Model year report

2004 Ford F-250 SD: what breaks, and at what mileage

What breaks on the 2004 Ford F-250 SD

On the 2004 Ford F-250 SD, the failure owners report most often is other engine problem, and the reports cluster around 20,000 miles. The earliest to appear is other powertrain problem, reported by a median of 5,000 miles. Overall it scores 75 out of 100, high risk for a 2004.

High risk for a 2004 — 41st riskiest of the 329 2004 vehicles we can rate. 345 owner reports; fleet size estimated from this year's own recall paperwork.

What owners report breaking

Owners have reported 51 named failure modes on the 2004 Ford F-250 SD, and the three most-reported carry 29% of everything filed, which is an unusually even spread for one model year.

Other engine problem leads with 51 reports, about 4.0 per 1,000 vehicles and with the middle half of reports between 7k to 55,000 miles.

Other electrical problem follows with 24 reports, usually reported between 25k to 90,000 miles. 4 of those reports mention a fire.

Other fuel system problem follows with 24 reports, usually reported between 44k to 115,000 miles.

By system, the reports fall mostly into engine (105), electrical (46) and fuel (38).

The mileage the reports cluster at

305 of the reports on the 2004 Ford F-250 SD came with an odometer reading, and half of those were filed before 58,000 miles.

Cumulatively, 46% by 50,000 miles, 75% by 100,000 miles and 93% by 150,000 miles of the dated reports had been filed, with 1 filed above the top of the chart.

The busiest stretch is between 0 and 10,000 miles, which alone holds 17% of the dated reports.

38% of the dated reports were filed below 36,000 miles, which is early enough that a fair number of these cars were still under a factory warranty when the owner complained.

In the order they tend to show up: other powertrain problem around 7k, other engine problem around 20k, other speed control problem around 37k and other wheel or tire problem around 40k.

Median

Other engine problem

20k
Other electrical problem

67k
Other fuel system problem

88k
Misfire or rough idle

101k
Other speed control problem

37k
Control module (ECM/PCM/BCM) failure

75k
Other suspension problem

59k
Other wheel or tire problem

40k
DPF, EGR or DEF system failure

84k
Other steering problem

70k
Stalling while driving

86k
No-start or intermittent start failure

103k

Tick median reported mileage Solid middle half of reports Faint 10th to 90th percentile Colour how bad the failure is when it happens

Showing the 12 most-reported failure modes of 51. The full list is in the table below.

How reports accumulate

Share of reports filed by each mileage

half by 58k

Every report with an odometer reading, cumulative, from 0 to 200,000 miles. A further 1 report came in above that, which is why the line stops short of the top. A curve that climbs early is a car with early problems, whatever its total.

Line share of reports filed by that mileage
Dashed the median reported mileage

Severity, and what it costs

Across the named modes, 15 mention a crash, 14 a fire and 8 an injury. Those are the words owners used in their own complaints, and NHTSA does not verify them, but they are the closest thing in this data to a measure of what a failure actually did.

The average severity weight across every report on this year is 4.48, where a stalled engine or a failed airbag weighs many times more than a rattling trim panel, and a figure this high means the reports are dominated by failures with safety consequences rather than annoyances. The weighting is set out in full on the methodology page.

What the top failures cost to put right, as editorial estimates for an independent US shop rather than figures from NHTSA: other engine problem at $300–$4,000, other electrical problem at $250–$2,000, other fuel system problem at $300–$2,200 and misfire or rough idle at $250–$1,600. Dealer labour, a seized bolt or a part that is no longer made can push any of these past the top of its range.

39% of the reports on this year sit in the engine, transmission, drivetrain or cooling systems — the four where a repair bill is usually four figures.

Every reported failure mode

Mileage figures are percentiles of owner-reported readings. Click a column to sort.
Failure mode	System	Reports	With reading	25th	Median	75th	Per 1,000	Typical repair	Severity
Other engine problem	engine	51	43	7k	20k	55k	4.0	$300–$4,000	High
Other electrical problem	electrical	24	21	25k	67k	90k	1.9	$250–$2,000	Moderate
Other fuel system problem	fuel	24	24	44k	88k	115k	1.9	$300–$2,200	High
Misfire or rough idle	engine	18	11	75k	101k	176k	1.4	$250–$1,600	Moderate
Other speed control problem	adas	16	14	2k	37k	60k	1.2	$250–$2,000	Critical
Control module (ECM/PCM/BCM) failure	electrical	15	15	60k	75k	86k	1.2	$700–$3,000	High
Other suspension problem	suspension	12	12	39k	59k	76k	0.9	$350–$2,000	Moderate
Other wheel or tire problem	wheels	12	9	36k	40k	106k	0.9	$200–$1,500	High
DPF, EGR or DEF system failure	emissions	11	10	63k	84k	97k	0.9	$800–$5,000	High
Other steering problem	steering	11	9	32k	70k	90k	0.9	$350–$2,400	High
Stalling while driving	engine	10	10	28k	86k	97k	0.8	$300–$2,500	Critical
No-start or intermittent start failure	engine	10	9	83k	103k	103k	0.8	$200–$1,800	Moderate
Other powertrain problem	transmission	9	9	4k	7k	14k	0.7	$400–$4,500	High
Tire blowout or tread separation	wheels	8	6	—	105k	—	0.6	$200–$1,500	Critical
Other body or interior problem	body	8	3	—	130k	—	0.6	$200–$2,000	Moderate
Fuel injector failure	fuel	7	7	—	93k	—	0.5	$450–$2,800	Moderate
Parking brake failure	brakes	7	7	—	12k	—	0.5	$250–$1,300	Moderate
Oil leak	engine	6	6	—	7k	—	0.5	$250–$2,200	Moderate
Radiator or coolant leak	cooling	6	5	—	58k	—	0.5	$350–$1,900	High
Fuel gauge or level sensor failure	fuel	6	2	—	125k	—	0.5	$300–$1,200	Moderate
Wiring harness or short circuit	electrical	6	6	—	18k	—	0.5	$400–$3,500	High
Turbocharger or supercharger failure	engine	5	5	—	14k	—	0.4	$1,500–$4,500	High
Differential or transfer case failure	drivetrain	5	5	—	30k	—	0.4	$900–$4,200	High
Exhaust leak or fumes in the cabin	emissions	5	5	—	17k	—	0.4	$250–$2,000	High
Cruise control failure	adas	4	4	—	120k	—	0.3	$200–$1,400	High
Door latch or handle failure	body	4	4	—	3k	—	0.3	$250–$1,200	High
Torque converter failure	transmission	3	3	—	232	—	0.2	$1,100–$3,200	High
Loss of braking	brakes	3	3	—	53k	—	0.2	$400–$3,000	Critical
Steering rack, gear or tie rod failure	steering	3	3	—	80k	—	0.2	$700–$2,600	High
Control arm, ball joint or bushing failure	suspension	3	3	—	21k	—	0.2	$400–$2,200	High
Rust or structural corrosion	body	3	3	—	79k	—	0.2	$500–$6,000	High
Engine bay fire	engine	2	2	—	77k	—	0.2	$4,000–$20,000	Critical
Head gasket failure	engine	2	2	—	102k	—	0.2	$1,400–$4,000	Critical
Cooling fan failure	cooling	2	2	—	145k	—	0.2	$350–$1,300	Moderate
Harsh or jerky shifting	transmission	2	2	—	4k	—	0.2	$600–$4,000	Moderate
ABS module or sensor failure	brakes	2	2	—	13k	—	0.2	$500–$2,400	High
Airbag failed to deploy in a crash	airbag	2	2	—	65k	—	0.2	$1,000–$5,000	Critical
Seat belt or retractor failure	airbag	2	2	—	31k	—	0.2	$200–$900	High
Other lighting problem	lighting	2	2	—	98k	—	0.2	$120–$1,200	Moderate
Piston, ring or cylinder wall damage	engine	1	1	—	10k	—	0.1	$3,000–$9,500	Critical
Overheating	cooling	1	1	—	10k	—	0.1	$400–$3,500	High
Complete transmission failure	transmission	1	1	—	450	—	0.1	$2,800–$8,000	Critical
Manual clutch or hydraulics failure	transmission	1	1	—	86k	—	0.1	$900–$2,800	Moderate
Fuel leak or fuel odor	fuel	1	1	—	35k	—	0.1	$300–$2,500	Critical
Engine sensor failure	electrical	1	1	—	77k	—	0.1	$180–$900	Moderate
Brake line, hose or caliper failure	brakes	1	1	—	110k	—	0.1	$250–$1,600	Critical
Airbag warning light or occupant sensor fault	airbag	1	1	—	37k	—	0.1	$300–$1,600	High
Liftgate, tailgate or trunk failure	body	1	1	—	42k	—	0.1	$250–$1,500	Moderate
Wiper or washer failure	glass	1	1	—	109k	—	0.1	$120–$800	Moderate
Other brake problem	brakes	1	1	—	169k	—	0.1	$300–$1,800	High
Other driver assistance problem	adas	1	1	—	140k	—	0.1	$250–$1,800	High
Unclassified problem	other	2	1	—	239k	—	0.2	—	Moderate

Rate per 1,000 uses a fleet-size estimate derived from recall paperwork for this exact model year. It is a lower bound. Repair costs are typical independent-shop ranges for the failure, not figures from these reports.

How often, against how many were built

Scaled by an estimate of how many of these cars exist, the 2004 Ford F-250 SD draws about 27 per 1,000 vehicles, which puts it in the 92nd percentile of complaint rates among 2004 vehicles we can rate.

That denominator is the weakest number on the page and it is fair to say so plainly. Rate per 1,000 uses a fleet-size estimate derived from recall paperwork for this exact model year. It is a lower bound.

The working figure is 12,864 vehicles. If the true number is twice that, every rate on this page is half what it says; the ranking against other 2004 vehicles, which is what the risk score uses, is far more robust than the rate itself.

What owners wrote

Verbatim from NHTSA complaint narratives, trimmed for length. The odometer reading is the one the owner gave.

Recalls on the 2004 model year

NHTSA has issued 4 recall campaigns covering the 2004 Ford F-250 SD, affecting an estimated 14,570 vehicles. A recall is a different kind of evidence from a complaint: it is the regulator and the manufacturer agreeing that something has to be fixed, and the fix is free for as long as the car exists.

The campaigns cover exterior lighting:tail lights, wheels:hub, exterior lighting and electrical system:wiring. Whether the work was actually done on the car in front of you is a question only the VIN can answer, and the manufacturer or NHTSA will answer it free.

One caution about reading these together: a recall usually raises the complaint count for the same part, because owners who read about it go and file. The mileages stay informative; the counts get noisy.

11V352000

EXTERIOR LIGHTING:TAIL LIGHTS

26,715 vehicles 2011-07-13

Defect: Ford is recalling certain model year 2011 ranger trucks built from january 25, 2011, through april 25, 2011 at the twin cities assembly plant, and service parts distributed to dealers for certain 2004 through 2011 model year ranger trucks, 2002 through 2005 model year excursion vehicles, and 2002 through 2007 model year f-250, f-350, f-450, and f-550 trucks for failing to comply with the requirements of federal motor vehicle safety standard no. 108, "lamps, reflective devices, and associated equipment." the multi-function switch was shipped with a subcomponent (slider)…
Consequence: Non-functioning lights could increase the risk of a crash.
Remedy: Dealers will replace the switches free of charge. The safety recall began on august 15, 2011. Owners may contact ford motor company customer relationship center at 1-866-436-7332.

07E106000

WHEELS:HUB

130,000 vehicles 2007-12-17

Defect: Certain federal-mogul replacement wheel hub assemblies with the brand names: national, carquest p/nos. 515020, 515021, 515025, 515053, 515054, 515059, and 515060, shipped between january 23, 2006, and december 20, 2007, sold for light duty and medium duty trucks. The inboard retention nut used to maintain hub bearing assembly can loosen resulting in an ABS light indication, noise, and/or wheel separation.
Consequence: Wheel separation can result in a vehicle crash.
Remedy: Federal-mogul will notify customers and will replace the hub assembly free of charge. The recall began on february 7, 2008. Owners can contact federal-mogul toll-free at 877-489-6659.

06E026000

EXTERIOR LIGHTING

61,944 vehicles 2006-03-23

Defect: Certain pro-a motors corner lamps, turn signals, and headlights sold as replacement lamps for use on certain passenger vehicles listed above. Some combination lamps that are not equipped with amber side reflectors fail to conform to federal motor vehicle safety standard no. 108, lamps, reflective devices, and associated equipment.
Consequence: Without the amber reflectors, the vehicle will be poorly illuminated, possibly resulting in a vehicle crash without warning.
Remedy: Pro-a motors will notify owners and offer to repurchase the lamps. The recall began on april 3, 2006. Owners may contact pro-a motors at 323-838-2988.

05V270000

ELECTRICAL SYSTEM:WIRING

180,104 vehicles 2005-06-10

Defect: Certain pickup trucks, sport utility vehicles and vans equipped with 6.0l diesel engines may experience stalling without warning while driving and may or may not restart.
Consequence: Should the engine stall, a vehicle crash could occur.
Remedy: Dealers will upgrade the fuel injection control module (ficm) wire harness or replaced, and/or have a new injection control pressure (icp)) sensor connector installed free of charge. The recall began on july 22, 2005. Owners may contact ford at 1-800-392-3673.

Recall work is free at a franchised dealer regardless of the car's age. Check the VIN at nhtsa.gov/recalls before assuming it was done.

How it ranks in the 2004 field

The score at the top of the page, placed among its peers. The zones are the same thresholds the scorer applies, read out of the scorer itself, so the picture and the band word cannot disagree.

Risk score against the rest of the 2004 field

Scores are ranked within the model year, never across years, because an older car has had longer to accumulate reports.

Left fewer and less serious reports
Right more, or worse
Marker this vehicle

Where 2004 sits in the model line

High risk for a 2004 — 41st riskiest of the 329 2004 vehicles we can rate. Because the ranking is against the same model year only, age cancels out of it.

Across the 29 model years of this car that carry enough reports to score, 1997 comes out best at 60 and 2019 worst at 81, with 2004 itself at 75.

If the model year is negotiable, 1997, 2016, 2025, 1999, 2000, 2026, 2002, 2015, 2001, 2024, 2021, 2005 and 2014 score lower than 2004 by a margin worth acting on. Same body, same engines, different luck — usually a supplier change or a mid-cycle fix, which the complaint data can show but never explain.

Within the 1999–2007 generation specifically, 1999 is the strongest year at 66 and 2004 the weakest at 75.

Scores compare each year against other cars of the same model year, so a low number on an older car is a real result and not an artefact of age.

Risk score by model year, out of 100

Shorter is better. Years with too few reports to score are shown without a bar rather than as a zero, because no data is not good news.

Within the 1999-2007 generation, 1999 Ford F-250 SD scores best at 66 and 2004 Ford F-250 SD worst at 75.

What the numbers say to check

The mileages below are where the first quarter of reports for each mode had already been filed, which makes them the point at which a fault is worth looking for rather than the point at which it happens: other speed control problem from about 2k, other powertrain problem from about 4k, other engine problem from about 7k and other electrical problem from about 25k.

On a 2004 Ford F-250 SD with more miles than that on it, the useful question to put to a seller or a mechanic is whether other speed control problem has been dealt with, and if so with what parts and at whose expense. A car that has already had the repair is in a different position from one that has not.

Treat it as where to point the inspection, not as a prediction. A well-maintained example can sail past every mileage on this page, and a neglected one can fail well before the first of them.

Where these figures stop being useful

345 owner reports; fleet size estimated from this year's own recall paperwork. Every count on this page is therefore a floor: it is the number of owners who went to the trouble of filing with a federal agency, which is a small and self-selected fraction of the owners who had the fault.

Of those 345 reports, 305 carried an odometer reading, so the mileages here describe 88% of the sample rather than all of it. Owners also round: readings pile up on multiples of ten thousand, which is why this site publishes "about 90,000 miles" and not "91,438".

The failure modes are assigned by software reading the owner's own words, which is accurate in bulk and wrong in individual cases. A mode with a handful of reports may contain a misfiled one.

And nothing here predicts what one car will do. These are other people's complaints, filed years apart, on cars maintained by strangers. Read the page as a map of where this model year has previously gone wrong, then have the specific car in front of you inspected.

Questions this page answers

What are the most common problems with the 2004 Ford F-250 SD?

The most-reported failures are other engine problem (51 reports, median 20,000 miles), other electrical problem (24 reports, median 65,000 miles) and other fuel system problem (24 reports, median 90,000 miles). Counts come from owner complaints filed with NHTSA, which are voluntary, so they show what owners bothered to report rather than every fault that occurred.

At what mileage do 2004 Ford F-250 SD problems start?

Other powertrain problem is the earliest failure mode to show up, with a median reported mileage of 5,000 miles and a quarter of reports before 5,000 miles. Across all failure modes on this year, the median report sits at 58,000 miles.

Is the 2004 Ford F-250 SD reliable?

It scores 75 out of 100 on our risk index, which is high — 41st riskiest of the 329 2004 vehicles we can rate. The score is a comparison against other 2004 vehicles, not a prediction about any individual car, and it is built from complaint rates, severity and how early failures appear.

Which year of the Ford F-250 SD is best?

Within the 1999–2007 generation, 1999 scores best at 66 out of 100 and 2004 worst at 75. Same body, same engines, different luck.

Where this comes from. Every figure above is computed from NHTSA owner complaints and recall records for this exact make, model and year. Complaints are voluntary and self-selected, so treat counts as a floor. The methodology page writes out each formula, and the same numbers are available as JSON.

What breaks at my mileage Compare with another car

Source Owner complaints and recall records published by the US National Highway Traffic Safety Administration, model years 1996–2027 Figures rebuilt 20 August 2026 Published by AtWhatMileage How every figure is computed