2004 Ford F-250 SD Problems

What owners report

Owners of the 2004 F-250 Super Duty most often describe stalling, loss of power, rough or surging idle, and repeated EGR cooler, oil cooler and turbocharger repairs on the 6.0L diesel. A second common theme is an intermittent high-speed front-end shake after a bump, along with reports of tire tread separation on original tires. Complaint mileages vary widely, from a few thousand miles on newer trucks to well past 100,000.

1. 1
   Engine cooling

   Stalling and no-start (6.0L diesel)

   • 134 complaints (53%)
   • median 49,191 mi at 3.8 yrs old (122 state mileage)
   • 12 mention a crash, fire or injury
   • owner-quoted repair $1,639 (median of 9 quotes)
   • filed 2004–2019

   Complaints describe the engine shutting off without warning while driving or idling, sometimes with a no-restart condition that lasts minutes or requires a tow. Several owners say dealers replaced the fuel injection control module or its harness, in some cases with the same stalling returning afterward. Others report repeated hard-starting and low-power episodes where the dealer could not duplicate the concern. Reported from roughly 2,000 to over 150,000 miles, across all seasons and at speeds from idle to highway.

   Recall 05V2700003 related service bulletins

   What to check: Ask for service records on the fuel injection control module and harness, and whether the 6.0L has had injector or FICM work. A long idle or cold-start test drive may help reveal rough running or a stumble.

   2 excerpts from owner complaints in NHTSA records

   “My 2004 Ford f250 superduty truck ran very rough and stalled in my front yard; and would not crank again. On october 5 2009, I had purchased it pre-owned from dealer, william mizell Ford, on conditions and that they agreed to provide a carfax report. Well , they hesitated and two months later, after the truck had stalled, I was told too bad it was sold as is.”

   NHTSA complaint #10320015, filed 2010-03, 140,000 miles

   “I bought this 2004 Ford f-250,6.0 diesel in may 2010 with 160k miles on it because lots of people told me to buy a diesel it would give me better performance than gas. I have had nothing but troubles ever since. It started not starting about 2 weeks after I bought it. The Ford house is no help at all. Ive had it there several times and all it done was cost me money. It has never stopped running driving down the road like the other complaints iv'e read. …”

   NHTSA complaint #10446700, filed 2012-02, 164,000 miles
2. 2
   Engine cooling

   EGR and oil cooler failures with smoke, coolant loss

   • 55 complaints (22%)
   • median 53,000 mi at 4.1 yrs old (49 state mileage)
   • 4 mention a crash, fire or injury
   • filed 2004–2019

   Owners describe heavy smoke, loss of power, hard starting or a no-start after EGR cooler problems, with coolant and oil cooler, head gasket and turbo replacement reported as the resulting repairs. Some complaints note the EGR cooler was replaced more than once, and that repairs fell outside the part warranty each time. Common between roughly 50,000 and 100,000 miles, with a few cases under 60,000 miles.

   3 related service bulletins

   What to check: Check the coolant level and condition and look for white or blue smoke on cold start; ask whether the EGR and oil coolers have been replaced and whether the charge air cooler was cleaned after any turbo work.

   2 excerpts from owner complaints in NHTSA records

   “I was merging on to highway stepped on pedal got heavy blue and black smoke drive could not see me almost rearended me . If I had not veered right he would have'.”

   NHTSA complaint #10313633, filed 2010-02, 111,100 miles

   “Multiple failure of turbo charger and connecting hose,have experienced no power,loss of power,back-fire conditions while in traffic. While towing and not towing. No accidents so far but several near misses. Turbo replaced or repaired 3 times,less than 51000 miles on truck. Vehicle has not been modified”

   NHTSA complaint #10303512, filed 2010-02, 49,650 miles
3. 3
   Vehicle speed control

   Surging or unintended acceleration at idle

   • 37 complaints (15%)
   • median 27,250 mi at 3.2 yrs old (32 state mileage)
   • 4 mention a crash, fire or injury
   • filed 2004–2019

   Owners describe the engine revving on its own at idle or surging forward with the brake applied, occasionally while stopped at a light or pulling away slowly. Dealers are reported to have reprogrammed the computer, replaced sensors or been unable to duplicate the concern, and complaints state the behavior continued after some repairs. Reported from as low as a few thousand miles up to about 100,000 miles, often at low speeds and at idle.

   2 related service bulletins

   What to check: Ask for records of any PCM reprogramming or sensor replacements, and note during a test drive whether idle speed holds steady in park and in gear.

   2 excerpts from owner complaints in NHTSA records

   “Engine revs up at idle and bogging while in motion and when stopping and making turns. Also, the vehicle intermittently lurches (jumps) forward at idle over powering the brakes. Then the vehicle will die completely, leaving me stuck in an intersection. This is a serious safety issue, could cause a major accident! I have had it in the Ford dealers service department 3 different times and the dealer was unable to duplicate the problem.”

   NHTSA complaint #10106252, filed 2005-01, 4,000 miles

   “My Ford f-250 superduty with 6.0 diesel has a hard starting issue and then the engine go from low idle to high idle causing to have to really apply the brakes in order to keep the vehicle from taking off. You can be just gradually taking off and then it accelerates with out warning. Have had instances when sitting at a stop and the engines RPM's jump causing the truck to start taking off and if not reacting fast enough would have hit a car in front of me. …”

   NHTSA complaint #10365358, filed 2010-11, 50,500 miles
4. 4
   Steering

   High-speed front-end shake after a bump (death wobble)

   • 18 complaints (7%)
   • median 50,671 mi at 4.6 yrs old (16 state mileage)
   • filed 2004–2013

   Complaints describe a violent steering wheel and front-end oscillation that starts after hitting a bump or expansion joint at highway speed and continues until the truck slows well below the speed limit. Owners report repeated dealer visits where the concern could not be reproduced or corrected, and some mention loose front ball joints found at inspection. Mostly reported between about 40,000 and 95,000 miles, typically at 45-70 mph after road irregularities.

   1 related service bulletin

   What to check: On the test drive, take the truck over a bump at highway speed if safe, and have a shop inspect ball joints, tie rods and the steering stabilizer before purchase.

   2 excerpts from owner complaints in NHTSA records

   “Driving at highway speeds I hit a bump and the front end of the vehicle began shaking violently until I slowed down significantly. This has happened twice in the past month. Have done some research and found that this is a common problem in my vehicle type and the reluctance of the manufacturer to find a solution to the problem. Afraid of what potentially may happen if this continues to occur with no dealership/manufacturer intervention.”

   NHTSA complaint #10229604, filed 2008-06, 128,000 miles

   “I own a Ford 250 super duty 2004. Since february 2009 I have sporadically experienced uncontrollable wobbling of the steering wheel. It appears that it happens after making sharp turns or bumps and doesn't matter with the speed. I've taken the truck to a service center and 3 or more times they've taken it apart and can't find anything. They suggested taking it to a Ford dealer. I did and explained it to the mechanic upon which he claims he's never heard of such a thing. …”

   NHTSA complaint #10276580, filed 2009-07, 94,000 miles
5. 5
   Tires

   Tire tread separation and blowouts

   • 13 complaints (5%)
   • median 42,150 mi at 7.3 yrs old (10 state mileage)
   • 2 mention a crash, fire or injury
   • filed 2005–2018

   Complaints describe tread separating from the tire with little warning while driving at highway speed, in some cases with the tire still inflated or with belt separation and body damage. Owners report the tire manufacturer declining claims on the grounds that the serials did not match recalled tires or that road damage was the cause. Mostly reported between about 25,000 and 40,000 miles on the original tires, at highway speeds.

   What to check: Inspect tire date codes and sidewalls for cracking or bulging, and replace older tires regardless of tread depth; ask when the current set was installed.

   2 excerpts from owner complaints in NHTSA records

   “My dick cepec fc ii tires had the tread seperate from the steel belts. Three developed air bubbles in the tread area, but one slung the tread off causing damage to my truck. I was told by dick cepec that the numbers didn't match the recalled tires so they would not be responsible for the tires or any damage.”

   NHTSA complaint #10422271, filed 2011-08, 106,000 miles

   “Tire failure. B f goodrich uuf212210. I had 2 of the tire fail in june 2012. I had the other 2 tire examined and were said to be good. The 3rd tire failed in september causing my truck to leave the hi way trotaling out the travel trailre I was towing to roll over and totaled out. B f goodrich denied my claim saying it was caused by a road hazzard. I never hit anything in any of the tire failures. I have the tire and photos of the other 2 tires that had belt failures. I do not believe in coincidence. …”

   NHTSA complaint #10484669, filed 2012-11, 121,000 miles

Buying note. Ask for a full service history, especially on the 6.0L diesel: coolant, EGR and oil cooler work, injector and FICM repairs, and any turbo replacement. Budget for a thorough pre-purchase inspection of the front suspension and steering and check the age of the tires.

Summary written with AI from a sample of 60 NHTSA complaints for this model year (picked at random, with complaints that state a mileage and recent ones taken first), then checked automatically against the source records. Where a problem shows a complaint count, every complaint for this model year was matched with fixed keyword rules (written with AI and tested against the sample), and the mileage, age and repair figures are calculated from those complaints; owners' figures are as stated, not verified. Other counts refer to the sample. The excerpts come from NHTSA's public complaint records and are unverified; capitalisation is normalised, NHTSA staff notes are removed, and shortened text ends with “…”. Something wrong? Request a correction.