Which parts fail
Components named in complaints (fuel pump, injectors, fuel tank, hybrid and EV propulsion).
Mileage when the problem started
Owner reports
Selected complaints filed with NHTSA by 2004 Ford F-350 owners, lightly cleaned up (personal details are redacted by NHTSA).
Takata inflators; my vehicle started all types of problems intermittent ones that cost me several thousand dollars never fixing the problem this is were it all began,,.my vehicle died going up fairly steep hill to grave yard, it immediately rolled back shoving a family members vehicle down hill a ways until they turned away from the cliff edge leaving me all alone.until going through a run off ditch stopping over it into 2 trees. I had no steering no brakes and thank god the trees were there to stop my truck if not their was a 100 foot cliff next.. I know nothing about recalls or such I just tried to fix my truck problem by problem as symptoms came on I have all types of recent receipts that all came from silverish dark maybe even gray matter stuff in the tank. When I get my bank statement I will itemize all and submit them when final cost is over.
Tl* the contact owns a 2004 Ford f-350. While driving various speeds, the vehicle stalled without warning. The contact placed the gear shifter into neutral and was able to restart the vehicle. In addition, the steering wheel became difficult to maneuver. While driving various speeds, the battery, oil pressure and check engine warning indicators illuminated. The vehicle was not taken to the dealer. The vehicle was taken to an independent mechanic where it was diagnosed that the fuel injection control module failed and needed to be replaced. The vehicle was repaired; however, the failure recurred. The manufacturer was notified of the failure and informed the contact that they did not have a record of the vehicle being serviced. No further assistance was offered. The approximate failure mileage was 150,000.
Tl* the contact owns a 2004 Ford f-350. The contact stated that the fuel tank strap was severely corroded and the fuel tank detached from the vehicle. The contact stated that this was the second time the failure occurred. An unknown Ford dealer was contacted and referred the contact to Ford USA. The manufacturer was notified of the failure and informed the contact that there was no recall and he would be responsible for the repair cost. The failure mileage was approximately 82,000. Updated 11/02/17
Tl* the contact owns a 2004 Ford f-350. The contact stated that while driving approximately 65 MPH, the vehicle suddenly loss motive power and stalled without warning. The contact restarted the vehicle however, the failure recurred. Upon inspection, the contact discovered the fuel filter was covered with silver debris. The cause of the failure was not determined. An unknown dealer was contacted. The manufacturer was not contacted. The failure mileage was 332,000.
I was driving my Ford f350 down a 2 lane road with a tractor trailer following close behind me at 60 MPH when my truck stalled. To avoid being crushed by the semi I veered off the road to the right and put my truck into the ditch and the semi had to swerve to make it all the around me. The truck would not restart and had a quater tank of fuel in it. I had to leave the truck there till the next day. The next morning I called the local dealer velde Ford they also said they couldn't tow it. I called a wrecker service and they hauled it to velde Ford. Velde Ford wouldn't have a diesel mechanic till Monday. Velde Ford also said they couldn't provide a rental car. They did find a third recall on my truck for the exhaust sensor. On Monday, velde called me to tell me the fuel pump had gone out and they ordered a new one which would be there on Tuesday. …
Engine began bucking, sudden power loss and power steering and power brake loss. Mechanic conclusion was that the lining of the fuel tank had dislodged and caused the engine to foul, causing a sudden power loss. Dealer said they had never heard of the problem but we later learned they were very familiar with it, had done dozens of repairs (replacement of tank with poly tank) and that a "secret" repair bulletin had been issued ty Ford to all dealers. This issue is now the subject of a class action lawsuit in new jersey. Google "Ford fuel tank lining" for more info on the suit, but by not issuing a recall this issue is a potential safety concern. Had we been in heavier traffic and unable to get the vehicle to the side of the road there May have been a serious accident.
Tl* the contact owns a 2004 Ford f350. The contact was driving at approximately 40 MPH when the vehicle suddenly began to shake and jerk forward. The vehicle was taken to a local mechanic who informed the contact that the EGR cooler and three fuel injectors were the cause for the failure. The vehicle was repaired at that time. Later, the high oil pressure pump and oil cooler failed. The vehicle was awaiting further repairs at the time of the complaint. The contact called the manufacturer but was told that she would have to assume all repair costs at her expense. The failure mileage approximately was 121,000. The current mileage was approximately 130,000.
The truck stalled in rush hour traffic, just before the entrance to a tunnel. This could have been a very serious safety issue had I not been able to get out of the travel lanes of the interstate. Managed to cross from the right lane, across a merge lane to the shoulder. Managed to restart engine. Excessive smoke, running rough. Stayed on shoulder until engine ran smooth enough to go. Taken to dealer. EGR valve replaced. Intake manifold cleaned. Turbo cleaned. Cost $1776.82 to repair. Supposedly not covered by warranty. This happened on either the first Monday of November or the last Monday of October, as well as the previous Friday.
My 2004 Ford f-350 6.0 diesel. Hesitate or surges while driving, and/or the engine May stall while driving at all speeds including highway speed, will lose power steering and brakes and when at a stop it will lunge forward. The engine May or May not restart after stall. I feel that this is a great safety concern I have almost lost control of my vehicle on a few occasions while towing my boat and going around corners. I have heard of other people having the same problems with their 2004 6.0 diesels. Please help!
Tl contact owns a 2004 Ford f350. In January of 2008, while driving 40 MPH, the vehicle stalled. The contact parked the vehicle and attempted to restart it, but was unsuccessful. The vehicle was towed to the dealer and they stated that the liner in the fuel tank delaminated, causing plastic pieces to flow through the fuel line, pump, and injector. The vehicle was repaired. The VIN was unknown. The current mileage was 55,000 and failure mileage was 45,000. Updated 11/19/08. Updated 11/19/08.
Fuel System complaints in other F-350 years
Frequently asked questions
How common are fuel system problems on the 2004 Ford F-350?
NHTSA has 25 complaints about the fuel & propulsion system of the 2004 Ford F-350, 16% of the model year's 159 complaints. The component named most often is fuel injection system › injectors (3 mentions).
Is there a recall for 2004 Ford F-350 fuel system problems?
No. NHTSA lists no fuel & propulsion system recall for the 2004 Ford F-350, 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 fuel system problems start?
Half of the complaints with a recorded mileage happened before about 89,000 miles, and 14% before 25,000 miles.
Is it dangerous?
Owners linked 2 crashes, 0 fires and 2 injuries to fuel & propulsion 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.