No-start or intermittent start failure on the 2004 Ford F-250 SD
1 crash 1 fire 2 of the 10 reports for this failure mention a crash, a fire, an injury or a death. Those are the owner's words on the complaint form, not a verified finding, and one report can mention more than one.
When no-start or intermittent start failure gets reported
Owners of the 2004 Ford F-250 SD report no-start or intermittent start failure at a median of 105,000 miles. A quarter of the reports come in before 85,000 miles and a quarter after 105,000 miles, from 9 reports that carried an odometer reading.
A part like this is normally expected to survive 88,000 miles. It is the 12th most-reported problem on this model year.
The mileage distribution
The reported range runs from 1,500 miles at the tenth percentile to 175,000 miles at the ninetieth, a spread of 173,500 miles across the middle 80% of reports.
A spread this wide points at use rather than design. Towing, climate, service history and city mileage all move a failure like this, so the median is a weak guide to any individual car.
22% of the dated reports were filed under 36,000 miles.
The whole distribution
| 10th | 25th | Median | 75th | 90th |
|---|---|---|---|---|
| 1,500 miles | 83,228 miles | 103,000 miles | 103,000 miles | 175,000 miles |
Read the 10th percentile as “one report in ten arrived this early”. Exact figures are shown in this table because it is the table of record; everywhere else on the site they are rounded to the precision the sample can carry.
What a percentile can and cannot tell you here
These five numbers describe the readings owners gave, in order. The median is the middle one: half the reports arrived below it. The 10th and 90th are the edges of the bulk of the distribution, and the distance between them is the part worth reading. A tight spread — say 70,000 to 95,000 miles — points at something that wears out on a schedule, and the schedule is knowable. A wide one, 20,000 to 190,000, points at a fault that hits some cars and never troubles others, which means the mileage on the listing in front of you tells you very little about your odds.
What these figures are not is a survival curve. Every reading here comes from a car whose owner filed a complaint, so the sample contains only failures: it cannot say what share of the fleet made it past 150,000 miles untouched, because those owners had nothing to report. Nor is the mileage the moment of failure — it is the odometer reading as recalled at the time of filing, which may be weeks later and is sometimes rounded to the nearest ten thousand by the person typing it.
Percentiles are shown at all only once 8 readings exist for the vehicle and mode. Below that the middle of a handful of numbers is noise wearing a decimal point, so the figures are withheld rather than dressed up.
What happens, and what it costs
Of these reports, 1 a crash and 1 a fire are mentioned. Owners write their own complaints and the agency does not verify them, so read this as what the reports say happened rather than as a confirmed count.
Putting it right typically runs $200–$1,800 at an independent US shop. That range is an editorial estimate held in this site's failure-mode catalogue, not a figure from NHTSA, and it is a repair cost rather than a diagnosis cost.
The same failure on other years
The same failure is reported on 11 model years of this car. It shows up earliest on the 2010, at a median of 5,000 miles, and latest on the 2020 at 120,000 miles.
By volume the 2003 carries the most reports, with 10; the 2004 has 10. A mode that appears across most years of a model is usually a design choice rather than a bad batch.
If one year stands out to the left, that is the year to avoid; if the whole line sits at a similar mileage, this is wear rather than a defect in one production run.
Tick median reported mileage Solid middle half of reports Faint 10th to 90th percentile Colour how bad the failure is when it happens
What owners wrote
Verbatim from NHTSA complaint narratives, trimmed for length. The mileage is the one the owner gave.
Tl*the contact owns a 2004 ford f-250 super duty. The contact stated that the environmental regulator (EGR) failed and ruined the motor. When the contact tried to start the vehicle, the engine began to emit smoke and would not start. There were no warning lights displayed. The vehicle was taken to an authorized dealership where the coolant, oil filter, gkt kit, head gaskets, EGR cooler, oil cooler, intake gasket and turbo were all replaced. The current and failure mileages were approximately 87,690.
Purchased a 2004 ford f250 superduty 6.0 liter diesel in april in june it began to stall out after changing both fuel filters and the air filter it continued to have this problem until it just won't start anymore have tried to resolve the situation with the dealer but with no help there don't know what to do until I seen the recall upon doing some research on the internet. *tr
Tl* the contact owns a 2004 ford f-250 sd. The contact stated that after several attempts, the engine failed to start. The vehicle was towed to the dealer where it was found that the fuel injection control module wire harness needed to be replaced. The vehicle was not repaired. The manufacturer was contacted about the failure and informed the contact that the vehicle was not included in NHTSA campaign id number 05v270000 (electrical system:wiring). The approximate failure mileage was 103,000..... Updated 03/08/13 *bf
Also reported on the 2004 Ford F-250 SD
Other engine problem
Other electrical problem
Other fuel system problem
Misfire or rough idle
Other speed control problem
Control module (ECM/PCM/BCM) failure
How far this goes
Complaints are voluntary, so 10 is a floor and not a count of affected cars. Mileages are typed in by owners and cluster on round numbers. And the mode itself is assigned by software reading the complaint text, which is reliable in bulk and fallible one report at a time.
Questions this page answers
At what mileage does no-start or intermittent start failure happen on the 2004 Ford F-250 SD?
Across 9 owner reports that included an odometer reading, half were filed by 105,000 miles. A quarter were filed before 85,000 miles and a quarter after 105,000 miles. These are the mileages owners reported when they complained, not a prediction for any individual car.
How common is no-start or intermittent start failure on the 2004 Ford F-250 SD?
10 reports have been filed with NHTSA, about 0.8 per 1,000 vehicles. Complaints are voluntary, so this is a floor rather than a count of affected cars.
What this is and is not. These are the mileages at which owners chose to complain to a federal agency, which is not the same as the mileage at which the part fails on every car. It skews toward failures that happened outside warranty, cost real money, or frightened someone. It is still the only public dataset that carries failure mileage at all, and the shape of a few hundred readings is informative even when a single one is not. Methodology · JSON · this failure on other cars
Source Owner complaints and recall records published by the US National Highway Traffic Safety Administration, model years 1996–2027 Figures rebuilt Published by AtWhatMileage How every figure is computed