Problems for specific Ford F-250 Super Duty years:
Problem Reports
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2004 Ford F-250 Super Duty Problems
Variable Vanes Inside Turbo Seize Due to Carbon Buildup
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.
High Pressure Diesel Fuel Injection Pump May Fail and Cause "No Start" Condition
The high pressure diesel fuel injection pump may fail, resulting in a "no start" condition.
Lack of Power Due to Loss of Turbocharger Boost to Engine
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.
One or More Spark Plugs May be Ejectioned From the Cylinder Head
There is a technical service bulletin for the V8 engines regarding a possible problem with the spark plug being ejected from the cylinder head, damaging the threads in the spark plug hole. If the vehicle is under warranty, cylinder head replacement is recommended. If the vehicle is out of warranty, Ford authorized the use of a specific thread insert to repair the head.
door paint and rust
both driver and passenger doors have paint falling off right in the middle at the bottom... also there is rust where the paint was coming off. the back doors are doing the same thing. also in the corners of the windows the paint is falling off and it is rusting in the corners right next to the rubber gasket for the windows all 4 doors on my crew cab..
White Smoke From Tail Pipe
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.
Ignition Coil Failure Due to Excessive Spark Plug Gap
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.
Delamination of diesel fuel tank
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 (#