NHTSA vehicle safety data

2009 Ford F-450 SD Recalls & Complaints

The 2009 Ford F-450 SD has 5 NHTSA recall campaigns and 3 owner complaints on file as of November 3, 2026. Recall repairs are usually free at an authorized Ford dealer.

NHTSA recall and complaint data for the 2009 Ford F-450 SD. Recall data is refreshed daily from NHTSA.

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2009 Ford F-450 SD owner complaints

Owners have filed 3 complaints with NHTSA about the 2009 Ford F-450 SD, describing incidents dated June 1, 2009 to December 23, 2014.

Most-cited components

Engine 2 complaints
Power Train 1 complaint
Tires 1 complaint
Unknown or Other 1 complaint

Newest complaints

ODI #10670564 · Filed January 6, 2015
MY 2009 FORD F-450 TRUCK CURRENTLY IS AT MY LOCAL DEALER WHICH IS KERRY FORD IN CINCINNATI WITH A BAD MOTOR AND BAD REAR DIFFERENTIAL. THE MOTOR HAS ONE FAILED LIFTER AND 2 FAILED ROCKER ARMS. THE REAR END HAS A BAD PINION BEARING WHICH SENT METAL THROUGH THE DIFFERENTIAL WHICH DESTROYED THE GEARS…
ODI #10583807 · Filed April 16, 2014
BOUGHT MY MOTOR HOME IN JUNE 2009 WITH MICHELIN TIRES SIZE LT 225/75R16 115/R/LRE LTX MS. SINCE NEW, MY TIRES HAVE BEEN CRACKING ON THE OUTSIDE OF THE TIRES MORE AND MORE. I ONLY HAVE LESS THAN 10,000 MILES ON THESE TIRES AND IT IS KEPT IN AN ENCLOSED GARAGE SINCE I BOUGHT IT. I AM VERY CONCERNED…
ODI #10435613 · Filed November 14, 2011
TL* THE CONTACT OWNS A 2009 FORD F-450 SD DIESEL. THE CONTACT STATED THAT EXHAUST FUMES WERE BEING EMITTED INTO THE VEHICLE. THE CONTACT MENTIONED THAT THE VEHICLE WAS TAKEN FOR REPAIRS A TOTAL OF THIRTY-FIVE TIMES. THE VEHICLE WAS TAKEN TO THE DEALER WHO DIAGNOSED THAT TWO OF THE EXHAUST PIPES WERE…

Read all 3 complaints

PTO Pressure Switch Oil Leak may Result in Fire

NHTSA #14V360000 · Equipment · NHTSA notice

Reported June 23, 2014 · Palfleet Truck Equipment Company, LLC

Potentially affected: 10 vehicles

Owners notified July 29, 2014 · Vehicles built June 1, 2009 – June 30, 2013 (per NHTSA) · Recall influenced by NHTSA's Office of Defects Investigation

Defect description

Palfleet Truck Equipment Company, LLC (Palfleet) is recalling certain model year 2009-2013 Ford F-350, F-450, and F-550 super duty vehicles modified by Palfleet and equipped with certain Muncie Power Products PTO Assemblies. In the affected vehicles, oil may leak from the PTO pressure switch onto a thermal blanket covering the exhaust.

Safety consequence

The leaking oil may soak into the thermal blanket covering the exhaust, which when combined with heat from exhaust, may result in an increased risk of fire.

Manufacturer remedy

Palfleet will notify owners, and dealers will install a new pressure switch kit that moves the switch away from the exhaust system, free of charge. The recall began on July 29, 2014. Owners may contact Palfleet customer service at 1- 502-376-2458.

Notes

Owners may also contact the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to www.safercar.gov.

PTO Pressure Switch Oil Leak may Result in Fire

NHTSA #14V328000 · Equipment · NHTSA notice

Reported June 13, 2014 · Iowa Mold Tooling Co., Inc.

Potentially affected: 21 vehicles

Repair completion: 57.14% (latest rate the manufacturer reported to NHTSA; dataset updated November 3, 2026)

Owners notified July 28, 2014 · Recall influenced by NHTSA's Office of Defects Investigation

Defect description

Iowa Mold Tooling Co., Inc. will notify owners and dealers to inspect the Muncie PTO pressure switch to determine if it is from the range of defective switches and if required, remove the pressure switch assembly and put a plug in the port where the PTO switch had been installed. This switch was never being utilized. This will be done free of charge. The recall is expected to begin in mid-July 2014. Owners may contact Iowa Mold Tooling Co., Inc. at 1-800-247-5958.

Safety consequence

The leaking oil may soak into the thermal blanket covering the exhaust, which when combined with heat from exhaust, may result in an increased risk of fire.

Manufacturer remedy

Iowa Mold Tooling Co., Inc. will notify owners, and dealers will install a new pressure switch kit that moves the switch away from the exhaust system, free of charge. The recall began on July 28, 2014. Owners may contact Iowa Mold Tooling Co., Inc. at 1-800-247-5958.

Notes

Owners may also contact the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to www.safercar.gov.

PTO Pressure Switch Oil Leak may Result in Fire

NHTSA #14V327000 · Equipment · NHTSA notice

Reported June 12, 2014 · Stahl

Potentially affected: 10 vehicles

Repair completion: 100% (latest rate the manufacturer reported to NHTSA; dataset updated November 3, 2026)

Owners notified November 12, 2014 · Recall influenced by NHTSA's Office of Defects Investigation

Defect description

Stahl is recalling certain model year 2009-2014 Ford F-350 Super Duty, F-450 Super Duty, and F-550 Super Duty vehicles modified by Stahl and equipped with certain Muncie Power Products PTO Assemblies. In the affected vehicles, oil may leak from the PTO pressure switch onto a thermal blanket covering the exhaust.

Safety consequence

The leaking oil may soak into the thermal blanket covering the exhaust, which when combined with heat from exhaust, may result in an increased risk of fire.

Manufacturer remedy

Stahl will notify owners, and dealers will install a new pressure switch kit that moves the switch away from the exhaust system, free of charge. Owners may contact Stahl customer service at 1-800-277-8245, or Muncie at 1-800-367-7867.

Notes

Owners may also contact the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to www.safercar.gov.

PTO Pressure Switch Oil Leak may Result in Fire

NHTSA #14V382000 · Equipment · NHTSA notice

Reported June 10, 2014 · SOMERSET WELDING & STEEL, INC.

Potentially affected: 4 vehicles

Owners notified August 4, 2014 · Vehicles built June 1, 2009 – June 30, 2013 (per NHTSA) · Recall influenced by NHTSA's Office of Defects Investigation

Defect description

Somerset Welding & Steel, doing business as J&J Truck equipment (J&J), is recalling certain model year 2009-2013 Ford F-350, F-450, and F-550 Super Duty chassis with 6.8L gasoline engines modified by J&J to be equipped with certain Muncie Power Products PTO Assemblies. In the affected vehicles, oil may leak from the PTO pressure switch onto a thermal blanket covering the exhaust.

Safety consequence

The leaking oil may soak into the thermal blanket covering the exhaust, which when combined with heat from exhaust, may result in an increased risk of fire.

Manufacturer remedy

Somerset will notify owners, and dealers will install a new pressure switch kit that moves the switch away from the exhaust system, free of charge. The recall began August 2014. Owner's may contact Somerset customer service at 1-800-777-2671.

Notes

Owners may also contact the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to www.safercar.gov.

Battery Equalizers or DC-DC Converters:Fire Risk

NHTSA #14V070000 · Electrical System · NHTSA notice

Reported February 11, 2014 · Monroe Truck Equipment

Potentially affected: 22 vehicles

Repair completion: 52.63% (latest rate the manufacturer reported to NHTSA; dataset updated November 3, 2026)

Owners notified March 24, 2014 · Vehicles built October 1, 2011 – October 31, 2011 (per NHTSA) · Recall influenced by NHTSA's Office of Defects Investigation

Defect description

Monroe Truck Equipment (Monroe) is recalling certain model year 2006, 2008 and 2009 Chevrolet C7500 vehicles, 2005-2006 Chevrolet Tahoe vehicles, and 2009 Ford F-350, and F-450 vehicles, equipped with Sure Power-brand battery equalizers or DC-DC converters containing a particular epoxy sealing, aka 'potting', compound. The specific potting compound used in the subject products for insulation was found to be capable of conducting electricity after being exposed to heat.

Safety consequence

Once electrically conductive, the material is capable of melting and burning, increasing the risk of a fire.

Manufacturer remedy

Monroe will notify owners, and Sure Power will replace the equalizers or converters, free of charge. The recall began on March 24, 2014. Owners may contact Monroe at 1-608-328-8127.

Notes

Owners may also contact the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to www.safercar.gov.

try.vin has no NCAP crash-test rating on file for the 2009 Ford F-450 SD. NHTSA rates some vehicles by body style — pickups by cab, vans by roof height — so check nhtsa.gov/ratings.

3 owner complaints have been filed with NHTSA for the 2009 Ford F-450 SD.

Power Train; Unknown or Other; Engine

ODI #10670564

Incident: December 23, 2014 · Filed: January 6, 2015

MY 2009 FORD F-450 TRUCK CURRENTLY IS AT MY LOCAL DEALER WHICH IS KERRY FORD IN CINCINNATI WITH A BAD MOTOR AND BAD REAR DIFFERENTIAL. THE MOTOR HAS ONE FAILED LIFTER AND 2 FAILED ROCKER ARMS. THE REAR END HAS A BAD PINION BEARING WHICH SENT METAL THROUGH THE DIFFERENTIAL WHICH DESTROYED THE GEARS. THE MOTOR IS A 6.4 LITER POWERSTROKE DIESEL AND THE REAR END IS A DANA 110. THE MOTOR ISSUES ARE COMMON KNOWLEDGE TO BOTH FORD REPAIR FACILITIES AS WELL AS FORD CORPORATE OFFICES. THE REAR END IS ALSO A KNOWN ISSUE BOTH WHICH CAN BE CONFIRMED BY ANY POWERSTROKE CERTIFIED MECHANIC. THE MOTOR ISSUE WAS CONFIRMED BY 2 SEPERATE SHOPS TO WHICH I WAS SUGGESTED BY MY REPAIR FACILITY AND MECHANIC TO CONTACT FORD CORPORATE FOR A "GOODWILL POLICY" TO COVER THIS ISSUE EVEN THOUGH IT IS CURRENTLY PAST THE WRITTEN WARRANTY DUE TO THE FACT FORD HAS COVERED NUMEROUS ENGINE FAILURES BECAUSE OF THIS INHERENT ISSUE. THE REGIONAL FORD REP DENIED ANY ASSISTANCE TO THIS ISSUE WHEN EVEN THE DEALER HAS SAID ITS COMMON AND SHOULD BE ADDRESSED. UPON FINDING OUT THE DECISION WHICH TOOK 2 WEEKS OF MY TRUCK BEING IN THE SHOP I WAS ADVISED TO CONTACT THE CORPORATE CUSTOMER RELATIONS LINE WHICH I DID TO TRY TO TALK TO MY REGIONAL MANAGER BUT AS PER FORDS POLICY I CANNOT GET A DIRECT CONTACT TO ANY REGIONAL REP OR ANYONE ABOVE THIS PERSON. MY DEALERSHIP SERVICE MANAGER STATES HE CANT EVEN GET A DIRECT NUMBER TO THE REP HIMSELF SO BASICLY FORD INSULATES ITSELF FROM ANY DIRECT CONTACT FOR A CONSUMER TO RESOLVE ANY ISSUES. I HAVE NUMEROUS DOCUMENTED FAILURES OF THIS VEHICLE WHILE UNDER WARRANTY WHEN IT HAS BEEN MAINTAINED TO THE VERY BEST SCHEDULE. THIS ISSUE IS AN INHERENT DESIGN FLAW OF THIS MOTOR WHICH SHARES THE SAME VALVETRAIN PARTS WITH THE PREVIOUS 6.0 LITER POWERSTROKE WHICH IS ALSO DOOMED FLEETWIDE WITH THESE SAME ISSUES WHICH AS ALSO HIGHLY DOCUMENTED.

Tires

ODI #10583807

Incident: June 1, 2009 · Filed: April 16, 2014

BOUGHT MY MOTOR HOME IN JUNE 2009 WITH MICHELIN TIRES SIZE LT 225/75R16 115/R/LRE LTX MS. SINCE NEW, MY TIRES HAVE BEEN CRACKING ON THE OUTSIDE OF THE TIRES MORE AND MORE. I ONLY HAVE LESS THAN 10,000 MILES ON THESE TIRES AND IT IS KEPT IN AN ENCLOSED GARAGE SINCE I BOUGHT IT. I AM VERY CONCERNED ABOUT THESE TIRES BLOWING OUT, BECAUSE OF THE WAY THEY LOOK, BUT AS I SAID, WE HAVE VERY LITTLE MILEAGE ON THESE TIRES AND THEY WERE SUPPOSED TO THE TOP OF THE LINE TIRES. PLEASE, REPLY. THANK YOU. ..UPDATED 04-16-14 *BF

Engine and Engine Cooling

ODI #10435613

Incident: September 1, 2009 · Filed: November 14, 2011

TL* THE CONTACT OWNS A 2009 FORD F-450 SD DIESEL. THE CONTACT STATED THAT EXHAUST FUMES WERE BEING EMITTED INTO THE VEHICLE. THE CONTACT MENTIONED THAT THE VEHICLE WAS TAKEN FOR REPAIRS A TOTAL OF THIRTY-FIVE TIMES. THE VEHICLE WAS TAKEN TO THE DEALER WHO DIAGNOSED THAT TWO OF THE EXHAUST PIPES WERE LEAKING, THE EXHAUST MANIFOLD WAS FRACTURED AND SUDS WERE COMING THROUGH THE FIREWALL INTO THE CAB. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE WHO DID NOT OFFER ANY ASSISTANCE. THE VEHICLE WAS REPAIRED. THE FAILURE MILEAGE WAS 500 AND THE CURRENT MILEAGE WAS 90,000.

Other Ford F-450 SD model years

Check your 2009 Ford F-450 SD VIN

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