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.
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.
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 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 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.
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.
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.