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-350 SD owners, lightly cleaned up (personal details are redacted by NHTSA).
Tl contact owns a 2004 Ford f-350 SD. While driving 20 MPH, white smoke was emitted from the tail pipe. The contact unhooked the trailer, but the vehicle would not move regardless of what gear it was placed in at the time. The vehicle remained in park for four hours before it was finally able to be moved. A few days later, the vehicle was driven to a nearby repair shop and the mechanic stated that the EGR cooler system was defective and could have blown a head gasket. The dealer will not assume responsibility for the repairs. The vehicle has not been repaired. The current and failure mileages were 125,000.
The truck started to stall on several occasions as I was attempting to get up to road speed of 55 MPH. The truck was losing speed, jerking and black smoke coming out of the exhaust. There were no indications of engine failure to warn me of any problems, ie. Engine light. This occurred on more than once, causing potential traffic hazard. The cam sensor and fuel injection control module needed to be replaced. The repair costs involved were high thank goodness there were no injuries or accidents due to the stalling. Thank you,
Tl* the contact owns a 2004 Ford f-350 SD. While driving 35 MPH, the vehicle stalled without warning. The vehicle was taken to a dealer. The technician diagnosed that the oil pump failed and needed to be replaced. The vehicle was repaired. The failure mileage was 161,000.
While driving on the highway at around 55mph, the truck stopped running with no prior warning or any prior issue. After it shut off the truck would crank but not start. Incident was very unsafe as the vehicle shut off at highway speeds.
We purchased 4, 2004 f-350 Ford diesel 6.0 liter ambulance conversions. All 4 vehicles are having reoccurring engine failures. The problems began on some of the vehicles at low mileage. The dealer continues to "patch" the engine problem. I have communicated with several other ambulance services and have found that they are having the same problems. The failure of these engines while transporting critical patients creats a very risky and dangerous situation for the patients and a hugh liability issue for the paramedics and our company.last night another engine failed while transporting an 18 year old with a broken neck to a higher level hospital. The delivery of the patient was delayed unnecessarily because another ambulance service had to be called and waited on to get to my crew to transport the patient. This happens almost each time I sent one of these ambulances on a trip. …
I have a 2004 f-350 turbo diesel 6.0 l. Truck. The truck surges when you drive it. It cuts out. It dies on the road when you are driving it. We have made several complaints to rich Ford in edgewood and albuquerque. This is a very serious safety hazard. They have attempted to fix it four times. The last time I took it to rich Ford in albuquerque was because I was waiting to pull out into traffic with my foot on the brake and the truck was surging forward into traffic. I was very scared as was my ten year old son. I had my foot pressed as hard as I could on the break and that was not stopping the truck from moving forward. I drove straight to the dealership, rich Ford of albuquerque, and they told me that they could not service my vehicle that day. I would have to wait two weeks. I was scared to drive the truck home. I am afraid for my family's safety. …
Engine dies and/or looses power. Happens at random times. The following items have been changed:ficm, , engine oil (thought problem due to oil pump), fuel filters, cam sensor switch, cleaned EGR valve and all passages, replaced injector pressure controller, replaced EGR valve. Last trip to dealer was May 3, 2010. No problems until today when pulling out of a side road onto main road engine died with vehicle blocking both lanes of traffic-push time--accident avoided only because no traffic. The basic problem with trying to get this vehicle repaired is no codes are set. After months of fails, it set a "bad ficm" code, changed ficm, no change in problem, repeated trips to dealer, finally get a "bad cam sensor" code, changed cam sensor, no change in problem. …
My husband and I purchased a used 2004 Ford f350 heavy duty truck in summer of 2006. I would say within the first 6-8 months of owning the truck we started having issues with the truck cutting out (no power). We had the truck into the shop on several occasions and they changed out a few hoses and did a few other things but the problem continued to occur. The truck was originally under warranty when the problem started and now they won't back the problem. We have had the truck in several times and they can't seem to find the problem and the truck continues to cut out (lose power). The truck loses power while driving down the road almost every other time we drive the truck. My husband and I have crossed major highways and had the truck lose power and almost got hit from oncoming traffic going 65-70mph. …
I have a Ford f-350 with a 6.0 diesel engine. This engine has been nothing but trouble. Which creates a hazard for all who own one and to the public . This is the second time I have complained to you about this engine. Why aren't you people doing something with Ford and international. Two times my truck has dumped half the oil out going down the road. Once when the high pressure pump blew a seal and again when the oil cooler and EGR cooler busted. If this truck is doing it then all the other 6.0 diesel trucks on the road are too. If you google the oil coolers and EGR coolers you will see just how big the problem is. If this is not a hazard then I don't know what is. …
We purchased this truck new to tow our 5th wheel. At 16,000 miles the turbo was replaced under warranty. Now at 31,412 miles, again, the turbo had to be replaced but this time at our expense. This second turbo rusted and was not repairable. Our truck has had all of the recommended maintenance done at the appropriate time/mileage. It has never had any after market equipment used on it or has it been abused in any way. This problem exists because of the poorly engineered and designed engine/EGR system. It puts moisture into the turbo without a method to remove it. Ford needs to step up and stand behind this engine that they contracted international to engineer, design, and build for them. We implore NHTSA to step up and hold Ford responsible to their customers and their product with recalls to fix the inherent problems that this engine and vehicle present.
NHTSA investigations
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-350 SD years
Frequently asked questions
How common are engine problems on the 2004 Ford F-350 SD?
NHTSA has 49 complaints about the engine & cooling of the 2004 Ford F-350 SD, 38% of the model year's 130 complaints. The component named most often is engine › diesel (15 mentions).
Is there a recall for 2004 Ford F-350 SD engine problems?
No. NHTSA lists no engine & cooling recall for the 2004 Ford F-350 SD, 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-350 SD engine problems start?
Half of the complaints with a recorded mileage happened before about 80,000 miles, and 19% before 25,000 miles.
Is it dangerous?
Owners linked 0 crashes, 2 fires 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.