2004 Ford F-250 SD Engine Problems

Which parts fail

• Engine › Diesel
  37
• Engine
  16
• Exhaust system › Emission control › Gas recirculation valve (EGR valve)
  7
• Exhaust system
  5
• Engine › Other fuel types › Turbo/supercharger
  4
• Exhaust system › Manifold/header/muffler/tail pipe
  3

Components named in complaints (engine, cooling system, oil leaks, timing chain, exhaust).

Mileage when the problem started

• Under 25k
  4444%
• 25k–50k
  99%
• 50k–75k
  1616%
• 75k–100k
  1414%
• 100k–150k
  1414%
• 150k+
  44%

Owner reports

Selected complaints filed with NHTSA by 2004 Ford F-250 SD owners, lightly cleaned up (personal details are redacted by NHTSA).

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.

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.

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.

Tl contact owns a 2004 Ford f250 super duty. The contact stated that the EGR cooler needed to be replaced three times. The vehicle would produce a lot of smoke and fail to accelerate properly once the EGR failed. The dealer stated that the manufacturer would not assume liability for the repairs. There was a factory warranty that covered the part for twelve months or 12,000 miles, whichever came first. The failure always occurred outside of the warranty. The VIN was unknown. The failure mileages were 99,000, 114,000 and 130,000. The current mileage was 130,000.

Tl contact owns a 2004 Ford f250 super duty. The contact stated that the vehicle began to pump out coolant and smoke. The dealer stated that the head gasket needed to be replaced. Upon further investigation, the contact found that this was a common issue with this particular vehicle, and was associated with the bolts used for the head gasket. There were no recalls for the vehicle and the manufacturer had not been notified. The VIN was unknown. The failure and current mileages were less than 140,000.

Tl contact owns a 2004 Ford f-250 super duty. The contact stated that the environmental regulator (EGR) failed and ruined the motor. When the contact tried to start the vehicle, the engine began to emit smoke and would not start. There were no warning lights displayed. The vehicle was taken to an authorized dealership where the coolant, oil filter, gkt kit, head gaskets, EGR cooler, oil cooler, intake gasket and turbo were all replaced. The current and failure mileages were approximately 87,690.

Engine was cold, sat over night, in the morning tried to start vehicle, glow plug light turned off and engine was cranked, engine cranked slow but did not start and within seconds engine compartment burst into flames. Fire was extinguished with a fire extinguisher. Fire destroyed passenger side of engine compartment, smoke damage in cab. Cause of fire unknown at this time. Has not been determined if vehicle can be repaired.

Takara recall I was driving down the freeway when the check engine light came on I all the sudden had a loss of power and it was like the motor was sputtering like it had a misfire after that it's very hard to start and barely moves it comes up with multiple injector codes that all failed at the same time some high some low

NHTSA investigations

Engine complaints in other F-250 SD years