Close

2004 Ford F-250 Super Duty Problems

RepairPal has identified the most common problems with the 2004 Ford F-250 Super Duty based on complaints from actual vehicle owners. We'll tell you what the problem is and what it'll take to fix it.

No car image 94a1663db56199c5353592009e34aaa51078a2469bed068bb8d6f0ba43accf97
Get a Repair Estimate
Guaranteed by certified locations nationwide. Learn more
RepairPal estimates are guaranteed at over 1,700 quality certified locations nationwide. Learn more
12
Known Problems

A severe lack of power may develop because the hose from the turbocharger to the intake manifold can come loose, resulting in loss of boost pressure to the engine.

The Ford F-250 Super Duty has known issues with the V8 engine ejecting spark plugs. This will make a tapping or knocking noise, plus the engine will begin to misfire at all speeds. The check engine light will also illuminate.

The threads on the cylinder head are too short and soft, allowing pressure from combustion to overwhelm and destroy the threads. 

When the spark plug ejects, the cylinder head becomes damaged, necessitating repair of the spark plug port threads, or replacement of the cylinder head and cylinder head gasket. 

Ford has recommended a method of repair for the cylinder head that prevents the spark plug from ejecting under future use. Replacement of all spark plugs is not necessary, but an updated spark plug design can help prevent this from happening in the future. 

There is a technical service bulletin for the V8 engine.

The cooler for the EGR valve can leak coolant internally, which causes white smoke to come from the tail pipe. Hot exhaust gases are cooled by the EGR cooler before being circled back into the engine.

A coolant leak from the radiator can be caused by a defective thermostat bypass. This can cause pressure spikes in the cooling system, which leads to radiator failure. The thermostat assembly and radiator should be replaced.

The high pressure diesel fuel injection pump may fail, resulting in a "no start" condition.

The VGT solenoid can fail. The VGT solenoid receives signals from the engine control module to adjust the boost that the (variable geometry) turbo is generating. A defective solenoid can also create an overboost or underboost condition when driving.

The 2004-2010 Ford F-250 with manual temperature and fan controls may have problems with the the blower motor only blowing air on certain settings. Most commonly the fan will only run on the highest setting. This is a well documented problem, and is caused by a failing blower motor resistor.

Correcting the problem is straight forward, and requires replacement of the small resistor. The resistor is normally found behind the glove box, next to the blower motor.

Delamination of the diesel fuel tank can occur resulting in a loss of power due to debris clogging the fuel filters. In some cases the fuel injection pump and/or fuel injectors have also been damaged. Ford has issued a service bulletin (#19728) addressing this concern.

An illuminated Check Engine Light could indicate that one or more of the ignition coils has failed due to excessive spark plug gap. To fix this problem, the ignition coils that have failed, the spark plugs, and all coil boots should be replaced.

It is common to see the variable vanes inside the turbo seize or bind from carbon buildup. This causes an overboost or underboost condition when driving.