2004 Ford F-250 Problems
- Complaints
- 154filed with NHTSA
- Median mileage
- 39,000miles, 125 complaints with mileage
- Recalls
- 2campaigns on record
- Trend
- StableComplaints filed in the last 3 full calendar years are within 25% of the 3 years before.
Sources: NHTSA records for the 2004 Ford F-250 (complaints, recalls, investigations). Report an error
What owners report
Owners of the 2004 Ford F-250 report two broad patterns: engines that stall or lose power while driving, and problems specific to the 6.0L turbo diesel, including turbo and EGR cooler failures and power surges. Complaints also describe exhaust manifold stud failures, brake line and caliper leaks, and electrical faults, with stalling reports spread from very low mileage up past 150,000 miles.
- Engine
Engine stalls or loses power while driving
- 57 complaints (37%)
- median 40,400 mi at 3.7 yrs old (48 state mileage)
- filed 2004–2025
Complaints describe the truck shutting off or losing motive power without warning, sometimes at highway speed, then restarting after a short wait or several attempts. Some owners say the dealer or an independent shop could not find a cause; others were told the fuel injection control module, turbo, or a wiring harness was at fault. Several complaints mention the vehicle had to be towed, and a few say the truck would not restart at all. Reported from as little as 83 miles up to roughly 296,000 miles, with many between 80,000 and 185,000 miles.
What to check: Ask for service records on the fuel injection control module, wiring harness and any prior stalling diagnosis, and test drive at highway speed and under load. A scan for stored or pending codes is worth doing before purchase.
2 excerpts from owner complaints in NHTSA records
“Dt: the truck keeps shutting down for no reason. It shuts down without warning on the highway. On other occasions the stalling would occur on upgrades while pulling the fifth wheel. The accelerator pedal would not respond when going above 70 MPH. The (icp sensor) was found to have a faulty connector.”
NHTSA complaint #10124578, filed 2005-06, 6,084 miles“When driving at an undetermined speed vehicle stalled. This caused the driver to drift to the side of the road. Consumer was able to restart the vehicle, and drove it to the dealership for inspection. The consumer stated that vehicle had been to the dealer on four occasions, but problem recurred.”
NHTSA complaint #10083722, filed 2004-07, 2,900 miles - Vehicle speed control
Surge, lurch or unintended acceleration at low speed
- 25 complaints (16%)
- median 6,084 mi at 1.5 yrs old (23 state mileage)
- 1 mention a crash, fire or injury
- filed 2003–2025
Owners describe the truck lunging forward with the foot off the accelerator, often when stopped at a light or idling, and idle speeds rising on their own. Some say the accelerator pedal felt stuck and RPMs did not drop after releasing it. Complaints note dealers often could not duplicate the condition, while a few report an ICP sensor or wiring harness was replaced. Mostly reported under about 15,000 miles, with a handful of cases at higher mileage.
What to check: Check for a documented ICP sensor or pedal assembly replacement, and ask whether the truck idles steadily. During the test drive, note whether RPMs settle promptly when lifting off the pedal.
2 excerpts from owner complaints in NHTSA records
“2004 Ford excursion: the engine fails during operation of the vehicle at various speeds which eliminates power brakes, steering. This is so dangerous, we were almost hit from behind by a 18 wheeler, the engine failed while exiting a ramp on I-95 at 55 MPH. I had to place the truck in nuetral, brake, turn and restart the truck without flipping over the edge of the ramp. …”
NHTSA complaint #10102332, filed 2004-12, 3,000 miles“While driving on the freeway the accelerator got stuck causing us to have an accident. As the truck increased in speed my husband stomped on the break and the truck was only gaining speed. We placed the truck on park and the truck eventually came to a stop causing the truck an immediate stop and forced us down a hill. The truck was totaled because we were pulling a 5th wheel.”
NHTSA complaint #11010238, filed 2017-07, 150 miles - Engine cooling
Turbo and EGR cooler problems on the 6.0L diesel
- 40 complaints (26%)
- median 57,039 mi at 5.6 yrs old (34 state mileage)
- 2 mention a crash, fire or injury
- filed 2004–2023
Owners of the 6.0L turbo diesel report loss of power, surging, white smoke from the exhaust and repeated turbocharger replacement, with some saying a dealer replaced the turbo several times. Complaints also describe EGR cooler failure and coolant or combustion problems attributed to head bolts, with repairs described as expensive and sometimes requiring the cab to be lifted. Reported from very low mileage (under 1,000 miles in one case) through roughly 150,000 miles.
What to check: Verify which engine the truck has, then ask for records of turbo, EGR cooler and head gasket work. Check coolant condition and look for white smoke or a surging idle on a cold start.
2 excerpts from owner complaints in NHTSA records
“The turbo in my Ford pickup has been replaced twice. I have spoken to other people that have had the same problem. My pickup is a 2004 f250 with a turbo diesel engine .”
NHTSA complaint #10233655, filed 2008-07, 27,645 miles“I have a 2004 f 250 super duty with the 6.0 engine it is a known fact that the bolts that hold the heads down streach when hot letting water into the oil system its all over the interrnet about the 6.o engine that Ford provides the only fix is to have the cab removed and replace the bolts with studs that can take the high temp that the engine produces this is only one of the problems but this problem cost me over 5000$ to fix sure would be nice for you all to look into this product that Ford has been useing and knows theres a problem with …”
NHTSA complaint #11183594, filed 2019-03, 112,245 miles
Buying note. Look closely at the engine in a 2004 F-250: service records for stalling, turbo, EGR and exhaust manifold work matter more than mileage, and a pre-purchase inspection should include a scan for codes, a cold-start check and a brake line inspection. Confirm which engine the truck has, since the diesel-specific issues do not apply to the gas versions.
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.
NHTSA recorded 154 consumer complaints for the 2004 Ford F-250. 125 of the complaints include a mileage, and 53% of those were filed for vehicles with under 50,000 miles; the median is 39,000 miles. Of all complaints, 8 involved a crash, 4 a fire, 5 an injury, according to the filers. NHTSA lists 2 recall campaigns and 16 technical service bulletins for this model year.
Not compared (before 2008). Model years 2008–2023 of the same vehicle that have at least 25 complaints are compared, and a model needs at least 3 of them.
Which parts are reported most
Complaints can name more than one part, so the counts add up to more than the total. Select a part to see its complaints, recalls and bulletins.
- Engine cooling44 29%
- Electrical system36 23%
- Engine19 12%
- Fuel system19 12%
- Vehicle speed control19 12%
- Transmission and drivetrain12 7.8%
- Brakes10 6.5%
- Steering10 6.5%
- Tires10 6.5%
- Air bags4 2.6%
Also reported: Body and structure (4), Other or unknown (3), Seat belts (2), Suspension (2), Visibility (wipers, defrost, mirrors) (2), Electronic stability control (1), Equipment (1).
Example complaints
Engine cooling: “Engine accelerates sporadically on its own. Engine occasionally dies at stop lights. Must keep brake pedal firmly pushed at stop as engine will suddenly accelerate. I have already replaced the turbo. The dealer says it could be many different things wrong. The 2003-2007 diesels are notorious for bad turbo, fuel injectors and a head bolt problem that requires removing the cab. I purchased this truck new and it now has 39000 miles on it. This is a serious safety concern.”
NHTSA complaint #10618762, filed 2014-08, 35,000 milesElectrical system: “My vehicle has being stalling while driving at 1st start up in the morning for over 3 weeks. The problem is now getting daily. I understand there is a recall 05s34 that has this problem with the Ford diesels. My vehicle in currently broken down about 60 miles from my home. The auto repair shop thinks its a hiring harness to the ficm.”
NHTSA complaint #10490409, filed 2012-12, 124,000 milesEngine: “The third from the front on the passenger side spark plug blew out and a heli coil was replaced and after under 500 miles it blew out again now they are replacing a second heli coil and I am worried on if it will hold and how dependable it will be. Second I am wondering if there is any compensation from Ford motor co. For the expenses of this procedure and if any head work/replacement is needed and whom wolud be responsable for the cost.”
NHTSA complaint #10873006, filed 2016-06, 155,000 milesFuel system: “Vehicle loses all power-stalls and loses function when idling. Has occurred when exiting freeway way and in a regular neighborhood streets. Need to restart after stall.”
NHTSA complaint #11387696, filed 2021-01, 200,000 milesMileage when problems were reported
53% of the 125 complaints with a mileage were filed for vehicles with under 50,000 miles; the middle half falls between 6,000 and 118,000 miles.
Complaints by year filed
Trend: stable. Complaints filed in the last 3 full calendar years are within 25% of the 3 years before.
Recalls and investigations
- 11V352000Jul 13, 2011Exterior lighting › Brake lightsCovers: Ford F-250 2002–2007, Ranger 2004–2011, F-350 2002–2007 +5 more
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…
- 04V229000May 17, 2004TiresCovers: Ford F-250 2004, F-350 2004
Certain lariat and king ranch model pickup trucks fail to comply with the requirements of federal motor vehicle safety standard no. 120, "tire selection and rims for motor vehicles other than passenger cars." some trucks were inadvertently equipped with an…
Recall details for the 2004 Ford F-250 → · Check a VIN at nhtsa.gov/recalls
Technical service bulletins
TSBs are manufacturer notes to dealers about known repair procedures. They are not recalls and do not by themselves mean a vehicle has a fault. 16 on record; the latest 10 are shown.
- 10017806Oct 31, 2005Engine cooling. Buck/jerk or surge - 6.0l vehicles built before 8/22/2005.
- 10012944Aug 18, 2005Transmission and drivetrain. Low/reverse gear set pinion shaft(s) that may walk out, causing metallic particle contamination. Customer satisfaction program 04b24. Transmission reverse planet replacement. *tt supplement #1 and…
- 10016823Aug 17, 2005Equipment. Customer satisfaction program 05b29: supplement#3. Charge air cooler duct replacement.
- 10012951Feb 21, 2005Transmission and drivetrain. 4x4 transfer case jump out of 4th or 4l - manual shift transfer case.
- 10012965Feb 1, 2005Body and structure. Service tips before arc welding on the frame or body of a unit.
- 10012958Feb 1, 2005Engine cooling. Lack of power, surge, and/or diagnostic trouble codes p2263 or p0299.
- 10014275Jan 1, 2005Transmission and drivetrain. A driveline clunk or bump when starting from a stop.
- 10013322Jan 1, 2005Electrical system. Popping or quavering from radio on the am band.
- 10013316Jan 1, 2005Transmission and drivetrain. A cold weather reverse engagement stall.
- 10014086Dec 13, 2004Transmission and drivetrain. General (pcm) power train control module programming procedures.
Other model years of the Ford F-250
| Year | Complaints | Median mi | Recalls | Crash ★ | MPG | Score (50 = typical) | Trend |
|---|---|---|---|---|---|---|---|
| 2014 | 142 | 81,000 | 0 | 4 | — | 43 · Typical | Falling |
| 2013 | 95 | 77,000 | 0 | 4 | — | 50 · Typical | Falling |
| 2012 | 266 | 78,750 | 1 | 4 | — | 100 · More | Falling |
| 2011 | 248 | 70,000 | 2 | — | — | 100 · More | Falling |
| 2010 | 73 | 75,666 | 0 | — | — | 29 · Fewer | Falling |
| 2009 | 54 | 67,703 | 0 | — | — | 28 · Fewer | Falling |
| 2008 | 197 | 70,000 | 7 | — | — | 100 · More | Stable |
| 2007 | 60 | 42,000 | 4 | — | — | Not compared (before 2008) | Falling |
| 2006 | 221 | 60,000 | 4 | — | — | Not compared (before 2008) | Falling |
| 2005 | 144 | 65,000 | 3 | — | — | Not compared (before 2008) | Falling |
| 2004 | 154 | 39,000 | 2 | — | — | Not compared (before 2008) | Stable |
| 2003 | 116 | 75,000 | 2 | — | — | Not compared (before 2008) | Falling |
| 2002 | 156 | 89,000 | 2 | — | — | Not compared (before 2008) | Rising |
| 2001 | 220 | 65,000 | 4 | — | — | Not compared (before 2008) | Falling |
| 2000 | 326 | 75,768 | 5 | — | — | Not compared (before 2008) | Falling |
| 1999 | 581 | 99,000 | 14 | — | 14 | Not compared (before 2008) | Falling |
| 1998 | 56 | 115,738 | 6 | — | 15 | Not compared (before 2008) | Stable |
| 1997 | 304 | 115,604 | 10 | — | 14 | Not compared (before 2008) | Stable |
| 1996 | 176 | 125,940 | 4 | — | 14 | Not compared (before 2008) | Stable |
| 1995 | 184 | 129,000 | 3 | — | 14 | Not compared (before 2008) | Stable |
| 1994 | 123 | 103,000 | 8 | — | 14 | Not compared (before 2008) | Falling |
| 1993 | 130 | 160,000 | 6 | — | 15 | Not compared (before 2008) | Stable |
| 1992 | 119 | 91,000 | 4 | — | 14 | Not compared (before 2008) | Stable |
| 1991 | 107 | 102,000 | 5 | — | 14 | Not compared (before 2008) | Falling |
| 1990 | 111 | 119,052 | 6 | — | 14 | Not compared (before 2008) | Falling |
| 1989 | 112 | 98,000 | 6 | — | 14 | Not compared (before 2008) | Stable |
| 1988 | 62 | 144,000 | 3 | — | 14 | Not compared (before 2008) | Stable |
| 1987 | 38 | 135,000 | 2 | — | 14 | Not compared (before 2008) | Stable |
| 1986 | 38 | 377,089 | 2 | — | 14 | Not compared (before 2008) | Stable |
| 1985 | 21 | — | 2 | — | 13 | — | Stable |
| 1984 | 10 | 208,000 | 3 | — | 13 | — | Not enough data |
All Ford F-250 model years · Best and worst years by complaints
Frequently asked questions
What are the most common problems with the 2004 Ford F-250?
Owners of the 2004 Ford F-250 report two broad patterns: engines that stall or lose power while driving, and problems specific to the 6.0L turbo diesel, including turbo and EGR cooler failures and power surges. The issues reported most often: Engine stalls or loses power while driving; Surge, lurch or unintended acceleration at low speed; Turbo and EGR cooler problems on the 6.0L diesel.
How many NHTSA complaints does the 2004 Ford F-250 have?
NHTSA recorded 154 consumer complaints for the 2004 Ford F-250 as of Oct 27, 2026. Complaints are unverified consumer reports and may be duplicated or inaccurate.
What part of the 2004 Ford F-250 is reported most often?
Engine cooling is named most often, in 44 complaints (29% of the total), followed by electrical system with 36.
Has the 2004 Ford F-250 been recalled?
NHTSA lists 2 recall campaigns for this model year. To check a specific vehicle, enter its VIN at nhtsa.gov/recalls.
At what mileage are problems with the 2004 Ford F-250 reported?
Among the 125 complaints that include a mileage, the median is 39,000 miles and the middle half falls between 6,000 and 118,000 miles; 53% were filed for vehicles with under 50,000 miles.
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.
Complaint counts come from NHTSA’s public complaint database; we count each complaint once. The source records for this vehicle are on nhtsa.gov. Scores and trends are our own summaries of that data, described in the methodology. This page is not legal, safety or repair advice: for a specific vehicle, check its VIN at nhtsa.gov/recalls and ask a qualified mechanic. See an error? Tell us.