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