2004 Ford F-350 SD Fuel system Problems

“The truck started to stall on several occasions as I was attempting to get up to road speed of 55 MPH. The truck was losing speed, jerking and black smoke coming out of the exhaust. There were no indications of engine failure to warn me of any problems, ie. Engine light. This occurred on more than once, causing potential traffic hazard. The cam sensor and fuel injection control module needed to be replaced. The repair costs involved were high thank goodness there were no injuries or accidents due to the stalling. Thank you,”

“Egr cooler on my Ford f-350 super duty diesel went out a little over a year ago. Truck was under warranty. They fixed it with about a $100 fee. Just today my truck started having the same issue so I took it in and they told me it was the EGR cooler and that because of that issue it has ruined the head gaskets also. The mechanic at Ford told me that most trucks that have this issue will always have this issue recurring every year or so. Wondering why this has not been recalled by Ford. …”

“Truck started running a little sluggish first two days and then began running rough and sluggish at time of acceleration and then blow big puff of black smoke out and take off with allot more power than normal.. It is at Ford dealership being repaired now having injectors, fuel pump and fuel tank recoated because they say Ford has a national back order on these tanks and will take 6 months to get. This tells me along with the problems I am finding other people are having online that this is a big problem.”

“I have a 2004 f350 diesel truck. As I was traveling on i75, the vehicle had a sudden loss of power and speed dropped to below 30 MPH. This caused a problem as I was moving substantially slower than surrounding traffic which was a safety problem. Examination of fuel tank by a repair person showed a delamination of the tank. I have had the tank cleaned out but will have to replace the tank. In researching the problem on the internet this seems to be a common problem with 2004 and 2005 Ford trucks.”

“We purchased this truck new to tow our 5th wheel. At 16,000 miles the turbo was replaced under warranty. Now at 31,412 miles, again, the turbo had to be replaced but this time at our expense. This second turbo rusted and was not repairable. Our truck has had all of the recommended maintenance done at the appropriate time/mileage. It has never had any after market equipment used on it or has it been abused in any way. This problem exists because of the poorly engineered and designed engine/EGR system. It puts moisture into the turbo without a method to remove it. …”