Diesel Engine problems of the 2004 Ford F-250 - part 1

39 problems related to diesel engine have been reported for the 2004 Ford F-250. The most recently reported issues are listed below.

car   Diesel Engine problem 1
Failure Date: 01/25/2012

The contact owns a 2004 Ford F-250 diesel. The contact stated that while driving 15 mph, excess smoke emitted from the exhaust pipe. The dealer was notified and stated that the egr cooler might be defective. The manufacturer was made aware of the failure and offered no assistance. The vehicle was not repaired. The failure and current mileages were 86,100. Updated 02/27/lj updated 02/27/12.

car   Diesel Engine problem 2
Failure Date: 06/04/2010

Is there anything that our government can do to helps alot of us with the problem we have with the Ford 6. 0 powerstroke engine alot of us have had to pay thousand and thousand of dollars to fix their defective diesel engine. Just tired !!!!! pay 40,000 to 65,000 for their truck then have to pay thousand move to keep them running. Problems (head gaskets, injector, fuel rail, oil cooler, oil pumps fuel injector control module, pcm, 0 basically the whole 6. 0 and components.

car   Diesel Engine problem 3
Failure Date: 05/31/2010

I bought this 2004 Ford F-250,6. 0 diesel in may 2010 with 160k miles on it because lots of people told me to buy a diesel it would give me better performance than gas. I have had nothing but troubles ever since. It started not starting about 2 weeks after I bought it. The Ford house is no help at all. Ive had it there several times and all it done was cost me money. It has never stopped running driving down the road like the other complaints iv'e read. But it has left me stranded 50 or 75 times, sometimes it will run perfect for months and all at once it wont start. Showing no codes Ford says they cant do a thing. In July last summer it did it 1500 miles from home on vacation. I had a wrecker take it to a shop and $7500. 00 and 6 weeks later they had put a new engine in it (said the camshaft broke and scored the piston wall) I came home now 6 months later its doing it again. I cant afford to take it to Ford, I cant trade it. What to do??.

car   Diesel Engine problem 4
Failure Date: 04/04/2009

The contact owns a 2004 Ford f250 super duty diesel. The contact stated that the check engine indicator illuminated on the instrument panel. The dealer advised her to immediately bring in the vehicle for repair and they found an oil leak that leaked into the icp sensor. The contact paid over $600 to have the vehicle repaired. The current and failure mileages were less than 47,000. Updated 12/09/09 the dealer informed the consumer that the problem will continue to happen due to a desgin flaw. The flaw was correcte in later models. Updated 12/10/09.

car   Diesel Engine problem 5
Failure Date: 06/06/2008

The turbo in my Ford pickup has been replaced twice. I have spoken to other people that have had the same problem. My pickup is a 2004 f250 with a turbo diesel engine .

car   Diesel Engine problem 6
Failure Date: 09/05/2007

2004 king ranch, 6. 0 diesel, turbo problems, again. Now truck surges at low speeds, in parking lot and at stop light. If my foot is not on the brake, the truck will move forward! almost hit a lady in the shopping center parking lot. Serviced for problems 8 times over 36 months. Can't fix?.

car   Diesel Engine problem 7
Failure Date: 08/24/2007

Engine surges and will increase speed by 700 rpms with no contact to pedal. Taken to dealership several times numerous recalls and repairs to wireharness and erg valve have not cured problem. Vehicle lurched forward while being parked bumper striking light pole minor damage.

car   Diesel Engine problem 8
Failure Date: 05/07/2007

2004 Ford f250 sd 6. 0l . Engine stalls at highway speeds put doesn't die. In 2005 wiring harness was replaced. In may 2007 took to southern Ford in manvel, TX they replaced egr valve & performed software update on ecm. Problem is worse from a stop accelerator will be depressed but truck will move only 3-5 mph. Pumping the pedal a few times will bring back acceleration. Happens intermittently almost caused accident as I tried to merge into traffic and engine lost power.

car   Diesel Engine problem 9
Failure Date: 05/02/2007

Ford super duty trucks with the 6-liter diesel engine, generally while towing a heavy trailer uphill, experience a high rate of turbo hoses blowing off. This creates a low power situation that leaves the truck without enough power to safely exit the roadway. On two-lane highways this is a serious safety concern. I have this truck, as do three of my acquaintances. Three out of four of us have had this happen. A search of Ford warranty repair records will confirm that this is a very common problem. Several acquaintances have had the problem more than once, in spite of Ford having done the repairs. The incident below involves a friend, not my own experience. I feel that this is a safety hazard that should be corrected with a recall of affected vehicles.

car   Diesel Engine problem 10
Failure Date: 03/15/2007

I have an ongoing problem with my 2004 f250 with the 6. 0l powerstroke diesel engine. The vehicle has a problem in the mornings after it has not run for several hours, it smokes, runs rough, and has severe hesitation. Forb has a TSB regarding this issue but they were unable to fix it. The smoking and rough running is merely an inconvenience, but the hesitation is a huge safety concern. The vehicle will operate at idle speeds but once the throttle is depressed the vehicle will not accelerate. This condition can last as long as several minutes. I have had a number of near accidents upon leaving my driveway or parking lots and pulling into traffic. Once in traffic the vehicle wouldn't accelerate. This condition occurs nearly every morning, especially in the winter, and has resulted in a number of near crashes. The TSB states that this is a common problem that mainly occurs after the vehicles have 15000 miles. I first reported my problem to Ford at 17,000 miles. I have had the vehicle back to the dealer numerous times and they just don't know what else to do but the dealer admits there is a problem. Feel free to contact me for more questions. The service manager, dean, at rio valley Ford has extensive knowledge on my truck also.

car   Diesel Engine problem 11
Failure Date: 07/01/2006

F250 diesel engine has uncommanded throttle advance. In traffic environment, I need to keep a large interval in case truck decides to advance throttle on its own. This situation rules out parking in the garage. Truck was purchased new from Ford, has been in shop 6 times for same problem.

car   Diesel Engine problem 12
Failure Date: 04/14/2006

Purchased new 2004 f250 6. 0l turbo diesel. Since purchase, have repeatedly experienced intermittent surging, stumbling, & stalling. Have returned vehicle numerous time with no trouble found. Subsequent recall came out and was performed in September 2005. Intent of recall was to address stated problems. Started experiencing problem again in February of 2006. Shop visit on 12 April 2006 revealed egr?? problem, and was replaced. Problems reappeared the next morning. Will take to the shop for another round!!.

car   Diesel Engine problem 13
Failure Date: 04/08/2006

F250 6. 0 powerstroke stalls, misses, and loses all power. Ford dealer has no idea of what could be causing problem. Have been unable to repair. Changed egr valve and a couple of other sensors. No change.

car   Diesel Engine problem 14
Failure Date: 11/25/2005

We own a Ford F-250 super duty with a 6. 0 diesel motor with a 100,000 mile warranty. Twice during that period, I reported that the motor was very noisy when starting on a cold morning. Finally at 99,987 miles the local dealer acknowledges that 5 injectors need replacing and & Ford will replace them as soon as I prove when every oil change was made. They specifically mentioned bills & receipts. After a few weeks gathering oil change information, a service advisor suggests taking it to the selling dealer, as they would be more disposed to fix the truck. The other service advisor says that they don't want to keep the work order open any more. The selling dealer couldn't help. After a lengthy process I get to the appropriate person at Ford who accepts my personal notes on the oil changes. But since the truck now has over 100,000 miles on it, Ford won't do the work, even though the problem had been reported several times prior to the 100,000 mile limit. I believe the local dealer set me up so Ford wouldn't have to pay for the work.

car   Diesel Engine problem 15
Failure Date: 10/15/2005

2004 Ford f250 super duty, engine shuts off and on driving down the highway, lose power steering and brakes. Very unsafe vehicle when this happens. This has occurred 7 separate times. Once after recall done thus recall did not fix the problem. Leery to drive now. Less than 100 driven since.

car   Diesel Engine problem 16
Failure Date: 10/02/2005

While accelerating on a hill, the engine would miss, appear to be trying to stall, and black smoke would come out of the tail pipe. The dealer had to replace the icp. Since these symptoms are similar to those described in recall #05s34, I thought my truck should be included. It wasn't and I had to pay a $100 deductible to have it repaired. The service rep said they had several of these same problems on other trucks.

car   Diesel Engine problem 17
Failure Date: 08/22/2005

1) while entering interstate and/or traveling at interstate speeds, and hauling a trailer. 2) the cac(charge air cooler) duct blows off of the turbo. This leaves the vehicle with a lack of power, requiring finding a safe place to pull off the road. 3) existing hardware is re-attached and torqued to spec, and redesigned parts have also been installed.

car   Diesel Engine problem 18
Failure Date: 06/21/2005

Our f250 superduty has left us in the middle of no where 3 times. We would be driving the truck, park it and then try to start it back up and it would do nothing- this has happened twice. Once it just shut down while driving. Each time road side asst. Has come to get the truck. This purchase has been the biggest mistake and I do spread the word. By the way- it has been the o-rings and gaskets in the motor.

car   Diesel Engine problem 19
Failure Date: 06/17/2005

The inner cooler tube for the turbo blew apart,filled with oil,causing the tubro to be replaced16000 miles. 8 months later it happen all over again 26500 miles.

car   Diesel Engine problem 20
Failure Date: 05/11/2005

While driving the truck shut off and just completely died. The driver was unable to control the vehicle because there were no brakes and no power steering. As a result the truck veered into oncoming traffic. Once the vehicle stopped the driver had to restart the truck. The key had to be turned back to neutral ,then try to restart. The truck was just at the dealership a week before this happened for a blown radiator hose. Ford has been notified of this incident, but will not return the consumer's phone call. The consumer is still trying to be in contact with Ford customer service.

car   Diesel Engine problem 21
Failure Date: 02/17/2005

Complained of exhaust odor inside vehicle. Oil is leaking from the glow plugs onto the exhaust manifold. Serious fire hazard. I've taken the vehicle to the dealer to be "fixed" and this is my third trip.

car   Diesel Engine problem 22
Failure Date: 02/01/2005

1. ) we were driving in the pet Smart parking lot and the vehicle lurched forward on it"s own and almost ran over a lady and her little dog! I had to slam on the brakes and shut it off! 2. ) vehicle will stall and accelerate without warning. Very scary and dangerous!! 3. ) three trips to the dealer and it still has not been repaired.

car   Diesel Engine problem 23
Failure Date: 12/20/2004

Engine was cold, sat over night, in the morning tried to start vehicle, glow plug light turned off and engine was cranked, engine cranked slow but did not start and within seconds engine compartment burst into flames. Fire was extinguished with a fire extinguisher. Fire destroyed passenger side of engine compartment, smoke damage in cab. Cause of fire unknown at this time. Has not been determined if vehicle can be repaired.

car   Diesel Engine problem 24
Failure Date: 10/29/2004

The engine stalled which caused the vehicle to loose power steering and power brakes. This is very hazardous when pulling a fifth wheel camper. There were a number of stalls that seemed to have been different from the original problem in that the vehicle begin to run rough prior to the stalling. The engine alos lost coolant.

car   Diesel Engine problem 25
Failure Date: 10/28/2004

2004 Ford-f250 king ranch diesel series: engine revs up at idle over powering the brakes enough to cause the truck to jump forward between 1-2 ft. This is a serious safty issue at intersections. This occurred 1 day after dealership updated the engine computer code. The original cause to take the truck into the dealership was the power loss and massive engine shaking at idle as described by others.

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