23 problems related to gas recirculation valve (egr valve) have been reported for the 2004 Ford F-250. The most recently reported issues are listed below.
Tl-the contact owns a 2004 Ford F-250. The contact stated in the fuel system, there was a cone that breaks apart in the fuel pickup sender unit. The failure recurred numeros. The contact stated that while driving the vehicle stalled without warning. The contact bearly was able to coast over to the side of ramp and was not able to restart the vehicle. The contact stated that the vehicle was towed more than once to grieco Ford of delray beach dealer, (3000 s federal hwy, delray beach, FL 33483, (561) 278-0303) and was diagnosed the the cone pickup disintegrated in the fuel tank and needed to be replaced. The vehicle was repaired. The technician replaced the cone unit, fuel filter, fuel lines and injector. The manufacturer was notified of the failure and provided a case number: cas-24538661. The failure mileage was approximately 59,000. Aw.
I have a 2004 f 250 super duty with the 6. 0 engine it is a known fact that the bolts that hold the heads down streach when hot letting water into the oil system its all over the interrnet about the 6. O engine that Ford provides the only fix is to have the cab removed and replace the bolts with studs that can take the high temp that the engine produces this is only one of the problems but this problem cost me over 5000$ to fix sure would be nice for you all to look into this product that Ford has been useing and knows theres a problem with that engine,,you go to trade it in at Ford and they see it has a 6. 0 engine in it and the price drops ,way ,way to much for a truck that sold new for 45000$ , I found my truck leaking water in the drive way setting still no reason for it to start leaking ,,I have the bills from Ford dealer where I had it fixed if needed please look into this engine its not right to put so much money into a truck that has this problem that not one other engine Ford has does what the 6. 0 does ,also bad egr it has to be by passed this stuff should not happen also showed water in gas emptyed the cantainer and then gas gauge stops working and gas light stays on all the time ,,,,never buy Ford.
Our 2004 f250 diesel 4x4 super duty was parked in the driveway overnight, properly plugged in due to the cold. A neighbor woke us up to state it was on fire. The entire front and interior of the truck was engulfed in flames before the fire department arrived. After it was extinguished, the county fireman pointed the believed the point of ignition appeared to be at the firewall on the drivers side due to the fact that the master brake cylinder & battery were disintegrated. Plus the secondary battery & radiator were partially intact which are in the front. The fire dept stated that if it had been a frontal point of ignition due to the block heater the radiator & battery on front passenger side would've burned first due to aluminum materials.
The contact owns a 2004 Ford F-250 tdi. The contact stated that while driving 55 mph, white smoke started to emit out of the exhaust pipe. The vehicle was taken to the dealer. The technician diagnosed that the vehicle had blown a head gasket. As a result, the cooler, egr, and head gasket needed to be replaced. The manufacturer was made aware of the failure. The vehicle was repaired. The failure mileage was 75,961 and the current mileage was 76,000.
Driving on interstate 65mph. Engine started binding down and speed dropped to 25mph and finally completely died. Had it towed home. Now won't start. Have replaced egr cooler and oil cooler previously . This time replaced fuel pump and all fuel filters. Will crank and run for a very short amount of time then will die again- and not crank back for awhile. Just repeats this process. Now told that it needs head gaskets or high pressure pump. These problems are very expensive. Why will Ford not fix these problems that seem to be on all 6. 0 diesel models?.
2004 Ford f250. Consumer states faulty icp sensor or faulty egr valve the reverse planet gear in the transmission was replaced. The egr valve replaced three times, the egr cooler, oil cooler were all replaced. The r&r turbo intake was replaced twice, the turbo inner cooler, wiring harness on the engine, transfer case, ficm module were replaced. The alternator and battery were replaced three times, the valve assembly, high pressure and regular oil pumps were replaced and a new egr shield was installed. The vehicle also stalled while driving down the interstate.
2004 Ford F-250 sd. Consumer requests assistance in helping obtain satisfactory attention and results related to recalls and repairs the consumer stated the egr valve was bad and needed to be replaced. The vehicle ran fine for awhile, until the egr valve went bad again. The fuses burned out on a consistent basis, the battery died, the fuel gauge did not give accurate readings, the vehicle stalled on several occasions and the crank position sensor failed.
My 2004 F-250 diesel, 79,292 miles, has been at the local Ford dealership since sept. 7th. There are so many diesels broken down, mine did not get pulled into the bay for work until the last week in oct. It is still in the bay waiting an engine as of Nov. 11th. Over 2 months in the shop. They changed the oil prior to diagnosing blown head gaskets and over boosting turbo, so they could not confirm if water was in the oil pan. Diagnoses was to replace the head bolts, gaskets, egr cooler, rebuild an over boosting turbo, at a cost of about $3,000. 00. After the heads were deemed unusable, much pitting, corrosion of the head where the cylinder imprint is located, the cost went to $7,5000. Since they failed to inspect the oil for coolant, I had little alternative than to request an entire engine, at a cost of $15,500. 00. I have worked on engines, and know some of the aspects of blown head gaskets. I requested assistance from Ford. They said the dealership was willing to take a 10% discount. After more phone calls, they offered an additional $400. 00 off after the discount. I am looking at spending $13,500. 00 plus $1,205. 25 in sales tax, back up to about $15,000. 00 for a truck with 79,292 miles. Ford motor corporation did not offer a dime. I am requesting the national transportation safety board investigate, find Ford at fault for knowingly not recommending service bulletins for: 1)over boosting turbos to be replaced with the new designed ones. 2)the head bolts be replaced with the heavier, larger circumference bolts. 3)updated head gaskets. 4)stainless egr cooler so much information has been written on the obvious faults, and the corrections that could be made if Ford were forth coming in disclosing the problems, before consumers were required to make huge investments on their engines. There is also a safety issue of the over boosting, and engine accelerating uncontrollably.
The contact owns a 2004 Ford F-250 super duty. The contact stated that while driving 10 mph white smoke began to come from the exhaust and the vehicle started to hesitate and shut off. The contact took the vehicle to the dealer who stated that the egr(exhaust gas recirculation system) was not working properly and needed to be replaced. The egr was being replaced by the dealer when the complaint was filed. The egr was replaced twice. The contact stated that the manufacturer needed to issue a recall on the engine since numerous owners has experienced the problem. The failure mileage was 60,000.
Our family was traveling to the beach on a very busy interstate when our 2004 Ford f250 diesel, pulling a 35 foot RV, started running hot. I pulled over in the emergency lane to investigate. Let the truck idle and cool for a bit, returned to the interstate to try and get to the next exit for a less dangerous place to work on it. It continued to run hot and upon exiting the interstate on the down ramp the vehicle shutoff, with no power brakes to stop the truck and camper, I was unable to stop the vehicle at the stop sign and blew through it. Thank goodness nothing was coming. Turns out all the water was gone, due to either a blown head gasket or egr oil cooler failure and the motor overheated and ruined. Ford wants to replace the engine for $17,500. The truck has 63,000 miles on it and is just out of warranty. This is a known engine failure problem for Ford yet they do not stand behind the problem. If I had known they were having problems I would have had mine fixed or replaced prior to having to pay thousands of dollars to replace the motor. I paid $50,000 for a truck with a premium to get a diesel that is suppose to last forever, and it does not even last more than 63,000 miles. Thousands of people have had to face this problem, and have had to spend thousands of dollars to fix it. All you have to do is search blown head gaskets Ford f250 on google to find thousands of people with this problem. The extremely hot exhaust gases get recirculation into the intake manifold, but first it has to be cooled. When the cooler fails, all the water from your engine goes out the exhaust, through the turbo (bye bye turbo), then you are pumping extremely hot gases back into the intake manifold which boils the water, creating extremely high pressures, which lifts the heads and blows the head gaskets. What kind of stupid design is that? now I have to pay for all of those design problems? I now have a $50,000 boat anchor, which is not worth repair. Help please!!!!!!.
The contact owns a 2004 Ford F-250 super duty. The contact stated that the vehicle was smoking excessively and loosing anti-freeze through the exhaust. The vehicle was taken to the dealer three times within one month to address the failure. The dealer advised the egr valve would need to be replaced. The vehicle was left with the dealer where the contact was awaiting repairs. The failure mileage was 144,000 and the current mileage was 147,000.
The contact owns a 2004 Ford F-250 super duty. The contact stated that the environmental regulator (egr) failed and ruined the motor. When the contact tried to start the vehicle, the engine began to emit smoke and would not start. There were no warning lights displayed. The vehicle was taken to an authorized dealership where the coolant, oil filter, gkt kit, head gaskets, egr cooler, oil cooler, intake gasket and turbo were all replaced. The current and failure mileages were approximately 87,690.
The contact owns a 2006 Ford F-250. The contact stated that the egr cooler and turbo failed which caused smoke to be emitted. The dealer stated that the egr cooler needed to be replaced. The manufacturer had not been notified. The vehicle was being repaired. The VIN was unavailable. The current mileage was approximately 150,000. The failure mileage was approximately 100,000.
The contact owns a 2004 Ford f250 super duty. The contact stated that the egr cooler needed to be replaced three times. The vehicle would produce a lot of smoke and fail to accelerate properly once the egr failed. The dealer stated that the manufacturer would not assume liability for the repairs. There was a factory warranty that covered the part for twelve months or 12,000 miles, whichever came first. The failure always occurred outside of the warranty. The VIN was unknown. The failure mileages were 99,000, 114,000 and 130,000. The current mileage was 130,000.
2004 Ford 6. 0 liter diesel motor- egr cooler cracking and thus causing coolant leaks into the exhaust system and engine cylinders. Egr cooler failure causes coolant to enter engine cylinders thus increasing cylinder pressures on heads. Head bolts stretch and head gaskets fail. Water in cylinder leads to major engine failure. 1000's of Ford 6. 0 liter diesel owners have the same problem. Dealers repair them constantly. Ford dealer parts dept states that they have parts in stock because they change them out on a daily basis. My vehicle was 2 months out of warranty when part failed at 53,163 miles. Egr cooler cracked, leaked out coolant in the exhaust and into the motor, thus motor failed. Dealer says need new motor at $10,000. Ford needs to recall the older egr cooler component. Currently when they change them out under warranty, they replace it with a new and improved egr cooler. If it is new and improved, why isn't the old one recalled if they know it is a bad design?.
Egr cooler has been replaced 4 times in less than 30,000 miles.
For the past 4 months we have had our truck in the shop three times, because of the egr valve. Truck constantly blows out black smoke and has no pick up speed. Still having issues the day after the truck was taken into the shop.
The contact owns a 2004 Ford F-250 sd. While driving approximately 65 mph, the engine began to rev excessively high. There was no power response when the accelerator pedal was depressed. In addition, the check engine warning light illuminated on the instrument panel and remained lit until the engine was turned off. The driver pulled over to the side of the road and the vehicle restarted. The vehicle was taken to an authorized dealer for diagnostic testing and they stated that the failure was contributed to the turbo and engine sensors. The turbo outlet hose, map sensor, and egr throttle body were replaced under warranty; however, the failures recurred on thirty separate occasions. The vehicle was taken to an authorized dealer and an independent mechanic on three separate occasions, but there were no resolutions. The vehicle has not been repaired. The failure mileage was 77,000 and current mileage was 120,000.
Consumer had egr sensor replaced. Check engine light came on making vehicle feel like it was going to die. The egr valve has been replaced five times. The vehicle rolled although the parking brake was applied. The dealer adjusted the parking brake.
Contact states: 2000 Ford f250. The vehicle has 31,000 miles on it and has been in the shop several times for the same thing. The vehicle will die while driving down the highway. It will die while you are stopped at a red light. The dealer cannot find the problem. They have replaced the egr valve which is part of the engine 4-5 times. The problem still exits. The manufacturer said they could fix it. They have been working on it since it had 3,000 on it. Vehicle is still under warranty. At present it has 31,000 on it and is still having the same problem. The consumer is concerned for his safety. The consumer said the dealer or the mfr cannot give him any reason why the car keeps dying on the highway. They cannot specifically identify what is causing the problem.
The consumer stated that 2004 Ford f250 intermittently on the road. This has happened about 20 times. The dealer fixed the truck and when the consumer picked up vehicle it still stalled. The truck was put on a diagnostic machine once and the truck pulled up 9 codes. The parts replaced were the valve and modulator, egr valve and gasket, reprogrammed automatic transmission control module ( pcm), and road tested. The vehicle then surged on the road test. The dealer found that egr valve was stuck, and it was replaced. The dealer felt that it may be the wiring harness.
The contact owns a 2004 Ford f-20. The contact stated that there was a recurring failure with the egr valve cooler. The turbo engine also failed and as a result, caused damage to the engine heads which resulted in a stalling failure. In addition, the fuel level gauge would not provide accurate fuel level readings. The failure was reported to the manufacturer. The vehicle was not repaired. The failure mileage was 1,500 and the current mileage was 43,322.
The contact owns a 2004 Ford F-250 super duty. The contact stated that the turbo component of the diesel engine failed. The component was replaced by an authorized dealer. In addition, the contact stated that the engine would exhibit an unusual increase in rpms yet there was no power to the engine. The vehicle was taken back to the dealer where the egr valve was repaired. The contact then noticed a massive oil leak and the dealer replaced the injector control press. The contact continued to notice a lack of power and the vehicle would sporadically stall without warning. The dealer inspected the vehicle and replaced the egr cooler and oil cooler. The manufacturer offered no assistance. The failure mileage was approximately 3,000 and the current mileage was 53,183.