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2004 Ford F-350 Super Duty Problems

RepairPal has identified the most common problems with the 2004 Ford F-350 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.

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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.

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. This issue can affect all diesel F-350, F-450, F-550, F-650, and F-750 Super Duty models.

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.

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

The rear sliding glass window may stop working, or binds in motion. The power slider cable binds causing slow, or no operation. The glass assembly will need to be replaced, the cable is included in the assembly.

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 2004-2010 Ford F-350 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.

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 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.

A leak in the exhaust down pipe and cause smoke to be seen around the front of the vehicle and engine compartment, and exhaust fumes in the cab. The exhaust down pipe should be replaced.

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.