2004 FORD F-450 SD Fuel System, Diesel Problems

10/17/13 I WAS DRIVING ON THE INTERSTATE WITH A LOAD OF CATTLE RUNNING FINE AND JUST LOST POWER GOING ON THE INTERSTATE GOING FROM 65 TO 10 MILES AN HOUR. TRAFFIC ZIPPING BY. I THOUGHT IT WAS THE FUEL FILTERS BUT IT DONE THE SAME AFTER I CHANGED THEM. I TOOK IT TO A GARAGE AND HE SAID HE THE TANK LINER WAS COMING APART NOW IT MESSED UP MY INJECTORS, AND I THINK FORD SHOULD HAVE A RECALL ON SOMETHING LIKE THAT BEFORE SOMEONE GETS KILLED OR SEVERLY HURT!!!! IT IS IN THE SHOP NOW AND I THINK FORD SHOULD PAY SOMETHING ON THIS. *TR

AT APPX. 80,000 MILES ON OUR 2004 F450 SD FUEL TANK DELAMINATED CAUSING FUEL SYSTEM FAILURE WHICH RESULTED IN SUDDEN LOSS OF POWER. WE HAVE ALWAYS PURCHASED HIGH QUALITY DIESEL FROM REPUTATABLE GAS STATIONS (CHEVRON, SHELL). VEHICLE REPAIRED AT FORD AND HAD CONTACTED FORD MOTOR COMPANY REGARDING REIMBURSEMENT OF COST AND WAS DECLINED. *TR

Mileage: 80,000

TL* THE CONTACT OWNS A 2004 FORD F-450. THE CONTACT STATED THAT THE VEHICLE STALLED WHILE DRIVING 55 MPH. THE CHECK ENGINE LIGHT ILLUMINATED AFTER THE FAILURE OCCURRED. THE VEHICLE WAS TOWED TO THE DEALER WHERE THE DEALER PERFORMED A DIAGNOSTIC THAT LOCATED THE FAILURE AS THE FUEL LINER DELAMINATING. THE DEALER REPLACED THE FUEL TANK AND THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE FAILURE AND THE CURRENT MILEAGE WAS 200,000. UPDATED 01/11/12

Mileage: 200,000

TL* THE CONTACT OWNS A 2004 F-450 SD. WHILE DRIVING, THE CONTACT STATED THAT THE VEHICLE WOULD LOOSE POWER AND WOULD STALL INTERMITTENTLY. THE DEALER DIAGNOSED THAT THERE WAS DELAMINATION FOUND IN THE FUEL TANK LINING, WHICH WAS FLAKING OFF AND CAUSING A LEAK IN THE FUEL FILTER AND FUEL PUMP. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE VEHICLE WAS REPAIRED. THE FAILURE MILEAGE WAS UNAVAILABLE AND THE CURRENT MILEAGE WAS 34,000.

2004 FORD F450 AMBULANCE. CONSUMER STATES DEFECTIVE OF THE FUEL TANK *TGW THE CONSUMER STATED AS A RESULT OF A SERIOUS STRUCTURAL DEFECT OF THE FUEL TANK, THE VEHICLE STALLED DURING SEVERAL EMERGENCY CALLS. THE COATING IN THE INTERIOR DIESEL FUEL TANK CORRODED AND COLLECTED AS SEDIMENT, WHICH EXTRACTED INTO THE FUEL SYSTEM. THE FUEL LINE BECAME CLOGGED AND DAMAGED THE FUEL PUMP AND VALVES. *JB UPDATED 03/01/12 *BF UPDATED 03/16/12 UPDATED 04/18/12

FUEL TANK DELAMINATION. TRUCKS STARTED RUNNING BAD, WOULD EVENTUALLY STOP. HAS LEFT ME AND MY EMPLOYEES STRANDED SEVERAL TIMES, SOMETIMES IN UNSAFE TRAFFIC AREAS. NEW FUEL TANKS INSTALLED, FUEL PUMPS INJECTORS PUT IN NEW. ENTIRE FUEL SYSTEM CLEANED. JUST UNDER $5000.00 EACH TIME. FORD SAYS BIOFUEL IS THE CAUSE. NEVER HAVE USED BIOFUEL IN ANYTHING. *TR

Mileage: 110,000

2004 FORD F-450 SUPER DUTY. TRUCK WAS RUNNING AS IF IT WAS RUNNING OUT OF FUEL, GOT TO A STOP LIGHT AND THE TRUCK STALLED. GOT THE TRUCK TO RESTART. THAT EVENING I HAD THE FUEL FILTERS CHANGED THINKING THAT WAS THE PROBLEM, THEN THE TRUCK RAN FINE. TWO DAYS LATER THE TRUCK DID THE SAME THING, AND I WAS DRIVING AT 25MPH, TRUCK WOULD NOT RUN ANY FASTER, THEN THE TRUCK STALLED IN THE MIDDLE OF A TWO LANE ROAD. THE TRUCK AT THIS TIME DID NOT RESTART. I HAD TO GET THE TRUCK TOWED. I GOT ADVICE FROM A MECHANIC AND HE DRAINED THE TANK AND HE FOUND SILVER FLAKES IN THE TANK. I CALLED UNIVERSAL FORD IN RICHMOND VIRGINIA AND THEY HAD IT TOWED THERE TO LOOK AT THE TRUCK, AND THE TECHNICIAN VERIFIED THAT THE TANK WAS CONTAMINATED FROM THE TANK DUE TO DELAMINATION OF THE INTERIOR OF THE TANK. FORD MOTOR COMPANY SAID THAT THE COST WAS $783.93 FOR PARTS AND $258.10 FOR LABOR, FOR A TOTAL OF $1042.03 AND FORD MOTOR WAS WILLING TO PAY ONLY $312.00. THIS IS ONLY FOR A TANK REPLACEMENT, NOT THE FILTERS, FUEL PUMP OR INJECTORS IF THESE PARTS ARE CONTAMINATED. I REFUSED THE SERVICE, ON THE FACT THAT THE SERVICE MANAGER SAID THAT THIS WILL PROBABLY HAPPEN AGAIN WITH THE NEW TANK AS WELL. I HAVE FOUND SOMEONE THAT CAN FIX MY TANK FOR LESS MONEY, BUT I WOULD LIKE RESULTS AND THIS NEEDS TO BE ADDRESSED BEFORE SOMEONE DOES GET KILLED, IF THEY HAVEN'T ALREADY. FORD IS SAYING TO MY KNOWLEDGE THAT THIS IS THE LOW-SULFUR DIESEL FUEL AND NOT THERE FUEL TANKS. I HAVE CONTACTED A LAWYER AND HE IS DEALING WITH OTHER CLIENTS WITH THE SAME ISSUE. *TR

Mileage: 109,240

MY 2004 FORD F-450 HAS A FUEL TANK CORROSION/DELAMINATION PROBLEM. FORD REFUSES TO FIX THE DEFECT. THE DELAMINATION IS CAUSING A CLOGGING OF THE FUEL SYSTEM WHICH CAUSES THE ENGINE TO SHUT DOWN WHILE DRIVING. I HAVE CHANGED THE INJECTORS AND CHANGE/CLEAN THE FUEL FILTERS REGULARLY I HAVE READ ONLINE THE COMPLAINTS OF NUMEROUS OTHER OWNERS OF THE SAME TYPES OF TRUCK. *TR

Mileage: 98,479

OUR 2004 FORD F450 DIESEL TRUCK LOST POWER WHEN DRIVING ON THE HIGHWAY. WE TOOK IT TO FORD AND THEY TOLD US THE LINER IN THE FUEL TANK WAS COMING APART AND THEY WANTED $2100 TO REPLACE THE TANK. I SAW ON SEVERAL WEB SITES THAT THIS IS A COMMON PROBLEM THAT FORD IS WELL AWARE AND REFUSES TO TAKE RESPONSIBILITY FOR. I SAW OVER 1,000 BLOGS FROM PEOPLE WHO HAVE HAD THE SAME PROBLEM AND FORD TELLS THEM IT IS THE FUEL THEY ARE GETTING AND NOT A DEFAULT IN THE TANK DESIGN. I BELIEVE THEY SHOULD OWN UP TO THEIR MISTAKE AND RECALL THESE TANKS INSTEAD OF MAKING MONEY OFF OF REPLACING THEM. *TR

Mileage: 81,000

THE DIESEL FUEL TANK ON MY 2004 FORD F450 IS DELAMINATING ON THE INSIDE OF THE TANK AND CAUSING FUEL CONTAMINATION WITH METALIC PARTICLES. IF THIS CONDITION HAD GONE UNDISCOVERED IT WOULD HAVE RESULTED IN FAILURE OF THE INJECTOR PUMP AND ULTIMATLY THE ENGINE ITSELF. THIS IS A SERIOUS FACTORY DEFECT WITH DRIVER/PASSENGER SAFETY IMPLICATIONS FOR ALL LATE MODEL FORD SUPER DUTY TRUCKS. FORD SHOULD BE FORCED TO RECALL THESE TRUCKS AND REPLACE THE DEFECTIVE TANKS REENGINEERED FUEL TANKS. *TR

Mileage: 48,101

I HAVE 2 2005 FORD F450'S THAT BOTH HAVE HAD FUEL TANK DELAMINATION. I HAVE TALKED WITH THE DEALER AT LENGTH ABOUT THE SITUATION. OFF THE RECORD THE SERVICE ADVISOR ACKNOWLEDGED THAT THIS IS A HUGE PROBLEM AND THERE IS NO PROMISE THE NEW TANKS WILL NOT HAVE THE SAME PROBLEMS. AFTER SEARCHING ONLINE MESSAGE BOARDS I HAVE FOUND THAT THE PROBLEM IS WIDESPREAD. BASICALLY THE FUEL TANK THAT THE MANUFACTURER CHOSE TO USE WHEN BUILDING THE TRUCK WILL NOT HOLD UP TO THE FUEL TYPE THAT THE MANUFACTURER REQUIRES TO BE USED IN THE TRUCK. *TR

Mileage: 67,818

THIS COMPLAINT STEMS FROM PROBLEMS EXPERIENCED WITH MY 2004 FORD F-450 DIESEL POWERED TRUCK. I PURCHASED THIS 2004 FORD NEW TRUCK IN LATE 2004. AT PRESENT, THE ODOMETER READS APPROXIMATELY 63,000 MILES. I EXPERIENCE LOSS OF POWER AT VARIOUS INTERVALS WHICH CAUSES THE VEHICLE TO SLOW DOWN AND POWER IS LIMITED TO A FEW MILES-PER-HOUR. I HAVE RETURNED THE TRUCK TO FORD FOR REPAIR NUMEROUS TIMES AND FORD HAS NOT BEEN ABLE TO REPAIR THE PROBLEM. FORD HAS REPLACED THE TURBO TWO TIMES, THE WIRING HARNESS, THE EGR AND OTHER PARTS IN THE ATTEMPT TO REPAIR THE PROBLEM. I RETURNED THIS TRUCK TO FORD AGAIN ON 12-26-2008. THE SERVICE DEPARTMENT REMOVED THE FUEL FILTER AND THEY FOUND THAT THE LAMINATION OR LINING OF THE FUEL TANK HAS SEPARATED FROM THE METAL WHICH MAKES UP THE FUEL TANK. THIS APPEARS AS A FLAKY SILVER SUBSTANCE WHICH CLOGGED THE FUEL FILTER AND LINES AND IS VERY EXPENSIVE TO REPAIR. I HAVE RESEARCHED THIS FAILURE ON THE INTERNET AND IT APPEARS THAT THERE ARE HUNDREDS OF COMPLAINTS WHICH POINT TO THE SAME FAILURE OF THE FORD FUEL TANK, ESPECIALLY ON DIESEL POWERED VEHICLES. A SAMPLING OF THE INTERNET POSTS CAN BE VIEWED AT HTTP://WWW.FINISHING.COM/442/19.SHTML. IT APPEARS THAT FORD HAS TAKEN THE POSITION THAT THE PROBLEM IS DUE TO THE FUEL THAT IS USED IN THE NORMAL OPERATION OF THE VEHICLE. I DO NOT BELIEVE THIS STATEMENT TO BE TRUE. I BELIEVE THERE IS A MANUFACTURERS DEFECT IN THE APPLICATION OF THIS LAMINATE OR, THAT THE LAMINATE IS NOT OF CORRECT MATERIAL FOR THE INTENDED PURPOSE. THE BOND WHICH HOLDS THE LAMINATE TO THE STEEL FUEL TANK IS BREAKING DOWN AND CAUSING THE VEHICLE TO MALFUNCTION. I URGE YOU TO INVESTIGATE THIS MATTER IMMEDIATELY. I KNOW YOUR DEPARTMENT IS AWARE OF THIS PROBLEM BECAUSE I HAVE READ YOUR RESPONSE IN NUMEROUS INTERNET CHAT ROOMS AND I URGE YOU TO ACT IMMEDIATELY TO DEMAND FORD RECALL AND MAKE RIGHT THESE MANUFACTURER DEFECTS. THANK YOU FOR YOUR PROMPT ATTENTION TO THIS MATTER. *TR

I HAVE A COMPLAINT ABOUT THE FUEL TANK IN MY 2004 F-450, THE TRUCK WAS LOSING POWER AND DRIVING LIKE A PLUGGED FUEL FILTER AND AFTER CHANGING FUEL FILTERS MANY TIMES I HAD FOUND A "GREY FLAKE LIKE" MATERIALS IN BOTH FILTERS. I DECIDED TO TAKE TRUCK TO FORD DEALER IN LINCOLN, NE TO HAVE LOOKED AT AND FIXED. THEY CALLED BACK TELLING ME THE FUEL TANK LINING WAS BAD IN THE FUEL TANK AND NEEDED TO BE REPLACED AT MY EXPENSE. IT ALSO CAUSED ONE INJECTOR TO GO BAD(HOPEFULLY NOT MORE) AND A "NOZZLE ASSEMBLY". THEY CHARGED ME TO DISPOSE OF THE 25(OR SO) GALLONS OF FUEL, AND CHARGED ME FOR NEW FUEL. THE TOTAL BILL WAS $2066.23. THEY SAID THEY TALKED TO FORD AND FORD WOULD NOT WARRANTY ANYTHING. IN LOOKING ON INTERNET THERE ARE MANY PEOPLE WITH SAME PROBLEM. THE TANK HAS A LINER IN IT THAT HAS DISSOLVED CAUSING THE PROBLEMS. I AM THE ORIGINAL OWNER, TRUCK HAS 32000 MILES AND SHOULD NOT! NEED A FUEL TANK AFTER 4 YEARS. I HAVE OLD FUEL TANK. THANKS, CHRIS KEMS. *TR

Mileage: 32,193

OPERATING IN ROUTE TO A MEDICAL EMERGENCY CALL. REMOVED FOOT FROM ACCELERATOR TO APPLY BRAKES, WHEN RETURNED TO THROTTLE; ENGINE REMAINED AT IDLE. HAD TO DISPATCH ANOTHER AMBULANCE TO THE CALL. TOWED THE IUNIT TO A LOCAL DEALER. DEALER HAS REPLACED THE THROTTLE SENSOR. UNKNOWN IF RETAINED OLD PART.

Mileage: 17,573