Which parts fail
Components named in complaints (engine, cooling system, oil leaks, timing chain, exhaust).
Mileage when the problem started
Owner reports
Selected complaints filed with NHTSA by 2004 Ford F-250 owners, lightly cleaned up (personal details are redacted by NHTSA).
The contact owns a 2004 Ford F-250. The contact stated while driving at an undisclosed speed, the vehicle lost motive power and stalled. There was no warning light illuminated. The vehicle was able to be restarted; however, the failure recurred. The dealer was not contacted, and the vehicle was not repaired. The manufacturer was made aware of the failure. The failure mileage was approximately 140,000.
I purchased this truck in January 2023. Drove just fine for 2 months and started having this issue. While driving my 2004 f250 sd 6.0l turbodiesel 4x4, (egr deleted, bulletproofed and studded engine, cold air intake, oil cooler, sct x4 tuner) a "fizzle" noise was heard more on passenger side; acting like fuel wasn't reaching engine; and truck stalled right after noise was heard. Wouldn't restart on a hot engine. Crank-no start. Drained both batteries attempting to restart. Restarted after cold engine but would stalled out and not be able to restart while hot engine. Replaced both fuel filters, fuel pump, some module in front bumper relating to fuel system. A friend that knows diesel engines has been trying to find out why its operating the way it is. I treated the gas tank to (2) SEAFOAM for trucks and had valvoline in Ferndale, WA do an oil change after purchasing it. …
I have a 2004 f 250 super duty with the 6.0 engine it is a known fact that the bolts that hold the heads down streach when hot letting water into the oil system its all over the interrnet about the 6.o engine that Ford provides the only fix is to have the cab removed and replace the bolts with studs that can take the high temp that the engine produces this is only one of the problems but this problem cost me over 5000$ to fix sure would be nice for you all to look into this product that Ford has been useing and knows theres a problem with that engine,,you go to trade it in at Ford and they see it has a 6.0 engine in it and the price drops ,way ,way to much for a truck that sold new for 45000$ , I found my truck leaking water in the drive way setting still no reason for it to start leaking ,,I have the bills from Ford dealer where I had it fixed if needed please look into this engine its …
Experience stalling without warning while driving and May or May not restart. It will also stall after letting off the throttle when approaching a stop and occasionally while while stopped at a light. RPM's will also drop to 500 and I have no throttle response, if it doesn't stall completely. This May occur 4 or more times a day, then May not occur again for a few days or weeks. There is absolutely no telling when it will occur, it is to random to identify the problem. Now my horn and cruise control have stopped working as well, when I replace the fuse it blows immediately. I have replaced the ficm, ebp sensor and wiring, fuel pump and still have not resolved the problem. My truck is not safe to drive. This has been happening since shortly after buying the truck in 2018, but seems to be getting worse as the temperature warms up. …
Driving the vehicle 20mph lost all power to engine, left without power steering, brakes or control of vehicle. Pulled over and tried to start vehicle, it did not start, but after a few minutes it restarted. This has happened three times in February 2015. I contacted Ford motor company, was assigned a case number. She checked on NHTSA recall 05V270000. She stated that the repairs to this vehicle have already been completed and that I was now on my own in regards to repairs. While doing research, I have found out that people are still having some problems regarding this issue. Ford seems to have washed their hands of this issue of responsibility regarding their vehicles. This is why I am filing a case.
Tl* the contact owns a 2004 Ford f-250. While driving 40 MPH, the vehicle stalled and it took numerous attempts to restart. There were no warning indicators illuminated. The dealer was not notified. An independent mechanic diagnosed the vehicle, but was not able to locate the cause of the failure. The manufacturer was notified. The vehicle was not repaired. The contact stated that the failure was similar to what was listed in NHTSA campaign number: 05V270000 (electrical system). The failure mileage was 150,000.* 'parts of this document have been redacted to protect personally identifiable information pursuant to the freedom of information act (foia), 5 U.S.c. 552(b)(6).'
Tl* the contact owns a 2004 Ford f-250. While driving approximately 65 MPH, the vehicle stalled without warning. The vehicle was pulled over to the side of the road and restarted. The failure recurred three times. The vehicle was taken to an independent mechanic to be diagnosed, but the cause of the failure could not be determined. The manufacturer was made aware of the failure and referred the contact to NHTSA. The dealer was not contacted. The vehicle was not repaired. The failure mileage was approximately 296,000.
Faulty exhaust manifold bolts break off and cause excessive noise, exhaust enters the drivers cabin, vehicle will not pass emissions inspection and is expensive to repair. I have 4 Ford vehicles with this problem. First incident was at around 50,000 miles and 48 months after purchase. Ford refused to make repairs under any portion of the factory warranty. They claim lifetime emissions warranty doesn't cover it, nor the 100,000 powertrain warranty. I have spent over $8000.00 making repairs to these exhaust manifolds.
Tl* the contact owns a 2004 Ford f-250. The contact stated that while driving at 40 MPH, the vehicle loss motive power and stalled without warning. The contact coasted the vehicle over to the shoulder of the roadway. The vehicle was restarted and resumed normal vehicle operation. The failure recurred 4 times. The vehicle was not taken to be diagnosed nor repaired. A dealer was not contacted. The manufacturer was not made aware of the failure. The failure mileage was approximately 180,000.
The third from the front on the passenger side spark plug blew out and a heli coil was replaced and after under 500 miles it blew out again now they are replacing a second heli coil and I am worried on if it will hold and how dependable it will be. Second I am wondering if there is any compensation from Ford motor co. For the expenses of this procedure and if any head work/replacement is needed and whom wolud be responsable for the cost.
NHTSA investigations
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…
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…
Engine complaints in other F-250 years
Frequently asked questions
How common are engine problems on the 2004 Ford F-250?
NHTSA has 63 complaints about the engine & cooling of the 2004 Ford F-250, 41% of the model year's 154 complaints. The component named most often is engine › diesel (11 mentions).
Is there a recall for 2004 Ford F-250 engine problems?
No. NHTSA lists no engine & cooling recall for the 2004 Ford F-250, though it has 2 recalls for other components. If the problem is widespread, a repair may still be covered by an extended warranty or a manufacturer service bulletin — ask a dealer.
At what mileage do 2004 Ford F-250 engine problems start?
Half of the complaints with a recorded mileage happened before about 28,000 miles, and 49% before 25,000 miles.
Is it dangerous?
Owners linked 0 crashes, 1 fire and 0 injuries to engine & cooling 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.