Diesel Engine problems of the 2004 Ford F-350 - part 1

2004 Ford F-350 sd. Consumer writes in regards to vehicle engine the consumer stated two turbochargers were replaced on the vehicle under warranty. The turbocharger needs to be replaced again. Also the egr cooler, head gasket, oil cooler lines and the injectors all failed.

The contact owns a 2004 Ford F-350 superduty. The contact stated that while driving, the check engine light illuminated. The vehicle was taken to an authorized dealer who stated that the head gasket was defective. The dealer stated that the stud package needed to be replaced for a permanent fix. The vehicle had not been repaired. The manufacturer offered no assistance when contacted. The current and failure mileages were 81,300 updated 04/29/11.

The contact owns a 2004 Ford F-350. The contact stated that coolant was observed leaking from the vehicle. The vehicle was taken to the dealer where the dealer confirmed that the head gasket needed to be replaced. The manufacturer was made aware of the failure. The vehicle was not repaired. The failure mileage was 60,000 and the current mileage is 73,047. . . Updated 04/19/12 updated 04/25/jb.

Head gasket failure and other problems with the 2004 F-350 6. 0l powerstroke diesel engines.

The contact owns a 2004 Ford f350 super duty. The contact stated that the head-gasket failed and would cause the engine to lose water. The vehicle was re[paired at a cost of $3000 the manufacturer was not contacted. The failure was 144,000. Updated 12/29/10 updated 04/0/611.

The contact owns a 2004 Ford F-350 superduty. The contact stated that the nozzle on the fuel injector separated from the body of the injector which caused progressive engine damage. The contact noticed the failure when the vehicle began emitting black smoke and "running rough". The vehicle was taken to an authorized dealership where the contact was informed that the engine needed to be replaced. Another dealer installed the new engine which was also defective and had to be replaced due to oil mixing with the antifreeze. The contact called the manufacturer who offered no assistance. The current mileage was approximately 115,800. The failure mileage was approximately 115,000. Updated 01/11/2011 updated 02/23/11.

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. If they sold say, 300,000 of these trucks a year from 2003 to 2007 , that's 5 years times 300,000 times 5 quarts (less than half, truck holds 15 qts)5 x 300,000 x 5 = 7,500,000 qts of possible oil spilled or 1,875,000 gallons of oil spilled if these trucks only spill 5 quarts over their life time. Most of the trucks will do it more than once. When the oil cooler busts the oil goes into the radiator and out the over flow into the environment. Updated 05/04/10.

My vehicle has been bucking and jerking intermittently since way before above. Date it stopped running at a stop sign then bucked and jerked so in 2013 it got so bad that I finally had it checked out. I thought it was transmission, had it checked and was referred to local mechanic who was acquainted with the problem and has worked on several trucks with the 6. 0 diesel engine. He said for $1200 you might repair it, no guarantees. He said it had to do with the electronic accelerator. I didnt have it repaired. In August 2014 it stopped and jerked at stops sign more than once. I took it to the same mechanic andhe replaced a sensor located under the turbo, for $600, and that solved that problem. In October 2014 I was towing a trailer and the truck would not shift into 4th gear. I stopped and restarted the engine and it went back to normal operation, but it still bucks and jerks today I called my local Ford dealer and he said that he has no recalls for my VIN number. I only drive it occaisionally. It has 59,000 miles on it now.

2004 f350 diesel 6. 0 ,egr cooler went out. I was in the middle of the hwy when this occured. Clouds of smoke went out the tailpipe, engine overheating stranding me in the center lane stopped before I could get over to the shoulder. Passerby's help me push my truck off a busy hwy. Smoke was so thick I couldnt nor could other drivers see around me. Ford has had numerous complaints on this engine and part,but have failed to respond,or they waiting for a death to occur. The internet is full of complaints for the exact same thing. Letters to Ford motor CO. And my local dealer leif johnson Ford were unsuccessful. I'm not able to pay the almost $3000 the dealer wants to fix the problem. This is an obvious defect on Ford's part. Very fustrated as I have a expensive truck just parked for several months in my driveway. Updated 2/17/10 updated 02/22/10.

The contact owns a 2004 Ford f350. The contact stated that smoke appeared from the egr cooler tube. She also smelled antifreeze in the cab of the vehicle. The vehicle was taken to the dealer and they stated that it was still safe to drive and to return if the failure worsened. Later, the contact noticed thick, black oil coming from the exhaust. The vehicle was taken to a repair shop and the mechanic replaced the egr cooler tube with a kit from Ford at the contact's expense. The failure mileage was 79,000. Updated 06/09/09.

Vehicle is now in the shop for the 6th time, vehicle is under 100,000k mile warranty with Ford. Ford knows of all the problems with the 6. 0 diesel engine and does nothing to fix them. Now there are several problems, oil leak, coolant leak, boost leak, and charging system problem. Vehicle has exhibited several problems, still Ford continues to fail to correct the problems. Pundmann Ford now states nothing is covered under warranty. I purchased the vehicle in December 2008 and it has been in the shop now for the 6th time. I want immediate assistance from the Ford motor company!.

The contact owns a 2004 Ford f350. While driving at highway speeds, the vehicle will spontaneously decelerate from 60 mph to 15 mph. In addition, the engine warning indicator illuminated on the instrument panel. The contact took the vehicle to a local repair shop and a mechanic stated that there was excessive carbon in the engine. There is currently no remedy for the failure. The engine size is 6. 0l v8. The failure mileage was 40,000 and current mileage was 70,000. Updated 05/05/09 updated 05/06/09.

2004 Ford f350 dump truck shuts down with no warning. Consumer states that Ford will not honor truck warranty and will not repair the problem. The consumer stated when the dump truck shut down, there was no power steering or brakes. The dealer stated the problem was with the diesel tank and diesel line which had eroded due to containments in the diesel gas, however the problem recurred two more times.

I have a 2004 F-350 superduty 4x4 [6. 0 diesel]. I drove through water the depth of the stock tires. The engine ingested water by way of the intake. I was advised by the Ford dealership that the incident destroyed the engine. The air intake is located at the front grill. I believe this is a flaw in design, causing easy access for the water to enter from the air intake. I am getting no assistance from the Ford company or my vehicle insurance in covering the damage, which is estimated at $ 15,000. 00 dollars. I am not sure if this type of problem is occurring often.

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.

Ford 6. 0 diesel sold to 384000 people and endangers every one of them each time they get in one. They never know when or where it will break down or how much danger it will put them in. My truck has never been right since I bought it. The problems will be never ending. If Ford thinks the trucks are ok then why are they suing International harvester for the engines. Why can' t something be done to protect the public from this corporate injustice.

The pickup truck keeps running very rough and lurching forward while in drive. The truck has almost completely died on me several times. Even when you have your foot on the brake it will lunge forward and has almost caused me to hit the car in front of me. I have taken it to the dealer 5 or 6 time over the past several months. They have done a upgrade on the computer and replaced several valves/parts. Every time this mystery problem keeps coming back. It seems to surface at it's worst when the temperature outside gets warmer, above 50 degrees. Ford has basically been no help and seems to be stumped over the problem. I have spent at least $500 on a warranty item that has not been fixed. After reading other complaints, it seems as if I'm not the only one with this problem. This problem needs to be solved before it gets worse and causes accidents.

Failure of egr cooler and engine head gaskets caused failure of engine. Ford is installing a complete new engine with redesigned parts at my expense. Engine is available at car dealership.

Two separate times my f350 diesel stalled while driving and then kicked back in 20 seconds later. Dealer states no problem found. Now truck stalled out while at intersection trying to turn left. This time it took 16 starts before it would move.

2004 Ford f350 crewcab rear seal has been replaced three times, turbo unit has been replaced twice. ***** the rear abs sensor was replaced.

Ford F-350 sd 6. 0 l diesel, several times while driving, truck began to surge/cut-off. This happened under load while going uphill. Truck taken to several dealerships cross country during trip. No one able to diagnose or reproduce fault.

I have a 2004 Ford f350 and a f250 both have the 6. 0l diesel engine. There is a real problem with the fuel injectors and turbo and possibly the fuel pump according to the dealer. Both trucks load up and start to run very rought the only way to stop the situation is to floor the throttle intill it clears up producing an extremely amount of black smog. Several times the trucks have stalled while driving leaving us without power brakes and steering. Ret urn trips to the nearest dealer have not been a good experince they tell us that because there are so many 6. 0l diesels with the same problem Ford is slapping them on thier hands for fixing these problems with the driviability warrenty. I left the dealer not sure where to turn the trucks are not fixed and this conditions do create a hazard. The dealer even told me they had a whole fleet of school buses with the same problem they were fixing so the problem is not just my problem they know of the problem and even know of the solution without even looking but it appears Ford is holding the dealers hostage and leaving the customers with a hazardous vechicle. I feel this is not a driviablity warrenty but a serious recall issue. Thanks for any help you can do with this.

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. Not only is the patient placed in danger, but my company is quickly getting an unfavorably reputation because of these breakdowns. This is costing us business. My paramedics are refusing to drive these vehicles because of the risk of liability that they may have knowing the mechanical history of these vehicles. All of the trucks are still under the 100,000 mile warranty. Ford has shown no interest in helping us with this issue. Even if the engines make it to 100,000 miles , I know that they will not last much past that. Please look into this. We are paying good money out each month for vehicles that will not do the job . The georgia lemon law does not apply to us . Help!.

The contact owns a 2004 Ford F-350 super duty. The contact stated that while driving 60 mph, the vehicle stalled without warning. The contact stated that the failure would occur every time the contact drove the vehicle. The contact took the vehicle to the dealer to have a full egr valve repair, fuel injector repair, and a turbo charger repair. None of the repairs remedied the stalling of the vehicle. The contact stated that neither the dealer nor the manufacturer was able to solve the stalling issue. The contact stated the failure was a safety hazard that the manufacturer needed to address. The vehicle was not repaired. The failure mileage was 76,000. Updated 02/22/11.

Occasionally while stopped in gear with the brake depressed my truck will "surge" and lurch forawd as the idle increases. If I'm not depressing the brake firmly the truck move foward and won't stop untill very firm pressure is applied to the brake.

I have a 2004 f350 superduty with 6800 miles, it stalls and loses power every time I drive it. While pulling into traffic recently it stalled and almost caused several wrecks. Ford has tried to fix this problem three times with no luck. I also know sevreal other Ford superduty's with the same problem. One of these stalled pulling into traffic , but no wreck. My Ford service demartment has not fixed any of these trucks.

On 16 April 2005 , I took my F-350 turbo diesel dually in for 10,000 mile service ( vehicle had 9400 miles) also asked to have left speaker checked and scheduled an appointment for the recall on the transmission pins replacement. Upon completion of 10,000 mile service I noticed that the vehicle was making a thumping sound when decelerating on the road . Went back to the dealership and asked that they check to see if everything was back in place , reason for this was that they replaced the left speaker and did not put the door molding back on when they gave me back the car. Service person road in the vehicle and stated that they knew what the problem was and that it was listed on the Ford engineering website, they printed out the memo stating it was an known problem and had to do with the air filter vibration and that no adjustment was necessary. Upon leaving the dealership again for the third time the noise started to increase in volume and then would not accelerate , I returned and had the diesel mechanic test drive the vehicle , the vehicle showed no indication on dash panel and showed rpms increasing but vehicle not accerating and continuing to make thumping vibration noise. Mechanic stated I was not going anywhere with this truck . I have a loaner from the dealership and as of today April 25,2005 my truck is still at the dealership for repairs.

Vehicle stalls without warning and under no particular load or temperature conditions.

2004 Ford f350 crew cab 4 wheel drive w/ 6. 0 diesel engine and automatic transmission. VIN:1ftsw31p74eb06149 1. ) I was on a 180 mile trip, descending hill (from 3800 feet to 1000 feet elevation) at less than 30 mph with cold outdoor temperature. 2. ) while coasting down steep grade an engine stall nearly caused an accident due ot loss of power assist for steering and brakes. 3. ) dealer recalibrated eec system. My son had the same problem with his truck (near an idenical vehicle) under the same conditions.

All of the following is documented on Fords computer system through magnussens in newark, CA. June04, started with a rough idle problem took my 2004 f350 back to dealer. Did a reflash seem to fix for a while. Progressed to rough and searching idle. Approximately 9 times back to dealer, each time either clear check engine light or replace parts, approximately 7 or 8 days out of service from June till late August, last time replaced the entire turbo assembly. Each time just replaced parts, never did the dealership or Ford corporate have a definite answer to what caused the problem. Each time code p0299 was on the check engine. Between the 2 and 9th incidents, the vehicle stalled unexpectedly in the middle of a downhill coasting turn almost resulting in a crash each time. Total of 5 times, last occurrence of stall was first time vehicle presented any problems since turbo replacement on two thursdays ago on my way to work. After I got in to work I called Ford support and my dealership and started a replacement process through what Ford calls the dsb dispute settlement board. I am not comfortable driving this particular unit any more and fear I might not be able to stop the vehicle safely one of these times it stalls and may cause injury to myself or another. I have done a lot of research regarding others who might have had this problem and it led me here.

Incident occurred in the afternoon, the temp was about 70 degrees. The truck was loaded with my family (5 including myself); we were traveling over a hill at about 50 mph. A sign indicated a 6 percent grade. On the way up the hill, at about 2000rpm and about 45 mph we noticed a large amount of black smoke being expelled from the tailpipe. There was no hesitation on power output at that time, then coasting down the other side of the hill the engine shut down. Fortunately we were able to narrowly avoid the traffic ahead with what little brake action I could apply. When the engine was started again, the "check engine" light came on. After being taken to the dealer the sensors were replaced on the turbocharger and other undisclosed work was done to the engine. Lately the truck has been mimicking these symptoms.

When truck originally purchased bubble on tire, and dealer said they all come that way, tire went flat while parked about a month later, no holes, we were told tire was no good, had to be replaced. Truck kept stalling, loss of brakes and steering while navigating downhill, solenoid assembly replaced. 2 days later kept stalling. Dealer had truck 21 days to rebuild transmission, again solenoid assembly replaced after that replaced wiring harness. Since then, caliper broke and brakes went, turbo has been replaced. Vehicle has repeatedly stalled, noises from rear end with no dx. Now engine smoking, loss of power, rpms jump while idling. Truck has also repeatedly changed gears automatically, ie while at red light truck would jump to 3rd and then truck would stall.

2004 Ford F-350 with a oil leak. Consumer states that the oil leak was between the engine block and the bell housing for transmission. He states that the vehicle has been serviced 7-8 times for the same oil leak. The manufacturer stated even though there was oil seepage, there was no safety or diesel engine durability issue involved. The consumer was informed the oil leak was normal. The manufacturer's opinion was that the oil was leaking from the oil pan, however, the consumer disagreed with their findings. The steering damper was replaced due to a leak.

2004 f350. Owned truck for 13 months, the truck has been in the shop numerous times. It surges while driving and also goes dead while driving. Recall work was done and did not fix the problem.

Engine stalls/stops running, leading to a loss of steering and braking. This has ocurred three times, twice at low speed when coming to a stop, once at high speed.