Huge win for car owners! All TSBs to be made public. The Center for Auto Safety just made the NHTSA (US Government) make public the full text of all TSBs from now on. They are the same organization that has petitioned the NHTSA & filed lawsuits to protect car owners over exploding gas tanks & other major safety issues. Whenever you drive in your car, you are safer thanks in part to a lot of work over the years by this small but very effective consumer advocacy group.

Please take a moment & say thank you by donating $5 or whatever you can to the Center for Auto Safety.


hardly worth mentioning
Crashes / Fires:
0 / 0
Injuries / Deaths:
0 / 0
Average Mileage:
66,680 miles

About These NHTSA Complaints:

This data is from the NHTSA — the US gov't agency tasked with vehicle safety. Complaints are spread across multiple & redundant categories, & are not organized by problem.

So how do you find out what problems are occurring? For this NHTSA complaint data, the only way is to read through the comments below. Any duplicates or errors? It's not us.

2004 Ford E-350 fuel system problems

fuel system problem

Find something helpful? Spread the word.
Get notified about new defects, investigations, recalls & lawsuits for the 2004 Ford E-350:

Unsubscribe any time. We don't sell/share your email.

2004 Ford E-350 Owner Comments

problem #10

Sep 202006


  • 50,800 miles


The contact owns a 2004 Ford E-350. The contact stated that the vehicle would lose power when accelerating and then stall. The contact would have to wait thirty minutes before the vehicle was able to be restarted. The contact stated the failure would occur without warning. The vehicle was taken to the dealer several times, but there was no solution to the problem. The contact did research and feels the problem is caused by the fuel tank delaminating. The failure mileage was 50,800 and the current mileage was 120,000.

- Cape Coral, FL, USA

problem #9

Apr 162007

E-350 8-cyl Diesel

  • 50,000 miles
I am the original owner of a 2004 Ford E 350 diesel, it has been in the shop many of times for the same problem truck stops running in middle of intersections, highways etc does not start and needs to be towed.Ford dealership has no idea what is wrong with truck, I get truck back same thing happens. Repeatedly. Now that the truck is out of warranty same thing happens result: Delaminating fuel tank, little slivers of paint clogging fuel lines, pumps and injectors.

- Cape Coral, FL, USA

problem #8

Jan 122011

E-350 8-cyl

  • 154,000 miles
Fuel tank delamination in my 2004 Ford E-350 has cause a need for an expensive total fuel system replacement. Obviously it is a huge problem as there are many complaints online of the exact same problem all over the country. Ford says its the bio diesel that is causing the problem, but its funny how Dodge and Chevy aren't having any problems...

- Nixa, MO, USA

problem #7

Apr 112008


  • 196,000 miles


Vehicle cuts out during driving.

- Beltsville, MD, USA

problem #6

Aug 132009

E-350 Diesel

  • 128,000 miles
Van stopped running in freeway 2004 Ford E-350 diesel problem with tank delamanation 4 vans same thing all came to a stop in the roadway.

- Marietta, GA, USA

problem #5

May 082009


  • miles
Vehicle lost power 4 different times. Fuel pump excess noise, fuel pump clogged. Dealer contacted Ford Motor Corp who blamed condition on diesel fuel. Fuel pump was replaced as well as fuel filters and fuel tank. We are out $3000 for the repairs.

- Broomall, PA, USA

problem #4

Apr 062009


  • 30,000 miles


Fuel tank liner is separating causing corrosion and rust in the fuel tank. Ford refuses to warranty the problem. They are blaming it on the diesel fuel, which is inaccurate. I have one confirmation from a customer that they finally covered his repair, however, he had to lodge complaints with both the NHTSA and the BBB. So I am officially lodging a complaint against Ford Motor Company, steven's Ford (the dealer), and the warranty company. The safety aspect of this is the truck stalls while driving and does not restart. The truck also experienced a loss of power when going uphill. Both of which can cause a dangerous situation when in heavy traffic. This is a chronic problem that Ford is aware of and is denying responsibility. I personally know of at least 5 people who have had similar problems with their E350 vans due to corrosion in the fuel tank. This is not an isolated incident and should be covered under the warranty. (please note there is less than 36,000 miles on this, but Ford is not taking responsibility, neither is the warranty company from which an extended warranty was purchased). Ford is trying to blame the reason on use of more than 5% mixture of biodiesel and is saying that the reason they are not covering the problem is that there is rust in the fuel tank. The rust is a reaction from the fuel in a poorly designed fuel tank. If it were a diesel fuel problem this would occur in different makes of trucks, not just Ford. There is a huge problem, that is not only a safety, but an environmental one as well.

- Islip, NY, USA

problem #3

Jul 152008


  • 30,000 miles
I own 4 diesel powered Ford E350 vans. In 2008 I have had a fuel tank replaced in a 2000 and 2004 van. I decided to have my 2007 checked and found that the fuel filters were clogged. I have spent over $7000 so far. Although Ford did not replace the tank in my 2007 I am starting to wonder when I will have to have this done. I have one other 2000 that just started having problems. I don't need to spend another $7000. I asked for about delamination but they said its the fuel I'm using. I saw the fuel filters that came out of the vehicles and it was a gray/ silver material.

- Mahopac, NY, USA

problem #2

Jul 082008


  • 28,000 miles
2004 E-350 Ford diesel 06 fuel tank delamination Ford replaced tank..08 fuel tank delamination again @ 14000 mi. Cost to me $2200. Dealer said Ford will not admit to a tank problem and could not assure me the delamination problem has been corrected to date..I can't afford $2,200 every 14000 mi. I use only hess diesel fuel. I know I am not alone with this problem, the dealership said they do at least two a month. This is a dangerous condition..the truck loses power and stalls.

- Islip, NY, USA

problem #1

Apr 012005

E-350 Diesel

  • Automatic transmission
  • miles
From the very first day we owned our brand new Ford E-350 diesel cube van we have had an ongoing drivabilty problem. The engine cuts out while driving almost coming to a stall and spits black or blue smoke out of the tail pipe. We have had the vehicle to the dealership five times to date to have this problem fixed. The dealership cannot find the problem. We have tried to take the truck to a different dealer, but they say they cannot fix it because another dealer has already worked on the truck and got paid, so we have to take it back to them. We use this truck for business and have had to rent a truck several times to take the truck in and find the next day that it is still not fixed. We are out $400.05 that we believe either the dealership or Ford should reimburse us for. I called the Ford customer service line and was basically told that rental reimbursements are not covered in the warranty. Should we be resposible for having to pay these fees? we bought a brand new truck so we would not have this is also not our fault the dealership cannot find the problem. We have been more than patient and feel we should get our truck fixed properly and be reimbursed for our losses. We see there has been a recall on our vehicle and still have not been notified. Which only means once again we have to pay to rent a truck while ours goes in for repairs, with no guarentee that it will get fixed that time either.

- Mount Morris, MI, USA

Not what you are looking for?