Most common 2004 Ford F-550 SD problems
Share of the 49 complaints; one complaint can involve more than one system. "~" is the median mileage when the problem started.
Ford F-550 SD complaints by model year
Best F-550 SD years: 2018, 2013, 2017. Years to avoid: 2000, 1999, 2004, 2006, 2005. Compare all years →
2004 Ford F-550 SD recalls (2)
Exterior lighting › Brake lights
Ford is recalling certain model year 2011 ranger trucks built from January 25, 2011, through April 25, 2011 at the twin cities assembly plant, and service parts distributed to dealers for certain 2004 through 2011 model year ranger trucks, 2002 through 2005 model year excursion vehicles, and 2002 through 2007 model year f-250,…
Remedy: Dealers will replace the switches free of charge. The safety recall began on August 15, 2011. Owners May contact Ford motor company customer relationship center at 1-866-436-7332.
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 defect investigations
Federal safety investigators have looked into a possible defect involving the 2004 Ford F-550 SD:
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.
What 2004 Ford F-550 SD owners say
Fuel & propulsion system all 26 →
Dt: the vehicle surged and accelerated on its own. This happened this has happened a t least 50 times or more. While driving 43 MPH vehicle shut down. Had to slam on the emergency brake and pull it to the curb. Also, while driving at 38 MPH or 1100 rpms there was vibration coming from the engine. It felt like it was coming right from consumer's feet. It felt like transmission disengaged. Then, after 10-15 seconds it felt like it kicked back in. There was a loud pop when this happened. The vehicle was burning more fuel than it did when first purchased it. Sometimes the water and fuel lights came on. The dealer told him that when this happened he should pull over. But when he does there is no water in the fuel. The fuel gauge will completely go to low then come back up after about 10-15 miles. Also, the air bag light will come on. …
I own two 2004 Ford f-550 and one 2003 f-550 superduty trucks. Interior fuel tank coating is de-laminating and rusting at around 100,000 miles. Vehicles stop without any warning. Silvery material in water separator and fuel filters. I know of several vehicle owners that have this same problem and Ford will do nothing. My vehicles stop suddenly in heavy traffic and we were lucky no one was injured. I have replaced the 2003 and one 2004 tank assembly. Other 2004 is showing silvery residue also. I know of a dealer in st louis mo., that has replaced many tanks for customers with the same problem. This is a defective tank coating and Ford should be held responsible. It is my understanding they (Ford) have known of this issue since 2005 and will do nothing. Do people need to be hurt/killed before action is taken? …
Engine & cooling
On July 7 2006 at 8:00 am I was notified by our branch manager in the hartford ct area that one of our trucks was totaled due to fire that burned down the truck overnight. Our driver parked the truck at his driveway at hone at 10:00 pm, and the fire took place at 2:00 am, 4 hours after his arrival home. I went to see the truck and met the fire marshal of the town of colchester ct where the driver resides. The truck was completely burned, and according to the fire marshall the fire started at the turbo unit of the truck. This was a 2004 Ford f550 cab-chassis truck VIN number [redacted] with 28,000 miles. It was under the 3 years 36,000 miles warranty of Ford. I contacted Ford and they had an independent engineering company that came to examine the truck. A report on their finding was issued to Ford. Based on this report Ford issued a letter to me on August 11 2006. …
Truck was taken to dealer for overheating problem. On the first trip out with the truck after being picked up from the dealership, the truck overheated and caught fire. Extensive damage and neither dealership or Ford want to investigate source of fire. Truck was under warranty at the time of the incident.
Electrical system
Tl* the contact owns a 2004 Ford f-550 SD. While driving approximately 55 MPH, the vehicle stalled without warning. The vehicle restarted; however, the failure recurred approximately one mile later. The vehicle did not restart and was towed to the contact's job. The vehicle was taken to the dealer where it was diagnosed that the wiring harness was faulty, melted, and needed to be replaced. The vehicle was not repaired. The manufacturer was made aware of the failure and stated that the VIN was not included in NHTSA campaign number: 05V270000 (electrical system). The approximate failure mileage was 155,862.
Tl contact owns a 2004 Ford f550. Two hours after the vehicle was parked, it caught fire. The contact stated that it was an electrical fire inside the cab that did not seem to affect the engine. The fire was not reported to the fire department or police. The contact used water and a fire extinguisher to extinguish the flames. The vehicle has not been taken to a dealer or mechanic and has not left the scene of the fire. The current and failure mileages were 50,000.
Frequently asked questions
Is the 2004 Ford F-550 SD a good car?
Based on 49 owner complaints filed with NHTSA, the 2004 F-550 SD rates avoid: 5.8× as many complaints as a typical year of the F-550 SD at the same age. It is one of the F-550 SD years we suggest avoiding. Complaint counts don't account for sales volume or individual maintenance, so have any used car inspected before buying.
What is the most common problem with the 2004 Ford F-550 SD?
The fuel & propulsion system — 26 complaints, 53% of all complaints for this model year, most often about storage › tank assembly. Next are the engine & cooling (17) and electrical system (9).
How many recalls does the 2004 Ford F-550 SD have?
There are 2 recalls for the 2004 Ford F-550 SD, the most recent from July 13, 2011 (brake lights). Recall repairs are free at any authorized dealer — check whether yours has been done with the VIN recall check.
What are the best and worst years of the Ford F-550 SD?
The best years by complaints, compared at the same age, are 2018, 2013 and 2017. Years to avoid or approach with caution: 2000, 1999, 2004, 2006 and 2005. See the full Ford F-550 SD years comparison.
At what mileage do 2004 Ford F-550 SD problems happen?
The median mileage reported in complaints is about 36,000 miles; 67% of problems with a recorded mileage started before 50,000 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.