 (ELECTRICAL SYSTEM:WIRING); THEREFORE, THEY WOULD NOT ASSUME ANY FINANCIAL RESPONSIBILITY FOR THE REPAIRS. THE VEHICLE HAS NOT BEEN REPAIRED. THE FAILURE MILEAGE WAS 120,000 AND CURRENT MILEAGE WAS 337,000.
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…
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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
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.