KnownCarProblems2004 Ford F-250 SD Problems and Recalls
Owners filed 254 complaints with NHTSA about the 2004 Ford F-250 SD, most often about the engine (45% of complaints, typically around 45,000 miles). It is 10th of 27 F-250 SD model years by number of complaints and has 2 recalls.
Most common 2004 Ford F-250 SD problems
Engine
114 complaints · 45%Half of these problems showed up before 45,000 miles. Parts named most often: engine, exhaust system, cooling system.
On 10-28-05 driving on 395 in victorville I stopped at a red light, the light turned green I proceeded and at about 30 MPH I heard a bang and what seemed to be a real bad exhaust leak. I was close to a Ford dealer so I limped it over to them. They told me what it was and gave me an estimate to repair it... $4100.00.…
Engine surges and will increase speed by 700 rpms with no contact to pedal. Taken to dealership several times numerous recalls and repairs to wireharness and erg valve have not cured problem. Vehicle lurched forward while being parked bumper striking light pole minor damage.
Electrical
56 complaints · 22%Half of these problems showed up before 80,500 miles. Parts named most often: wiring, 12v/24v/48v battery, starter assembly.
The contact owns a 2004 Ford F-250 SD. The contact was driving 60 MPH when the vehicle stalled without warning. The vehicle was towed to a local repair facility but the technician was unable to diagnose the failure. The manufacturer was contacted who advised that the vehicle was not included in NHTSA campaign id…
The contact owns a 2004 Ford f-250 super duty. The contact stated that the fuel injection control module was malfunctioning, causing the vehicle to jerk abruptly when initially started. After starting, the vehicle would sporadically stall. The dealer was contacted and advised that that vehicle was not included in…
Fuel system
38 complaints · 15%Half of these problems showed up before 93,000 miles. Parts named most often: fuel injection system.
Tl contact owns a 2004 Ford f-250. While driving 20 MPH, the contact stated that the fuel injector control module failed and needed to be replaced. The dealer was notified, but offered no assistance. The manufacturer was notified and also offered no assistance. The vehicle was not repaired. The current mileage was…
Tl contact owns a 2004 Ford f-250 superduty. The contact stated that while driving approximately 70 MPH, the vehicle suddenly stalled. The contact was able to restart the vehicle. The vehicle had been inspected and repaired four times in regards to the fuel injection system. The contact called the manufacturer who…
Transmission
21 complaints · 8%Half of these problems showed up before 11,000 miles. Parts named most often: automatic transmission, driveline, axle assembly, transfer case (4-wheel drive).
Transmission on 04 f 250 suddenly went into neutral in traffic. I was almost rear ended by a loaded dump truck. The truck is at the dealer ship now and they are telling me a recalled part caused the problem. I have heard of no recalls. Ford customer relations tells me that the program has been out for two weeks . Does…
Tl contact owns a 2004 Ford f 250 sd. While driving 45 MPH he heard a loud noise in the rear of the vehicle. After removing the rear tires he found that the brake lining was off of the brake shoe and broke into several pieces. The emergency brake cable caused the failure when it broke. The driver side window was off…
Wheels and tires
19 complaints · 8%Half of these problems showed up before 42,000 miles. Parts named most often: tread/belt, temporary/emergency spare tire.
I was driving approximately 45 miles per hour on the highway. I had the rear driver side tire blow out on the highway. This occurred without any warning of imminent failure. The tires had approx 40,000 miles on them and are the original tires supplied with the vehicle. It is a 2004 Ford f-250 lariat diesel extended…
The contact owns a 2004 Ford f-250 super duty equipped with ameritrack tr tires. While driving at approximately 35 MPH, the vehicle began to shake excessively. The vehicle was pulled over and the contact noticed the tread had separated from the front drivers side tire. The vehicle was driven to an independent repair…
Speed control
17 complaints · 7%Half of these problems showed up before 35,000 miles.
F250 diesel engine has uncommanded throttle advance. In traffic environment, I need to keep a large interval in case truck decides to advance throttle on its own. This situation rules out parking in the garage. Truck was purchased new from Ford, has been in shop 6 times for same problem.
Dt: the contact stated the throttle stuck. When the brake pedal was depressed the vehicle stopped. The vehicle was towed to a certified dealer. Diagnostics were performed. The air mass sensor was cleaned. The vehicle is now driving correctly. Updated 12/27/05.
Suspension
15 complaints · 6%Half of these problems showed up before 48,500 miles. Parts named most often: front, rear.
2004 Ford f250 hubs are worn out and need to be replaced. They had only been engaged three times when the failure occured. (front locking hubs)
Noticed a clunk in the front end over bumps. Inspected the front suspension and found over 7/16 side to side play in the left lower ball joint, and 3/8 side to side play in the right lower ball joint. I replaced both lower ball joints. I feel this is a very early failure and if left to get worse would cause an…
Steering
15 complaints · 6%Half of these problems showed up before 65,000 miles. Parts named most often: linkages.
Vehicle shimmy and shake, steering wheel oscillation starts at approx. 50 MPH after going over slight bump in roadway. Continues until brakes are applied and speed is reduced to under 45 MPH.
The contact owns a 2004 Ford f250 super duty. While driving approximately 45 MPH the vehicle suddenly stalled. The vehicle was towed to the dealer for diagnostic testing where the technician stated the fuel injection control module needed to be replaced. The contact stated there was a recall under NHTSA campaign id…
Complaints are owner reports to NHTSA, not verified defects. One complaint can name several components, so shares add up to more than 100%.
2004 Ford F-250 SD recalls
Lights: brake lights
Risk: Non-functioning lights could increase the risk of a crash.
Fix: Dealers will replace the switches free of charge. The safety recall began on august 15, 2011. Owners may contact ford motor company customer relationship center at 1-866-436-7332.
Full defect summary
Ford is recalling certain model year 2011 ranger trucks built from january 25, 2011, through april 25, 2011 at the twin cities assembly plant, and service parts distributed to dealers for certain 2004 through 2011 model year ranger trucks, 2002 through 2005 model year excursion vehicles, and 2002 through 2007 model year f-250, f-350, f-450, and f-550 trucks for failing to comply with the requirements of federal motor vehicle safety standard no. 108, "lamps, reflective devices, and associated equipment." the multi-function switch was shipped with a subcomponent (slider) that may experience deformation. A multi-function switch with a deformed slider may malfunction causing the turn signal, tail lights, hazard warning signal flashers and/or brake lights not to activate.
Electrical: wiring
Risk: Should the engine stall, a vehicle crash could occur.
Fix: 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.
Full defect summary
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.
Recall repairs are free at any franchised dealer. Enter your VIN at nhtsa.gov/recalls to see which recalls are still open on your car.
NHTSA defect investigations
Spark plug ejection from cylinder head
Summary
On september 6, 2005, odi received a petition requesting that the agency investigate allegations of engine spark plug ejection in certain model year 1997 through 2004 ford vehicles with triton v-8 and v-10 engines.odi received a total of 474 non-duplicative complaints on the subject vehicles where the complainant, or the dealer repairing the vehicle, reported that a spark plug detached from the cylinder and/or ejected from the engine.as of december 8, 2005, odi is not aware of any allegations where the alleged defect resulted in a loss of vehicle control, a crash, an injury, or a fatality in any of the 10,319,810 subject vehicles.in addition, odi is aware of only two incidents where the vehi
Engine stalling
Summary
In a june 7, 2005 letter, ford notified odi that it would be conducting a safety recall of approximately 180,000 ford f-super duty, excursion and e-series vehicles equipped with 6.0l diesel engines to correct two wiring related conditions that could result in engine stall (NHTSA recall no. 05v-270, ford no. 05s34).the affected vehicles were built between september 29, 2003 and may 31, 2004.according to ford, vehicles with the conditions may stall without warning and may or may not restart.ford will instruct owners of vehicles included in the recall to take their vehicles to a dealer to have the fuel injector control module wire harness upgraded or replaced and or have a new injection control
Engine stalling
Summary
Twenty five of the odi failure reports are duplicative of ford complaints.twenty odi reports do not contain a VIN (and may or may not be duplicative of ford reports).the 14 alleged crashes and 2 alleged injuries were all minor.submitted during preliminary evaluation (pe) 04-070, ford's response to odi's information request (ir) letter contained about 5,000 consumer reports (mors) and 8,700 field reports (cqis).ford reviewed the complaints and categorized them.the manufacturer reports shown above represent a count of unique vehicles that ford categorized as allegedly stalling due to a subject engine component ('a' category, see ford's ir response letter for further detail); some of these vehi
Questions about the 2004 Ford F-250 SD
- What are the most common problems with the 2004 Ford F-250 SD?
- By NHTSA owner complaints: engine (114 complaints, typically around 45,000 miles); electrical (56 complaints, typically around 80,500 miles); fuel system (38 complaints, typically around 93,000 miles).
- How many recalls does the 2004 Ford F-250 SD have?
- 2 recalls listed by NHTSA, the latest from July 13, 2011 (lights). Check your VIN at nhtsa.gov/recalls to see which ones are still open on your car.
- Is the 2004 a bad year for the Ford F-250 SD?
- It is 10th of 27 F-250 SD model years by number of complaints, with 254 complaints. Complaint counts are not adjusted for how many cars were sold, so popular years collect more of them, and the newest years have had less time to.