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-350 SD owners, lightly cleaned up (personal details are redacted by NHTSA).
Dt: consumer stated 2004 Ford f350 super duty was having electrical surge problems. Consumer was complaining to dealership that vehicle had surge problems for the past year and a half. The dealer said that they could not duplicate the problem. Dealer did updated the computer software and the truck ran some what better after that. The problem came back after a week, and went back to having computer surges. The truck was in the dealership for repairs on this issue five times. Same result, the truck would work for a little while, then back to the same surging problems which have been intermittent. The manufacturer has been contacted 5 to 6 times. Ford has not helped in resolving this issue. The lemon law has been looked into by the consumer. The lemon law was denied by the state. Consumer had asked Ford to investigate this problem. …
Tl contact owns a 2004 Ford f-350 SD diesel. The contact was driving approximately 60-70 MPH with a camper in tow as the vehicle stalled with the ABS warning light illuminated. The dashboard also became abnormally dim. After inspecting the vehicle, the contact discovered that the vehicle battery was dead and replaced it with the camper battery. The vehicle was taken to a local repair shop where they performed a diagnostic, but, they were unable to determine the cause of the failure. The vehicle battery was recharged and the failure did not recur for another four months. The vehicle was then taken to the same local mechanic where the mechanic replaced the fuel injector. The computer was removed from the vehicle and taken to an authorized dealer for a reset flash. The vehicle performed as normal until the failure recurred one year later. …
2004 f350 superduty 6.0 diesel 110025 miles on truck. The vehicle will some time sputter one to three times and the engine shuts off sometime starting, sometimes failing to start. While driving at times the engine will just shut off sometimes will restart sometimes it will not. I have had it in to a dealership shop to be fixed and they can not at this time find an answer. I feel this might be similar to a recall notice for other truck of this sort, but my vehicle VIN number does not follow under this according to the dealership. The NHTSA campaign number that has similar problem is 05V270000. There has not been any injuries or damage yet, but a vehicle that just shuts off when driving does not feel safe to me. I have only owed it since 6 aug 10 and no problem of this sort has been documented as reported on this vehicle. …
2004 f-350 super duty with 6.0l bought new in 2004.summer of 2006 experanced "surge" while driving on interstate in cruse control. Later same problem at 30 MPH. Problem was worst in September, truck surging and died at idle. I replaced cam sensor, no fix. Took truck to dealer. Loaded new program and changed sensor on turbo and changed transmission filters $200.00. Morning of oct 19 ,leaving for atlanta with familt and camper same "surge". In atlanta oct 20 in trafic truck surged and almost hit a car from behind. Monday oct 23, truck surging badly , tried to die at two red lights. Later no problem. Took to dealer again, found no problem. They wanted to change fuel filters ($120.00). Nov 02, son drove truck school, truck surged twice at red light, tried to push him through lntersection. Dealed has no fix. They have truck now (nov 03). They offered to sell my a new one for $15,000.00
Dt: the caller says truck sometimes loses power. There is no warning that it is going to happen every time. The caller said that sometimes the engine light would come on, and then vehicle would lose power, and sometimes the light would not come on when he lost power. It happens at any speed and when sitting still. Truck has been to dealer 5 times and they could not find the cause of the problem. He recently had recall work done on the wiring harness. After 170 miles the truck continued to lose power. The caller had an appointment next Tuesday with dealer. Manufacturer said to keep bringing it in. The vehicle has been taken to the dealer eight times for the same problem. The last time it was there they replaced the turbo and reprogrammed the computer.
Tl contact owns a 2004 Ford f350 super duty. The contact was driving approximately 70 MPH with the cruise control engaged when suddenly the all of the warning lights on the instrument panel illuminated, followed by the engine stalling. The vehicle restarted within ten minutes after several attempts. The failure occurred three times. The manufacturer was notified and stated that NHTSA campaign id number 05V270000, electrical system wiring was related to the failure; however, the VIN was excluded from the recall. The contact experienced the identical failure as mentioned in the safety recall. The vehicle had not been repaired when the complaint was filed. The failure mileage was less than 71,000.
Tl* the contact owns a 2004 Ford f-350 SD. The contact stated that while driving less than 20 MPH into an intersection, the engine suddenly stalled without warning. The engine restarted after numerous attempts. There was a recall associated with NHTSA campaign id number 05V270000 (electrical system: wiring). In 2007, the vehicle was repaired under the recall; however the remedy was insufficient and the failure recurred. The contact inspected the vehicle and detected that the failure was related to the wiring harness. The vehicle had not been repaired for the most recent failure. The manufacturer was notified of the failure. The approximate failure mileage was 120,000.
Tl contact owns a 2004 Ford f350 super duty. While driving at any speed, the contact stated that the vehicle would hesitate, shut off and then loose power intermittently similar to NHTSA campaign id number : 05V270000 ( electrical system:wiring). The vehicle was taken to the dealer where they performed a diagnostic test which confirmed that the wiring harness needed to be replaced as well as the injection control pressure sensor. The manufacturer was notified who advised the contact that his VIN was not covered under this recall. The vehicle was not repaired. The current mileage was approximately 71,000. The failure mileage was approximately 62,000.
Tl* the contact owns a 2004 Ford f350 super duty. While driving at speeds of 50 MPH, the contact stated the vehicle would hesitate and drive unusually rough. After driving the vehicle for a while, the failure would correct itself. The vehicle demonstrated sign of the failure since the date of purchase. The vehicle had been inspected by two separate dealers where the fuel injectors were replaced. The contact believed NHTSA campaign id number 05V270000 (electrical system: wiring) was directly related to the failure but could not confirm if his VIN was included with the recall. The failure mileage was 10,000 and the current mileage was 42,610.
I own a 2004 Ford f-350 super duty diesel truck and I purchased it brand from sheehy Ford dealership in marlow heights. This truck stalls while driving and has done so since I purchased the vehicle. I have taken it in to be repaired and the dealer said they fixed the problem, however the truck continues to stall. Please refer to campaign no. 05V270000. The dealership would like for us to share in the cost of repair, but we do not want to pay again for this vehicle to be fixed, have this problem happen again, and then the car not fall under warranty and we are stuck again with an unsafe vehicle and another high priced bill to pay.
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-350 SD years
Frequently asked questions
How common are electrical problems on the 2004 Ford F-350 SD?
NHTSA has 29 complaints about the electrical system of the 2004 Ford F-350 SD, 22% of the model year's 130 complaints. The component named most often is wiring (16 mentions).
Is there a recall for 2004 Ford F-350 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-350 SD electrical problems start?
Half of the complaints with a recorded mileage happened before about 73,000 miles, and 42% before 25,000 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.