20 problems related to gas recirculation valve (egr valve) have been reported for the 2004 Ford F-350. The most recently reported issues are listed below.
My truck has major engine damage bought it and three days later the egr went out then next thing you know I got a blown motor.
While driving vehicle has intermittent loss of power, diagnosed and serviced egr valve, replaced egr throttle valve and sealed the boost inlet tube.
Vehicle hard starting caused by failure of high pressure oil pump, replaced icp regulator, replaced egr valve and intake gaskets.
The contact owns a 2004 Ford F-350 sd. The contact stated that while driving 65 mph, the vehicle began to emit heavy amounts of smoke. The vehicle was taken to an independent mechanic for diagnosis and the contact was informed that two fuel injectors, two oil coolers, and the egr valve would need to be replaced. The vehicle was repaired. The manufacturer was notified of the failure. The failure mileage was 150,000 and the current mileage was 157,000.
We purchased this truck new to tow our 5th wheel. At 16,000 miles the turbo was replaced under warranty. Now at 31,412 miles, again, the turbo had to be replaced but this time at our expense. This second turbo rusted and was not repairable. Our truck has had all of the recommended maintenance done at the appropriate time/mileage. It has never had any after market equipment used on it or has it been abused in any way. This problem exists because of the poorly engineered and designed engine/egr system. It puts moisture into the turbo without a method to remove it. Ford needs to step up and stand behind this engine that they contracted International to engineer, design, and build for them. We implore NHTSA to step up and hold Ford responsible to their customers and their product with recalls to fix the inherent problems that this engine and vehicle present.
The contact owns a 2004 Ford F-350. The contact stated that while driving 45 mph, the vehicle decelerated to approximately 5 mph and the limp home mode message appeared on the instrument panel. The vehicle was safely driven to an authorized dealer, where the contact was informed that the egr and oil coolers needed to be replaced. The contact was also informed that the failure was common. The vehicle was not repaired. The manufacturer was made aware of the failure, but offered no assistance. The failure mileage was 72,000.
Engine dies and/or looses power. Happens at random times. The following items have been changed:ficm, , engine oil (thought problem due to oil pump), fuel filters, cam sensor switch, cleaned egr valve and all passages, replaced injector pressure controller, replaced egr valve. Last trip to dealer was may 3, 2010. No problems until today when pulling out of a side road onto main road engine died with vehicle blocking both lanes of traffic-push time--accident avoided only because no traffic. The basic problem with trying to get this vehicle repaired is no codes are set. After months of fails, it set a "bad ficm" code, changed ficm, no change in problem, repeated trips to dealer, finally get a "bad cam sensor" code, changed cam sensor, no change in problem. Dealer looked at egr, parameters determined to be out of limits, cleaned egr & all associated passages, ran fine for 10 days, failed 3 days in a row, old dealer out of business, new dealer changed both ipc & egr at my direction since they reported to me both items could cause the problem, ran fine from may 3 to may 8, 2010. Multiple failures today with one leaving me blocking both lanes of traffic at us25 & double culvert, georgetown, ky. Get vehicle out of harm's way, get it restarted, fails multiple times, then decides to run ok.
The contact owns a 2004 Ford f350. The contact was driving at approximately 40 mph when the vehicle suddenly began to shake and jerk forward. The vehicle was taken to a local mechanic who informed the contact that the egr cooler and three fuel injectors were the cause for the failure. The vehicle was repaired at that time. Later, the high oil pressure pump and oil cooler failed. The vehicle was awaiting further repairs at the time of the complaint. The contact called the manufacturer but was told that she would have to assume all repair costs at her expense. The failure mileage approximately was 121,000. The current mileage was approximately 130,000.
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.
2004 f350 6. 0 powerstroke boggs when taking off. Sometimes will act like you turned off switch when you push down the pedal there is no effect. Mostly when driving up the mountain its like it don't go past idle has not stalled yet. 8 injectors replaced front and rear injector harness replaced high pressure pump fuel mileage 13 mpg. Head gaskets replaced egr cooler rear main seal all under 65,000 miles.
On 01-06-2008 I started to have significant problems with my 2004 Ford F-350. It has just over 41,000 miles on it. It was smoking and had significant loss of power problems while at low road speed. Problem would clear once truck was >40 mph in speed. Took it to local Ford dealer on 01-07-2008. Their investigation showed that the egr valve was sticking. The valve assembly had to be replaced. The service person stated that this problem is common enough that they are keeping a couple of extra egr valve assemblies in their stock room. I asked if there was any indication of a product recall in the works. He said that he did not know of one but that one might happen in the near future and that I should keep my invoice just in case. My question/concern(s) is this: how often or frequent should an egr valve stick and/or fail? if their failure rate is high (1 failure per vehicle every 50,000 or less) then shouldn't there be a redesign and recall to improve the performance and safety?.
Vehicle had a stalling problem on accelleration. Vehicle idled fine, but frequently on acceleration from a stop after vehicle started to roll. Engine will misfire, shutter, or backfire for several seconds until clearing up. Also, vehicle misfired at highway speeds. Vehicle was taken to the dealer on several occations to find the cause of the problem, but they reported could not duplicate the problem. Dealer replaced several injectors and egr valve to no avail.
The contact owns a 2004 Ford f350. While at a stop light, the engine would rev. Depending on the contact's reaction time, the vehicle would move 4-5 feet. There were no warning indicators. The rpm would increase to 1,000. The dealer replaced the control module, three turbos, three egr valves, and the back pressure sensor. However, the failure continues. The failure mileage was 40,000 and current mileage was 61,000. Updated 01/11/08. Updated.
I own a 2004 f350 super duty Ford 6. 0 turbodiesel. I have had to replace the egr cooler three times starting in 2006. The last problem I had started out like the egr cooler then I developed and oil lose the when I ask the diesel mech. I was told the it sounded like a head gasket. That same diesel mech. Informed me that in the last 5 years he himself had to repair literally hundreds of 6. 0 Ford diesels for the same problem. My problem is that the problems I had started after the warranty was out and I was unable to get an extended warranty on the 6. 0 engine due to what the warranty agent described as a major engine development flaw by the 6. 0 designers. Looking on the internet I have seen thousands of complaints for the same thing. Yet I have seen no help from Ford.
: the contact stated upon starting the vehicle the oil pressure dropped and the engine died. The vehicle was towed to an independent repair shop where it was determined the oil pump and the lower intake manifold gaskets failed. The oil pump is made of aluminum which influenced the integrity of the pump, and caused the pump to wear out prematurely. The dealer was alerted of the problem, prior to the independent repair shop making the repair. Updated 5/10/2006 - the vehicle leaked coolant which caused the vehicle to overheat but the temp gauge did not indicate that the vehicle was overheating. The coolant also flowed through the egr valve which caused lose of power.
Diesel smell in the cab of a Ford f350 truck with 6. 0 engine. This is the second instance of this in this truck. Both have been covered by warranty, but the first time was in may of 05 and the second time was Feb 06 is this going to happen again. The smell is sickening and if you do not open the windows eyes water,feel tired, sick to stomach, all not good for driving down the road (people really look at you like you are nuts when its 5 degrees outside and you are driving around with your windows open). This time it has been blamed on the exhaust manifold, the first time it was what they called the down exhaust pipe. I believe that there is a bigger problem which has to do with the 6. 0 engine. Too much pressure for the exhaust. The other problem is with the radiator hose. I have 46700 miles on the truck and the radiator hose has to be replaced due to rubbing on the power steering gear box, Ford will not cover this under warranty, even though they have come up with a new hose and new part number to stop this from happening. I have not been told if they are replacing the hose with the old style or the new style.
There have been approximately 15 incidentas were the vehicle has stalled, while being driven or when attempting to stop at a stop sign or turn. The vehiclehas two methods of stalling - the first method is be idling very rough - as if miss firing on a cylinder/ timing issues where it blows black smoke. The second method is if you are stopped with your foot hopefully on the brake - the vehicle will rev up and lurch forward - if on the brake it will sometimes then stall. The vehicle has been to the shop at least 4 times - with multiple incidents per visit, the shop had replaced the egr valve and had reprogrammed the pcm everytime in the shop. Which takes me back to lousy fuel economy and has not yet fixed the problem. I am not happy.
Since new vehicle purchase, my Ford f350 diesel p/u experienced engine surging (200-250 rpm) while stopped with the automatic transmission in drive. The surge was significant enough to lurch the truck forward with the brake applied, such as at a stoplight. In several cases, I almost rear ended other vehicles before applying the brake hard enough to stop the truck from moving forward. I later learned to anticipate the surge using the brakes to minimize movement of the truck while stopped. My surging problem was confirmed on multiple occasions by technicians during test rides, but they could not duplicate the problem in the shop. In all cases, the first step was to reflash the ecm which masked the problem for several days while the truck relearned my driving habits and prevented a diagnosis. The engine had to be operated at full temperature in road conditions before the problem developed. In the shop, idling the engine to warm up to normal operating temperature was not sufficient to replicate the problem. Ford dealers made multiple attempts (10 or more) to diagnose the problem: replacing injector control pressure (icp) module, egr valve, and icp wiring connectors to no avail. The problem was finally diagnosed and corrected, out of warranty at approx. 44,500 miles, by replacing the engine wiring harness. I found a dealer who was willing to send a technician on a test ride with me and hook up an onboard computer laptop that identified the problem before reflashing the computer ecm. A number of surging complaints from other owners of Ford f350 are posted in online forums documenting similar circumstances and frustration. The incident date provided is the approximate date of the first occurrence. In my case, the surging occurred on a near daily basis, although intermittently, for 41000 miles of driving without any resolution from Ford. The engine wiring harness was replaced in Feb 2009 which corrected the surging in my truck. I paid a $100 deductible.
The contact owns a 2004 Ford f350. He stated that the egr valve cooler and head gaskets failed. The mechanic stated that electrolysis developed inside the engine and caused the failure. Each part has been repaired 2-3 times. He also noticed smoke coming from underneath the dashboard caused by melted fuses. The current mileage was 126,000 and the failure mileage was unknown. The contact stated that he noticed the failure at the time he purchased the vehicle.
While driving, t he vehicle stalled several times. The consumer would restart the vehicle while in motion. The brakes would go out when this would occur. The problem seemed to be resolved. The dealer replaced the egr valve (exhaust gas-recirculation). The vehicle idled erratically. The injector pressure regulator was replaced. The ebp sensor and the egr valve did not work properly and both were replaced. The ebp signal remained to fluctuate. Also ,the turbo charger was not working properly.