Most common 2004 Ford F-250 SD problems
Share of the 254 complaints; one complaint can involve more than one system. "~" is the median mileage when the problem started.
Ford F-250 SD complaints by model year
Best F-250 SD years: 2013, 2014, 2012. Years to avoid: 2019, 2017, 2018, 2020, 2016. Compare all years →
2004 Ford F-250 SD recalls (2)
Exterior lighting › Brake lights
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 model year excursion vehicles, and 2002 through 2007 model year f-250,…
Remedy: Dealers will replace the switches free of charge. The safety recall began on August 15, 2011. Owners May contact Ford motor company customer relationship center at 1-866-436-7332.
Electrical system › Wiring
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.
Remedy: Dealers will upgrade the fuel injection control module (ficm) wire harness or replaced, and/or have a new injection control pressure (icp)) sensor connector installed free of charge. The recall began on July 22, 2005.
NHTSA defect investigations
Federal safety investigators have looked into 3 possible defects involving the 2004 Ford F-250 SD:
Engine stalling
Twenty five of the odi failure reports are duplicative of Ford complaints.twenty odi reports do not contain a VIN (and May or May not be duplicative of Ford reports).the 14 alleged crashes and 2 alleged injuries were all minor.submitted during preliminary evaluation (pe) 04-070, Ford's response to odi's information request (ir) letter contained about 5,000 consumer reports (mors) and 8,700 field reports (cqis).Ford…
Engine stalling
In a June 7, 2005 letter, Ford notified odi that it would be conducting a safety recall of approximately 180,000 Ford f-super duty, excursion and e-series vehicles equipped with 6.0l diesel engines to correct two wiring related conditions that could result in engine stall (NHTSA recall no. 05v-270, Ford no.
Spark plug ejection from cylinder head
On September 6, 2005, odi received a petition requesting that the agency investigate allegations of engine spark plug ejection in certain model year 1997 through 2004 Ford vehicles with triton v-8 and v-10 engines.odi received a total of 474 non-duplicative complaints on the subject vehicles where the complainant, or the dealer repairing the vehicle, reported that a spark plug detached from the cylinder and/or…
What 2004 Ford F-250 SD owners say
Engine & cooling all 114 →
Driving on the highway , complete loss of throttle but the engine was still running at a low amperage. Was able to pull off the road and turned it off. It wouldn't start back up right away. Had to wait a while it would start and limped it home. No problems for a few days, then it started acting up again. A couple times it would start, but at a low idle with no response of the gas peddle. The final straw was last week. I was driving on the highway to work. Each time I came to a stop, it would lose throttle. I was able to turn it off and back on to get going. Then at a major intersection of hwy 41 and 145, it wouldn't turn back on and I was in the middle of the hwy. I had to push it to the side of the road and it would turn but not start. …
Tl* the contact owns a 2004 Ford f-250 SD. The contact stated that the vehicle stalled several times and was unable to restart. In other instances, the vehicle restarted with a delay and the engine was slow to gain speed, but later accelerated at a high rate of speed. Dan collins Ford [phone], located at 351 n o st, lakeview, or 97630) and crown motors [phone], located at 351 north o. Street, lakeview, or 97630) were notified, but were unable to replicate the failure. In addition, black smoke was present and the vehicle idled high and low. The vehicle was not repaired and was unsafe to be driven. The vehicle was excluded from NHTSA campaign number: 05V270000 (electrical system). The manufacturer was notified of the failure. The approximate failure mileage was 11,686.
Electrical system all 56 →
My truck started to stall intermittently, I've had it to the dealer to have numerous repairs performed. I saw NHTSA campaign number: 05V270000 which references Ford recall no. 05s34. I called to inquire at west brothers Ford in sullivan mo. And was told my truck has no recalls. I called Ford customer service and the first person said the recall expired and my truck was no longer under warranty. The second person said my truck wasn't affected because the recall said "certain" vehicles. My truck falls in the manufacture dates listed on the recall, has the 6.0 engine and is stalling now. I have owned my truck since new and it has not had this work performed on it. I would like an explanation of what "certain" vehicles apply to this recall and why mine doesn't. I would also like my truck fixed or reimbursed by Ford, unless they can show why my truck doesn't need the work done. …
2004 Ford f250 SD 6.0l sputters, lunges & dies out when idle, waiting in traffic or driving slowly. Luckily, it's been starting right back up. It has been occurring quite often lately. Looked up possible causes and found recall 05V270000 from 2005, which seems to be the exact issue I am having. Called Ford and was told there are zero recalls pertaining to this truck and that that particular recall does not include my truck. I have seen many of the same complaints about this same exact vehicle and how this issue hadn't been covered under said recall. I have the NHTSA recall no ea05003, but it has timed out and is no longer available for viewing on this site. Please realize that all these same vehicle owners are having the same dangerous issue and it isn't being taken seriously by Ford or the NHTSA.
Fuel & propulsion system all 38 →
Driving on the highway , complete loss of throttle but the engine was still running at a low amperage. Was able to pull off the road and turned it off. It wouldn't start back up right away. Had to wait a while it would start and limped it home. No problems for a few days, then it started acting up again. A couple times it would start, but at a low idle with no response of the gas peddle. The final straw was last week. I was driving on the highway to work. Each time I came to a stop, it would lose throttle. I was able to turn it off and back on to get going. Then at a major intersection of hwy 41 and 145, it wouldn't turn back on and I was in the middle of the hwy. I had to push it to the side of the road and it would turn but not start. …
My truck started to stall intermittently, I've had it to the dealer to have numerous repairs performed. I saw NHTSA campaign number: 05V270000 which references Ford recall no. 05s34. I called to inquire at west brothers Ford in sullivan mo. And was told my truck has no recalls. I called Ford customer service and the first person said the recall expired and my truck was no longer under warranty. The second person said my truck wasn't affected because the recall said "certain" vehicles. My truck falls in the manufacture dates listed on the recall, has the 6.0 engine and is stalling now. I have owned my truck since new and it has not had this work performed on it. I would like an explanation of what "certain" vehicles apply to this recall and why mine doesn't. I would also like my truck fixed or reimbursed by Ford, unless they can show why my truck doesn't need the work done. …
Frequently asked questions
Is the 2004 Ford F-250 SD a good car?
Based on 254 owner complaints filed with NHTSA, the 2004 F-250 SD rates use caution: 1.7× as many complaints as a typical year of the F-250 SD at the same age. It is one of the F-250 SD years we suggest avoiding. Complaint counts don't account for sales volume or individual maintenance, so have any used car inspected before buying.
What is the most common problem with the 2004 Ford F-250 SD?
The engine & cooling — 114 complaints, 45% of all complaints for this model year, most often about engine › diesel. Next are the electrical system (56) and fuel & propulsion system (38).
How many recalls does the 2004 Ford F-250 SD have?
There are 2 recalls for the 2004 Ford F-250 SD, the most recent from July 13, 2011 (brake lights). Recall repairs are free at any authorized dealer — check whether yours has been done with the VIN recall check.
What are the best and worst years of the Ford F-250 SD?
The best years by complaints, compared at the same age, are 2013, 2014 and 2012. Years to avoid or approach with caution: 2019, 2017, 2018, 2020 and 2016. See the full Ford F-250 SD years comparison.
At what mileage do 2004 Ford F-250 SD problems happen?
The median mileage reported in complaints is about 57,000 miles; 46% of problems with a recorded mileage started before 50,000 miles.
Source: U.S. National Highway Traffic Safety Administration (NHTSA) — owner complaints through October 20, 2026, recalls and defect investigations; fuel economy from the EPA. Complaints are unverified reports and are not proof of a defect. How we rate model years.