Which parts fail
Components named in complaints (battery, alternator, wiring, ignition, instrument cluster, infotainment).
Mileage when the problem started
Owner reports
Selected complaints filed with NHTSA by 2004 Ford F-250 SD owners, lightly cleaned up (personal details are redacted by NHTSA).
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.
Tl* the contact owns a 2004 Ford f-250 SD. While driving at various speeds, the vehicle suddenly shut off. After restarting the engine, the vehicle operated as normal. The vehicle was taken to the dealer where the cac tube was replaced, but the failure persisted. In 2014, the vehicle was taken to and independent mechanic. The technician replaced the fuel pressure regulator, the fuel injection control module, and one glow plug. The contact indicated that the failures continued to occur. The manufacturer was notified of the failures and the contact was informed that the VIN was not included in NHTSA campaign number: 05V270000 (electrical system). The contact indicated that the vehicle experienced the same failure listed in the recall. The failure mileage was 85,000.
Our 2004 f250 diesel 4x4 super duty was parked in the driveway overnight, properly plugged in due to the cold. A neighbor woke us up to state it was on fire. The entire front and interior of the truck was engulfed in flames before the fire department arrived. After it was extinguished, the county fireman pointed the believed the point of ignition appeared to be at the firewall on the drivers side due to the fact that the master brake cylinder & battery were disintegrated. Plus the secondary battery & radiator were partially intact which are in the front. The fire dept stated that if it had been a frontal point of ignition due to the block heater the radiator & battery on front passenger side would've burned first due to aluminum materials.
We have been having on and off problems for about a year with our vehicle stalling while driving. The vehicle would start up but only go about 3 blocks and then stall again. We have replaced the ficm. Vehicle seemed of for a few months and now we are having a problem with it running rough at low idle speeds and missing while driving and running rough. We have been told its the icp sensor and there May be a recall on these part.I called Ford today and our vehicle doesn not fall under this recall but yet we have had the same problems with the ficm amd icp (recall05s34) can you please check and see if any other 2004 Ford f250 super duties are having issues also that Ford is not fixing?????
Tl*- the contact owns a 2004 Ford f-250 super duty and stated that while driving between 40-50 MPH, the vehicle stalled without prior warning. The stalling seemed to occur when the engine had not warmed up completely. He did research online and felt that this vehicle should be covered under recall NHTSA campaign id number: 05V270000 concerning electrical system: wiring. He took it to the dealer, and they stated that the vehicle did not fall within the recall due to the VIN. The current and failure mileage were 112000. The consumer stated an accident occurred. The consumer attempted to stoop the vehicle, but the brakes and steering became stiff. Updated 03/07/07.
While driving, I began to smell smoke in the cab of my truck. I then opened my windows and continued to drive for about a 1/4 mile more until a surge of heavy smoke began to pour in to the cab via the A/C vents. I stopped the truck, and opened the hood. The passenger side of the engine compartment was on fire. I called the fire department and they came to extinguish the fire about 10 minutes later. Almost all of the electrical components and A/C system is burnt. I'm not sure if the truck runs, I am currently waiting for it to be repaired.
2004 Ford f-250 4x4 superduty 6.0l diesel - engine fire. Cause: negative battery cable vibrated loose and caused ground on A/C to overheat and catch the A/C housing on fire. Fire resulted from attempt to start the vehicle in the owner's driveway on a cool day. Vehicle was towed to local dealership and repaired ($1250). The repair included tack welding the negative cable to the engine block. A few months later, a resistor in the A/C blower had to be replaced. The dealership claimed it was unrelated and the repair was an addition $114.
1. When starting for the past couple of months the starter turned a little more slowly than it should have. On the morning of 7/2/05 the starter turned the engine very slowly but did not start the engine and it seemed like the batteries were dead. The key was turned off and removed from the truck. 2. A few minutes after removing the key from the truck a fire started under the hood on the passenger side. The truck was on fire for about 20 minutes and was totaled. 3. Nothing has been done since as the truck is totaled.
Tl* the contact owns a 2004 Ford f-250 SD. The contact stated that while driving at an unknown speed, the vehicle stalled without warning. In addition, the contact stated that while stopped, the vehicle stalled without warning. The vehicle was taken to an independent mechanic where it was diagnosed that the oil filter housing, the oil filter tube and unknown sensors needed to be replaced. The vehicle was repaired however, the failure recurred. The manufacturer was notified of the failure. The failure mileage was 197,000.
Related recalls
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 investigations
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.
Electrical complaints in other F-250 SD years
Frequently asked questions
How common are electrical problems on the 2004 Ford F-250 SD?
NHTSA has 56 complaints about the electrical system of the 2004 Ford F-250 SD, 22% of the model year's 254 complaints. The component named most often is wiring (21 mentions).
Is there a recall for 2004 Ford F-250 SD electrical problems?
Yes — NHTSA recall 05V-270 (wiring, Jun 10, 2005). Recall repairs are free at authorized dealers.
At what mileage do 2004 Ford F-250 SD electrical problems start?
Half of the complaints with a recorded mileage happened before about 81,000 miles, and 22% before 25,000 miles.
Is it dangerous?
Owners linked 2 crashes, 7 fires and 0 injuries to electrical system problems on this model year. If you notice symptoms, have the car checked before driving further.
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.