2004 Ford F-250 SD Engine cooling Problems
- Complaints
- 101about this part
- Share
- 40%of 254 total for the year
- Median mileage
- 30,750miles
- Trend
- StableComplaints filed in the last 3 full calendar years are within 25% of the 3 years before.
NHTSA recorded 101 complaints about the engine cooling of the 2004 Ford F-250 SD, 40% of the 254 complaints for this model year. Where a mileage was given, the median is 30,750 miles. 3 of these say a crash was involved and 5 a fire, according to the filers.
Example complaints
Selected from NHTSA records; personal details are removed. They are consumer reports, not findings.
“My 2004 Ford f-250 5.4l was making a ticking noise for a couple of days then today a big pop and terrible noise from under the hood. I have discovered that it blew a spark plug out of the head. From what I have read this is a common problem with this engine. I am looking at a several thousand dollar repair.”
NHTSA complaint #10256298, filed 2009-01, 75,766 miles“1.) we were driving in the pet smart parking lot and the vehicle lurched forward on it s own and almost ran over a lady and her little dog! I had to slam on the brakes and shut it off! 2.) vehicle will stall and accelerate without warning. Very scary and dangerous!! 3.) three trips to the dealer and it still has not been repaired.”
NHTSA complaint #10137041, filed 2005-09, 9,000 miles“Our f250 superduty has left us in the middle of no where 3 times. We would be driving the truck, park it and then try to start it back up and it would do nothing- this has happened twice. Once it just shut down while driving. Each time road side asst. Has come to get the truck. This purchase has been the biggest mistake and I do spread the word. By the way- it has been the o-rings and gaskets in the motor.”
NHTSA complaint #10126286, filed 2005-06, 8,200 miles“While accelerating on a hill, the engine would miss, appear to be trying to stall, and black smoke would come out of the tail pipe. The dealer had to replace the icp. Since these symptoms are similar to those described in recall #05s34, I thought my truck should be included. It wasn't and I had to pay a $100 deductible to have it repaired. The service rep said they had several of these same problems on other trucks.”
NHTSA complaint #10139461, filed 2005-10, 37,500 miles“For the past 4 months we have had our truck in the shop three times, because of the EGR valve. Truck constantly blows out black smoke and has no pick up speed. Still having issues the day after the truck was taken into the shop.”
NHTSA complaint #10229633, filed 2008-06, 70,000 milesRelated service bulletins
- 10055629Feb 1, 2014Ford: on some trucks, there is a no crank situation and if voltage on transmission range sensor at pin 21, is less than 5 volts, disconnect the engine cooling fan clutch…
- 10024865Apr 1, 20081999-2008 7.3l/6.0l/6.4l/4.5l diesel f-super duty - clean the charge air cooler (cac) system after certain turbo or engine failures - service tip.
- 10024325Mar 1, 20086.0l turbocharger carbon deposit diagnostics and service tips. *nj updated 5/29/08.
- 10023855Oct 1, 20076.0l--mil on--p0401, p0402, p0404, p1335--lack of power or surge with some 2003-2007 f-super duty, 2003-2005 excursion and 2004-2008 e-series vehicles.
- 10022295Jul 25, 2007Dtc's p006a or p132b - lacks power, surge, or flutter after field service action 06e17.
- 10022293Jul 25, 20076.0l diesel engine - oil leak or boost pressure leak at hot side charge air cooler duct.
- 10021464Apr 27, 20076.0l oil seep or boost pressure leak at hot side charge air cooler duct.
- 10021462Apr 27, 2007Cold start driveability - white smoke, lacks power, exhaust odor, surges, runs, rough, or no start.
- 10022243Apr 1, 2007Lack of power due to low fuel pressure - fuel tank liner seperation.
- 10021236Mar 23, 2007Lack of cooling fan operation.
Engine cooling: other model years
| Year | Complaints | Share of year |
|---|---|---|
| 2024 | 1 | 3% |
| 2023 | 1 | 2% |
| 2022 | 2 | 2% |
| 2021 | 3 | 2% |
| 2020 | 2 | 1% |
| 2019 | 2 | 0% |
| 2018 | 1 | 0% |
| 2017 | 3 | 0% |
| 2016 | 7 | 2% |
| 2015 | 2 | 1% |
| 2014 | 2 | 8% |
| 2013 | 1 | 5% |
| 2012 | 7 | 12% |
| 2011 | 4 | 3% |
| 2010 | 11 | 34% |
| 2009 | 5 | 22% |
| 2008 | 33 | 23% |
| 2007 | 4 | 7% |
| 2006 | 18 | 7% |
| 2005 | 37 | 13% |
| 2004 | 101 | 40% |
| 2003 | 72 | 40% |
| 2002 | 101 | 41% |
| 2001 | 91 | 32% |
| 2000 | 69 | 30% |
| 1999 | 95 | 38% |
| 1997 | 11 | 28% |
| 1996 | 4 | 36% |
| 1995 | 2 | 22% |
Other parts of the 2004 Ford F-250 SD
56 complaintsFuel system
38 complaintsTransmission and drivetrain
21 complaintsTires
17 complaintsVehicle speed control
17 complaintsSteering
15 complaintsSuspension
15 complaintsEngine
14 complaintsBrakes
8 complaintsBody and structure
7 complaintsAir bags
5 complaintsEquipment
5 complaints
← All problems reported for the 2004 Ford F-250 SD
About this data. Data from NHTSA (ODI) complaints, recalls, TSBs and investigations, updated Oct 27, 2026. Complaints are unverified consumer reports and may be duplicated or inaccurate.
To check a specific vehicle for open recalls, use its VIN at nhtsa.gov/recalls. Methodology