Problems owners report
Complaints filed with NHTSA about the 2004 Ford F-250 SD, by the system named in each complaint. One complaint can name several.
- Engine and engine cooling101
- Electrical system56
- Power train21
- Fuel system, diesel18
- Vehicle speed control17
- Tires17
- Suspension15
- Steering15
- Engine14
- Fuel system, gasoline9
NHTSA ODI complaints (public domain) · updated 23 Oct 2026 · 14 injuries and 0 deaths reported
Compared with other years
NHTSA ODI complaints by model year
Recalls
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, F-350, F-450, AND F-550 TRUCKS FOR FAILING TO COMPLY WITH THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 108, "LAMPS, REFLECTIVE DEVICES, AND ASSOCIATED EQUIPMENT." THE MULTI-FUNCTION SWITCH WAS SHIPPED WITH A SUBCOMPONENT (SLIDER) THAT MAY EXPERIENCE DEFORMATION. A MULTI-FUNCTION SWITCH WITH A DEFORMED SLIDER MAY MALFUNCTION CAUSING THE TURN SIGNAL, TAIL LIGHTS, HAZARD WARNING SIGNAL FLASHERS AND/OR BRAKE LIGHTS NOT TO ACTIVATE.
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.
Whether a recall was fixed on a particular car is known only to the manufacturer: check the VIN at nhtsa.gov/recalls.
NHTSA recalls · summaries in NHTSA's own words
Service bulletins
What Ford told its dealers about the 2004 Ford F-250 SD: known faults, fixes and updates.
| Bulletin | Summary |
|---|---|
| 10243490 | When performing any transmission fluid changes or topoffs involving MERCON SP, MERCON LV has replaced all versions of MERCON SP and can be used going forward. Mixing MERCON LV and MERCON SP in the same transmission is acceptable. After 30-Jun-2023, MERCON SP ATF will no longer be manufactured and will only be available until inventory depletes. |
| 10189008 | This SKU is a Transmission Line. The customer communication requested return of unsold inventory to inspect the connector. The transmission line connector may have an incorrect thread size, which will prevent it from being installed. |
| 10171326 | This SKU is a Spare Tire Hoist. Test results identified that the pull force parameter was not within specification, as a precautionary measure unsold inventory was requested to be returned for testing and containment. We don't have evidence that these test results have contributed to a product failure. |
| 10171325 | This SKU is a Spare Tire Hoist. Test results identified that the pull force parameter was not within specification, as a precautionary measure unsold inventory was requested to be returned for testing and containment. We don't have evidence that these test results have contributed to a product failure. |
| 10165713 | Some 2002-2008 F-Super Duty, F-150 and Mark LT vehicles may exhibit concern during or after programing the VSM. The programming may fail or vehicle symptoms such as inoperative door locks, dome lamps, door ajar indicators or auto lamps may occur after successful programing. To ensure the VSM is configured correctly, use the Integrated Diagnostic System (IDS) scan tool and select the blue ball and socket icon in the upper left corner. Select the utility knife in the bottom left corner. Select Update/Special Function and enter 53061 in the blue box then press the tick mark. The screen will go |
| 10148818 | This SKU is a front upper ball joint. The Customer communication requested return of unsold inventory to inspect for ball studs with excessive rotational friction in the ball joint assembly. Excessive friction in the ball joint assembly may cause a perceptible increase in steering effort. |
| 10056196 | FORD: WHEN SHIFTING BETWEEN PARK, REVERSE AND/OR DURING 2-3 SHIFT, AN INTERMITTENT CLUNK OCCURS WITH A TORQSHIFT TRANSMISSION. MODEL 2003-2014 F-SUPER DUTY, E SERIES, EXCURSION, F-53 MOTORHOME CHASSIS, LOW CAB FORWARD. *PE |
| 10055648 | FORD: THE RESTRAINT CONTROL MODULE (RCM) WHEN USING VCM II, WOULD HAVE AN ERROR CODE 35 AND DIAGNOSTIC TROUBLE CODE (DTC) B1035, AND DIFFICULTY ATTEMPTING PROGRAMMABLE MODULE INSTALLATION (PMI). MODEL 2001-2004 F-SUPER DUTY. *PE |
| 10055629 | FORD: ON SOME TRUCKS, THERE IS A NO CRANK SITUATION AND IF VOLTAGE ON TRANSMISSION RANGE SENSOR AT PIN 21, IS LESS THAN 5 VOLTS, DISCONNECT THE ENGINE COOLING FAN CLUTCH, ELECTRONICALLY, AND RECHECK VOLTAGE. MODEL 2003-2007 F SUPER DUTY, 2004-2010 E SERIES, 2003-2005 EXCURSION. |
| 10028404 | FORD TRUCKS SERVICE CAMPAIGN: SEE DOCUMENT SEARCH BUTTON FOR OWNER LETTER. VEHICLES HAVE EXPERIENCED SEVERE STEERING WHEEL AND FRONT WHEEL VIBRATIONS AND OSCILLATIONS AFTER TRAVELING OVER A BUMP OR DIP IN THE ROAD. MODELS 2006 F-250/350 SUPER DUTY 4X4. *PE UPDATED 7/22/09. CSC LETTER WAS RECEIVED. *PE |
| 10024865 | 1999-2008 7.3L/6.0L/6.4L/4.5L DIESEL F-SUPER DUTY - CLEAN THE CHARGE AIR COOLER (CAC) SYSTEM AFTER CERTAIN TURBO OR ENGINE FAILURES - SERVICE TIP. *NJ |
| 10024325 | 6.0L TURBOCHARGER CARBON DEPOSIT DIAGNOSTICS AND SERVICE TIPS. *NJ UPDATED 5/29/08. *NJ |
| 10023855 | 6.0L--MIL ON--P0401, P0402, P0404, P1335--LACK OF POWER OR SURGE WITH SOME 2003-2007 F-SUPER DUTY, 2003-2005 EXCURSION AND 2004-2008 E-SERIES VEHICLES. *NJ |
| 10023653 | 1999-2008 F250-F550 SUPER DUTY 4X4 WITH ELECTRONIC SHIFT TRANSFER CASE NOT ENGAGING 4X4. *NJ |
| 10022675 | BRAKE BOOSTER SYSTEM MAY EXHIBIT A BRAKE PEDAL KICKBACK AND/OR GRABBING CONDITION WHEN APPLYING THE BRAKES. *NJ |
| 10022295 | DTC'S P006A OR P132B - LACKS POWER, SURGE, OR FLUTTER AFTER FIELD SERVICE ACTION 06E17. *KB |
| 10022293 | 6.0L DIESEL ENGINE - OIL LEAK OR BOOST PRESSURE LEAK AT HOT SIDE CHARGE AIR COOLER DUCT. *KB |
| 10022243 | LACK OF POWER DUE TO LOW FUEL PRESSURE - FUEL TANK LINER SEPERATION. *KB |
| 10021621 | LACK OF POWER DUE TO LOW FUEL PRESSURE, FUEL TANK LINER SEPERATION. *KB |
| 10021619 | AIR FILTER WATER INGESTION / SNOW PACKING WITH CODES P0103. *KB |
| 10021484 | ADDING ADDITIONAL BULBS TO TURN INDICATOR OR HAZARD FLASHER CIRCUITS. *KB |
| 10021464 | 6.0L OIL SEEP OR BOOST PRESSURE LEAK AT HOT SIDE CHARGE AIR COOLER DUCT. *KB |
| 10021462 | COLD START DRIVEABILITY - WHITE SMOKE, LACKS POWER, EXHAUST ODOR, SURGES, RUNS, ROUGH, OR NO START. *KB |
| 10021236 | LACK OF COOLING FAN OPERATION. *KB |
| 10021232 | 6.0L TURBOCHARGER CARBON DEPOSIT DIAGNOSTICS AND SERVICE TIPS - LACK OF POWER, WHITE OR BLACK SMOKE, SURGE, P0238, P0299, P0404, P2262, AND/OR P2263. *KB |
NHTSA manufacturer communications (public domain)
NHTSA investigations
SPARK PLUG EJECTION FROM CYLINDER HEAD
ENGINE STALLING
ENGINE STALLING
NHTSA Office of Defects Investigation