2004 Ford F-550 SD Problems
- Complaints
- 49filed with NHTSA
- Median mileage
- 36,000miles, 39 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-550 SD (complaints, recalls, investigations). Report an error
NHTSA recorded 49 consumer complaints for the 2004 Ford F-550 SD. The part named most often is fuel system, with 26 complaints (53% of the total), followed by engine cooling (16) and electrical system (9). 39 of the complaints include a mileage, and 67% of those were filed for vehicles with under 50,000 miles; the median is 36,000 miles. Of all complaints, 1 involved a crash, 5 a fire, 4 an injury, according to the filers. NHTSA lists 2 recall campaigns and 69 technical service bulletins for this model year. Fuel system complaints overlap with 1 technical service bulletin filed under the same part. Engine cooling complaints overlap with 28 technical service bulletins filed under the same part.
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.
- Fuel system26 53%
- Engine cooling16 33%
- Electrical system9 18%
- Vehicle speed control2 4.1%
- Wheels2 4.1%
- Air bags1 2.0%
- Brakes1 2.0%
- Engine1 2.0%
- Body and structure1 2.0%
Also reported: Suspension (1).
Example complaints
Fuel system: “We own a fleet of Ford diesel engine trucks which continue to experience fuel delivery problems. The problem is engine cut-off and surging and hard starting. Ford says not their problem and charges us. I don't think we have the only ones. Toyota is not the only company not dealing with this problem. Think only the government will make them fix it.”
NHTSA complaint #10329666, filed 2010-05, 74,145 milesEngine cooling: “The truck in question is a 2004 Ford f-550 diesel. Upon depressing gas pedal, truck stalled and no longer worked properly. Truck was towed to local Ford dealer where it was determined that the fuel tank was suffering from rust inside the tank. Based on the work done, rust particles that formed inside the tank were forced through the fuel pump and filter damaging both and causing an issue with the fuel injectors. I called Ford directly to ask about any recalls for this issue and they told me there was no recall currently for this problem. …”
NHTSA complaint #10499917, filed 2013-02, 36,000 milesElectrical system: “While driving a Ford f-550 that I bought used on 01-25-06 from hub city Ford in lafayette, la...the engine lost power and stalled on a 65 MPH. Hwy (hwy 90). Apparently...there is good cause to believe that an ignored recall on this specific truck is the exact reason for this dangerous failure. Not to mention the now lost income from it being in the waiting line at hub city Ford...where I had it towed. I was promised that all was inspected and in good working order prior to driving the truck off the lot. Well...it wasn't. …”
NHTSA complaint #10149993, filed 2006-02, 262,257 milesTransmission and drivetrain: “Problem 1: in 2004 I purchased a new Ford f-550 with the gasoline v10. About one month after owning the truck the through-out bearing on the clutch started making noise and has done so. This year with only 49,000 miles on the truck now it does not want to go into gear sometimes.by the time I contacted my dealer he said that the truck was off warranty. Did they sell cheap bearings in these trucks, because my last f350 I had for 14 years without any problems. Problem 2: ever since I have owned this truck. When you are sitting at a light and get ready to go. …”
NHTSA complaint #10419489, filed 2011-08, 100 milesMileage when problems were reported
67% of the 39 complaints with a mileage were filed for vehicles with under 50,000 miles; the middle half falls between 24,000 and 68,000 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-550 SD 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…
- 05V270000Jun 10, 2005Electrical system › WiringCovers: Ford F-550 SD 2004–2005, Excursion 2004–2005, E-350 2004–2005 +4 more
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 details for the 2004 Ford F-550 SD → · 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. 69 on record; the latest 10 are shown.
- 10243490Sep 7, 2023Transmission and drivetrain. When performing any transmission fluid changes or topoffs involving MERCON SP, MERCON LV has replaced all versions of MERCON SP and can be used going forward. Mixing MERCON LV and MERCON SP in the…
- 10189008Feb 10, 2021Transmission and drivetrain. This SKU is a Transmission Line. The customer communication requested return of unsold inventory to inspect the connector. The transmission line connector may have an incorrect thread size, which…
- 10171326Jan 13, 2020Equipment. This SKU is a Spare Tire Hoist. Test results identified that the pull force parameter was not within specification, as a precautionary measure unsold inventory was requested to be returned for…
- 10171325Jan 13, 2020Equipment. This SKU is a Spare Tire Hoist. Test results identified that the pull force parameter was not within specification, as a precautionary measure unsold inventory was requested to be returned for…
- 10165713Sep 2, 2019Electrical system. Some 2002-2008 F-Super Duty, F-150 and Mark LT vehicles may exhibit concern during or after programing the VSM. The programming may fail or vehicle symptoms such as inoperative door locks, dome…
- 10056196May 1, 2014Transmission and drivetrain. Ford: when shifting between park, reverse and/or during 2-3 shift, an intermittent clunk occurs with a torqshift transmission. Model 2003-2014 f-super duty, e series, excursion, f-53 motorhome…
- 10055648Feb 1, 2014Equipment. Ford: the restraint control module (rcm) when using vcm ii, would have an error code 35 and diagnostic trouble code (dtc) b1035, and difficulty attempting programmable module installation (pmi)…
- 10055629Feb 1, 2014Engine cooling, Transmission and drivetrain. Ford: 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, electronically, and recheck…
- 10022295Jul 25, 2007Engine cooling. Dtc's p006a or p132b - lacks power, surge, or flutter after field service action 06e17.
- 10020150Jun 1, 2006Engine cooling. Repeat turbocharger or vgt replacement.
Other model years of the Ford F-550 SD
| Year | Complaints | Median mi | Recalls | Crash ★ | MPG | Score (50 = typical) | Trend |
|---|---|---|---|---|---|---|---|
| 2022 | 9 | 85,000 | 12 | — | — | — | Not enough data |
| 2021 | 12 | 148,000 | 9 | — | — | — | Not enough data |
| 2015 | 11 | 22,350 | 3 | — | — | — | Not enough data |
| 2014 | 9 | 33,006 | 6 | — | — | — | Not enough data |
| 2012 | 6 | 40,500 | 10 | — | — | — | Not enough data |
| 2008 | 26 | 33,000 | 4 | — | — | Not compared (fewer than 3 comparable model years) | Falling |
| 2007 | 23 | 32,500 | 1 | — | — | — | Falling |
| 2006 | 44 | 43,982 | 1 | — | — | Not compared (before 2008) | Falling |
| 2005 | 32 | 47,500 | 4 | — | — | Not compared (before 2008) | Stable |
| 2004 | 49 | 36,000 | 2 | — | — | Not compared (before 2008) | Stable |
| 2003 | 33 | 60,000 | 5 | — | — | Not compared (before 2008) | Stable |
| 2002 | 22 | 59,000 | 4 | — | — | — | Falling |
| 2001 | 29 | 130,000 | 6 | — | — | Not compared (before 2008) | Rising |
| 2000 | 72 | 51,500 | 5 | — | — | Not compared (before 2008) | Falling |
| 1999 | 61 | 65,000 | 8 | — | — | Not compared (before 2008) | Stable |
All Ford F-550 SD model years · Best and worst years by complaints
Frequently asked questions
How many NHTSA complaints does the 2004 Ford F-550 SD have?
NHTSA recorded 49 consumer complaints for the 2004 Ford F-550 SD as of Oct 27, 2026. Complaints are unverified consumer reports and may be duplicated or inaccurate.
What part of the 2004 Ford F-550 SD is reported most often?
Fuel system is named most often, in 26 complaints (53% of the total), followed by engine cooling with 16.
Has the 2004 Ford F-550 SD 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-550 SD reported?
Among the 39 complaints that include a mileage, the median is 36,000 miles and the middle half falls between 24,000 and 68,000 miles; 67% 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.