2004 Ford F-250 SD: engine failure

Filed Jan 14, 2013 · Electrical, Engine · 103,000 miles · NY

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 the federal safety agency campaign id number 05v270000 (electrical system:wiring). The approximate failure mileage was 103,000..... Updated 03/08/13

Filed Feb 4, 2012 · Electrical, Engine · 164,000 miles · TX

I bought this 2004 ford f-250,6.0 diesel in may 2010 with 160k miles on it because lots of people told me to buy a diesel it would give me better performance than gas. I have had nothing but troubles ever since. It started not starting about 2 weeks after I bought it. The ford house is no help at all. Ive had it there several times and all it done was cost me money. It has never stopped running driving down the road like the other complaints iv'e read. But it has left me stranded 50 or 75 times, sometimes it will run perfect for months and all at once it wont start. Showing no codes ford says they cant do a thing. In july last summer it did it 1500 miles from home on vacation. I had a wrecker take it to a shop and $7500.00 and 6 weeks later they had put a new engine in it (said the camshaft broke and scored the piston wall) I came home now 6 months later its doing it again. I cant afford to take it to ford, I cant trade it. What to do??

Filed Oct 21, 2010 · Engine · 3,000 miles · SD

Tl* the contact owns a 2004 ford f-250 super duty. The contact stated that the turbo component of the diesel engine failed. The component was replaced by an authorized dealer. In addition, the contact stated that the engine would exhibit an unusual increase in rpms yet there was no power to the engine. The vehicle was taken back to the dealer where the egr valve was repaired. The contact then noticed a massive oil leak and the dealer replaced the injector control press. The contact continued to notice a lack of power and the vehicle would sporadically stall without warning. The dealer inspected the vehicle and replaced the egr cooler and oil cooler. The manufacturer offered no assistance. The failure mileage was approximately 3,000 and the current mileage was 53,183.

Filed Aug 20, 2010 · Engine · 63,000 miles · SC

Our family was traveling to the beach on a very busy interstate when our 2004 ford f250 diesel, pulling a 35 foot rv, started running hot. I pulled over in the emergency lane to investigate. Let the truck idle and cool for a bit, returned to the interstate to try and get to the next exit for a less dangerous place to work on it. It continued to run hot and upon exiting the interstate on the down ramp the vehicle shutoff, with no power brakes to stop the truck and camper, I was unable to stop the vehicle at the stop sign and blew through it. Thank goodness nothing was coming. Turns out all the water was gone, due to either a blown head gasket or egr oil cooler failure and the motor overheated and ruined. Ford wants to replace the engine for $17,500. The truck has 63,000 miles on it and is just out of warranty. This is a known engine failure problem for ford yet they do not stand behind the problem. If I had known they were having problems I would have had mine fixed or replaced prior to having to pay thousands of dollars to replace the motor. I paid $50,000 for a truck with a premium to get a diesel that is suppose to last forever, and it does not even last more than 63,000 miles. Thousands of people have had to face this problem, and have had to spend thousands of dollars to fix it. All you have to do is search blown head gaskets ford f250 on google to find thousands of people with this problem. The extremely hot exhaust gases get recirculation into the intake manifold, but first it has to be cooled. When the cooler fails, all the water from your engine goes out the exhaust, through the turbo (bye bye turbo), then you are pumping extremely hot gases back into the intake manifold which boils the water, creating extremely high pressures, which lifts the heads and blows the head gaskets. What kind of stupid design is that? Now I have to pay for all of those design problems? I now have a $50,000 boat anchor, which is not worth repair. Help please!!!!!!

Filed Apr 23, 2010 · Body, Electrical · TX

Letter from congressman smith's office on behalf of constituent regarding ongoing issues with his 2004 f250 vehicle *tgw the consumer stated the vehicle was running rough, there was a severe rattle in the doors, black smoke emitted from the vehicle, the front end was loose, the battery was replaced twice, there was a problem with the steering, transmission and electrical system, the engine light illuminated and ultimately the engine was replaced because it blew a hole through one of the cylinders. *jb updated 05/03/10.

Filed Oct 12, 2009 · Engine · 53,163 miles · LA

2004 ford 6.0 liter diesel motor- egr cooler cracking and thus causing coolant leaks into the exhaust system and engine cylinders. Egr cooler failure causes coolant to enter engine cylinders thus increasing cylinder pressures on heads. Head bolts stretch and head gaskets fail. Water in cylinder leads to major engine failure. 1000's of ford 6.0 liter diesel owners have the same problem. Dealers repair them constantly. Ford dealer parts dept states that they have parts in stock because they change them out on a daily basis. My vehicle was 2 months out of warranty when part failed at 53,163 miles. Egr cooler cracked, leaked out coolant in the exhaust and into the motor, thus motor failed. Dealer says need new motor at $10,000. Ford needs to recall the older egr cooler component. Currently when they change them out under warranty, they replace it with a new and improved egr cooler. If it is new and improved, why isn't the old one recalled if they know it is a bad design?

Filed Sep 13, 2006 · Electrical · 89,450 miles · MO

The computer (PCM) shuts the truck down, kills the engine and everything associated with it (power steering,brakes,ect.). At 4735 miles the computer was reprogrammed due to truck not able to run. At 51,698 performed recall 05s34 fic module wiring harness repair. At 57,377 miles the truck shut down turning through an intersection leaving the truck in the path of traffic. The dealership was unable to communicate with the computer at all. Dealership replaces and reprograms PCM. At 57,398 miles the truck shut down again fully loaded with trailer running 65 MPH. Barely got truck to side of road and stopped safely due to no power brakes or steering. Dealership replaced fuse box assy. At 57,399 miles the truck started missing, dealership replaced engine loom. At or around 89,450 miles the truck shut down running 70 MPH on highway was almost unable to safely get truck to side of roadway. Dealership replaced PCM again and reprogrammed. Truck did not run long enough to go on a road test before shutting down again. Dealership replaced injector loom of wire harness. Each time I was towed after a shut down we had to make extra accommodations for our pets and other passengers with us. We feel we were extremely lucky this last time not to have been in an accident injuring other people as well as ourselves.