2004 Ford F-350 SD: what breaks, and at what mileage
What breaks on the 2004 Ford F-350 SD
On the 2004 Ford F-350 SD, the failure owners report most often is other engine problem, and the reports cluster around 85,000 miles. The earliest to appear is other electrical problem, reported by a median of 20,000 miles. Overall it scores 70 out of 100, high risk for a 2004.
High risk for a 2004 — 108th riskiest of the 329 2004 vehicles we can rate. 159 owner reports; fleet size estimated from this year's own recall paperwork.
The failures owners actually file about
Owners have reported 35 named failure modes on the 2004 Ford F-350 SD, and the three most-reported carry 30% of everything filed, which is an unusually even spread for one model year.
Other engine problem leads with 17 reports, about 1.3 per 1,000 vehicles and with the middle half of reports between 30k to 130,000 miles.
Other electrical problem follows with 15 reports, usually reported between 17k to 105,000 miles.
Other wheel or tire problem follows with 15 reports, usually reported between 68k to 155,000 miles.
By system, the reports fall mostly into engine (51), electrical (28) and wheels (28).
At what mileage it happens
139 of the reports on the 2004 Ford F-350 SD came with an odometer reading, and half of those were filed before 70,000 miles.
Cumulatively, 35% by 50,000 miles, 64% by 100,000 miles and 89% by 150,000 miles of the dated reports had been filed, with 2 filed above the top of the chart.
The busiest stretch is between 100,000 and 110,000 miles, which alone holds 11% of the dated reports.
29% of the dated reports were filed below 36,000 miles.
In the order they tend to show up: other electrical problem around 22k, tire blowout or tread separation around 59k, other engine problem around 85k and other wheel or tire problem around 132k.
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 35. The full list is in the table below.
How reports accumulate
Every report with an odometer reading, cumulative, from 0 to 200,000 miles. A further 2 reports 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
How bad it is when it goes
Across the named modes, 3 mention a crash, 2 a fire and 2 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 4.26, 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 wheel or tire problem at $200–$1,500 and tire blowout or tread separation at $200–$1,500. Dealer labour, a seized bolt or a part that is no longer made can push any of these past the top of its range.
35% 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
| Failure mode | System | Reports | With reading | 25th | Median | 75th | Per 1,000 | Typical repair | Severity |
|---|---|---|---|---|---|---|---|---|---|
| Other engine problem | engine | 17 | 17 | 30k | 85k | 128k | 1.3 | $300–$4,000 | High |
| Other electrical problem | electrical | 15 | 13 | 17k | 22k | 104k | 1.2 | $250–$2,000 | Moderate |
| Other wheel or tire problem | wheels | 15 | 13 | 68k | 132k | 155k | 1.2 | $200–$1,500 | High |
| Tire blowout or tread separation | wheels | 13 | 13 | 59k | 59k | 59k | 1.0 | $200–$1,500 | Critical |
| Head gasket failure | engine | 8 | 7 | — | 81k | — | 0.6 | $1,400–$4,000 | Critical |
| DPF, EGR or DEF system failure | emissions | 8 | 6 | — | 114k | — | 0.6 | $800–$5,000 | High |
| Control module (ECM/PCM/BCM) failure | electrical | 7 | 7 | — | 104k | — | 0.5 | $700–$3,000 | High |
| Oil leak | engine | 6 | 4 | — | 67k | — | 0.5 | $250–$2,200 | Moderate |
| Stalling while driving | engine | 6 | 5 | — | 83k | — | 0.5 | $300–$2,500 | Critical |
| No-start or intermittent start failure | engine | 6 | 2 | — | 89k | — | 0.5 | $200–$1,800 | Moderate |
| Turbocharger or supercharger failure | engine | 6 | 6 | — | 30k | — | 0.5 | $1,500–$4,500 | High |
| Wiring harness or short circuit | electrical | 6 | 6 | — | 39k | — | 0.5 | $400–$3,500 | High |
| Other fuel system problem | fuel | 6 | 6 | — | 69k | — | 0.5 | $300–$2,200 | High |
| Fuel injector failure | fuel | 5 | 5 | — | 76k | — | 0.4 | $450–$2,800 | Moderate |
| Other body or interior problem | body | 5 | 2 | — | 82k | — | 0.4 | $200–$2,000 | Moderate |
| Other steering problem | steering | 4 | 3 | — | 120k | — | 0.3 | $350–$2,400 | High |
| Other suspension problem | suspension | 3 | 3 | — | 36k | — | 0.2 | $350–$2,000 | Moderate |
| Misfire or rough idle | engine | 2 | 2 | — | 138k | — | 0.2 | $250–$1,600 | Moderate |
| Fuel tank, filler or EVAP failure | fuel | 2 | 2 | — | 85k | — | 0.2 | $250–$1,800 | Moderate |
| Cruise control failure | adas | 2 | 2 | — | 47k | — | 0.2 | $200–$1,400 | High |
| Steering rack, gear or tie rod failure | steering | 2 | 2 | — | 36k | — | 0.2 | $700–$2,600 | High |
| Other speed control problem | adas | 2 | 2 | — | 65k | — | 0.2 | $250–$2,000 | Critical |
| Radiator or coolant leak | cooling | 1 | 1 | — | 68k | — | 0.1 | $350–$1,900 | High |
| Overheating | cooling | 1 | 1 | — | 108k | — | 0.1 | $400–$3,500 | High |
| Manual clutch or hydraulics failure | transmission | 1 | 0 | — | — | — | 0.1 | $900–$2,800 | Moderate |
| Differential or transfer case failure | drivetrain | 1 | 1 | — | 4k | — | 0.1 | $900–$4,200 | High |
| Fuel pump failure | fuel | 1 | 1 | — | 152k | — | 0.1 | $600–$2,600 | High |
| Master cylinder or brake booster failure | brakes | 1 | 1 | — | 83k | — | 0.1 | $450–$2,200 | Critical |
| Premature brake pad or rotor wear | brakes | 1 | 1 | — | 18k | — | 0.1 | $300–$1,400 | Moderate |
| Brake line, hose or caliper failure | brakes | 1 | 1 | — | 68k | — | 0.1 | $250–$1,600 | Critical |
| Parking brake failure | brakes | 1 | 1 | — | 39k | — | 0.1 | $250–$1,300 | Moderate |
| Loss of power steering | steering | 1 | 1 | — | 47k | — | 0.1 | $600–$2,800 | Critical |
| Exhaust leak or fumes in the cabin | emissions | 1 | 0 | — | — | — | 0.1 | $250–$2,000 | High |
| Other powertrain problem | transmission | 1 | 1 | — | 2k | — | 0.1 | $400–$4,500 | High |
| Other brake problem | brakes | 1 | 1 | — | 38k | — | 0.1 | $300–$1,800 | High |
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-350 SD draws about 12 per 1,000 vehicles, which puts it in the 87th 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.
Other engine problem
I have a 2004 f350 superduty with 6800 miles, it stalls and loses power every time I drive it. While pulling into traffic recently it stalled and almost caused several wrecks. Ford has tried to fix this problem three times with no luck.I also know sevreal other ford superduty's with the same problem.one of these stalled pulling into traffic , but no wreck.my ford service demartment has not fixed any of these trucks
We purchased 4, 2004 f-350 ford diesel 6.0 liter ambulance conversions. All 4 vehicles are having reoccurring engine failures. The problems began on some of the vehicles at low mileage. The dealer continues to "patch" the engine problem. I have communicated with several other ambulance services and have found that they are having the same problems. The failure of these engines while transporting critical patients creats a very risky and dangerous situation for the patients and a hugh liability issue for the paramedics and our company.last night another engine failed while transporting an 18 year old with a broken neck to a higher level hospital. The delivery of the patient was delayed unnecessarily because another ambulance service had to be called and waited on to get to my crew to transport the patient. This happens almost each time I sent one of these ambulances on a trip. Not only is the patient placed in danger, but my company is quickly getting an unfavorably reputation because of these breakdowns. This is costing us business. My paramedics are refusing to drive these vehicles because of the risk of liability that they may…
Other electrical problem
Dt: consumer stated 2004 ford f350 super duty was having electrical surge problems. Consumer was complaining to dealership that vehicle had surge problems for the past year and a half. The dealer said that they could not duplicate the problem. Dealer did updated the computer software and the truck ran some what better after that. The problem came back after a week, and went back to having computer surges. The truck was in the dealership for repairs on this issue five times. Same result, the truck would work for a little while, then back to the same surging problems which have been intermittent. The manufacturer has been contacted 5 to 6 times. Ford has not helped in resolving this issue. The lemon law has been looked into by the consumer. The lemon law was denied by the state. Consumer had asked ford to investigate this problem. Ford said that they had no recalls or anything else on the truck. As of july 27, the truck stalled in the middle of the road. The truck had to sit for around 15 minutes before it would start owner could actually drive it. The truck ran yesterday for 3 miles and started stalling again, twice yesterday…
Dt*: the contact stated recall (05v270000) regarding electrical system: wiring was performed which resulted the vehicle to stall twice, make different noises and had problems accelerating at 48 MPH. The vehicle was taken to the dealer 8 times for this problem since 10/05 and the dealer was unable to duplicate the issue. Also the gas mileage went down from 17 to 12 miles per gallon.*ak
Other wheel or tire problem
Tl*the contact owns a 2004 ford f-350 sd. While driving 60 MPH, the contact heard a loud bang. The noise was due to the tread coming off the passenger side rear tire, which damaged the fender and the bed. The vehicle was able to be driven and is parked at the contact's residence. The VIN and engine size were unknown. The current and failure mileages were 42,000.
Tl*the contact owns a 2004 ford f-350 sd. The vehicle has continental general ameritrac (na), size lt235/85/r16 tires. While driving 55 MPH, the contact heard a loud noise coming from the rear of the vehicle. She inspected the vehicle and noticed that the tread separated from the outer driver side rear tire. As of august 23, 2007, neither the manufacturer nor the dealer has inspected the tire. The auto body shop stated that the tire appeared to be re-treaded. The failure mileage was 51,150 and current mileage was 52,050.
Recalls on the 2004 model year
NHTSA has issued 3 recall campaigns covering the 2004 Ford F-350 SD, affecting an estimated 14,397 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 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.
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.
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.
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.
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
How 2004 compares with the other years
High risk for a 2004 — 108th 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 25 model years of this car that carry enough reports to score, 1999 comes out best at 63 and 2012 worst at 81, with 2004 itself at 70.
If the model year is negotiable, 1999, 2000, 2002 and 2016 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 63 and 2006 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.
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-350 SD scores best at 63 and 2006 Ford F-350 SD worst at 75.
What to look at before buying one
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 electrical problem from about 17k, other engine problem from about 30k, tire blowout or tread separation from about 59k and other wheel or tire problem from about 68k.
On a 2004 Ford F-350 SD with more miles than that on it, the useful question to put to a seller or a mechanic is whether other electrical 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.
The limits of complaint data
159 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 159 reports, 139 carried an odometer reading, so the mileages here describe 87% 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-350 SD?
The most-reported failures are other engine problem (17 reports, median 85,000 miles), other electrical problem (15 reports, median 20,000 miles) and other wheel or tire problem (15 reports, median 130,000 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-350 SD problems start?
Other electrical problem is the earliest failure mode to show up, with a median reported mileage of 20,000 miles and a quarter of reports before 15,000 miles. Across all failure modes on this year, the median report sits at 70,000 miles.
Is the 2004 Ford F-350 SD reliable?
It scores 70 out of 100 on our risk index, which is high — 108th 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-350 SD is best?
Within the 1999–2007 generation, 1999 scores best at 63 out of 100 and 2006 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 Published by AtWhatMileage How every figure is computed