I have a 2004 ford f250 super duty with a 6.0 diesel. The egr cooler was replace twice under warranty and with the truck now out of warranty with 111,000 miles on it, the egr cooler went out once more and ford would not help me out on the repair so I had to pay for it myself. There is a huge problem with the 2003 through 2005 6.0 diesel. It has happened to thousands of owner. Owners of these vehicles are being forced to bypass the egr cooler, there by making it inoperable. This is in violation of epa standards and ford should be forced by the government to recall these vehicles and repair them right. This is not only a fairness issue; it is a clean air safety issue.
2004 Ford F-250 SD engine complaints
Page 3 of 5: complaints 41 to 70 of 114, newest first, as owners wrote them.
Erratic engine RPM stalling as well as sudden acceleration without moving accelerator pedal.
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?
2004 f250 super duty / engine chokes down and sometimes stalls. Happens often, mostly in city traffic. They claim to have replaced sensors and valves; but, the truck has progressively got worse (2-3 times a week).
Tl*the contact owns a 2004 ford f250 super duty. The contact stated that the egr cooler needed to be replaced three times. The vehicle would produce a lot of smoke and fail to accelerate properly once the egr failed. The dealer stated that the manufacturer would not assume liability for the repairs. There was a factory warranty that covered the part for twelve months or 12,000 miles, whichever came first. The failure always occurred outside of the warranty. The VIN was unknown. The failure mileages were 99,000, 114,000 and 130,000. The current mileage was 130,000.
Tl*the contact owns a 2004 ford f-250 sd. While driving approximately 65 MPH, the engine began to rev excessively high. There was no power response when the accelerator pedal was depressed. In addition, the check engine warning light illuminated on the instrument panel and remained lit until the engine was turned off. The driver pulled over to the side of the road and the vehicle restarted. The vehicle was taken to an authorized dealer for diagnostic testing and they stated that the failure was contributed to the turbo and engine sensors. The turbo outlet hose, map sensor, and egr throttle body were replaced under warranty; however, the failures recurred on thirty separate occasions. The vehicle was taken to an authorized dealer and an independent mechanic on three separate occasions, but there were no resolutions. The vehicle has not been repaired. The failure mileage was 77,000 and current mileage was 120,000.
Tl*the contact owns a 2004 ford f250 super duty. The contact stated that the vehicle began to pump out coolant and smoke. The dealer stated that the head gasket needed to be replaced. Upon further investigation, the contact found that this was a common issue with this particular vehicle, and was associated with the bolts used for the head gasket. There were no recalls for the vehicle and the manufacturer had not been notified. The VIN was unknown. The failure and current mileages were less than 140,000.
I have a 2004 f 250 super duty. I experienced a blow out of the spark plug on two occasions. The first I was able to put the plug back in and re-thread the plug. It just recently blew out the second time which will result in a greater repair. I have a mechanic whom I regularly use and he has stated to me that he is aware of no less than twenty five fords that he has personal knowledge or has experienced this problem first hand. This should most certainly be a recall. I was not aware of the potential for an engine fire. At first I believed the noise was probably from a blown exhaust gasket. I would have never imagined that a spark plug would have blown out of my engine let alone have any knowledge or concern that fuel vapor is being openly sprayed into the air. Now I realize that I also placed myself in harms way putting myself under the hood trying to locate the source of the noise. What if that vapor had ignited while I was peeking around in the engine? This is a serious hazard. I don't care what ford says or what silly excuse they can make for this. There is simply no reason why a spark plug should be blowing out of an engine like this. For whatever incoherent reasoning ford can derive it is most certainly irrelevant. What is the difference what causes this problem? What relevance does splitting hairs over this have? None because it is all speculation. The fact is that a very serious and dangerous condition is present as a result of this and the overwhelming evidence suggests it is a design flaw at the liability of ford. Will it take someone to be burned over 80% of their body to come to a conclusion that this should be recalled? Furthermore ford has a poor track record with recalls. I had a 93 f 250 recalled in 2004 for the draining double gas tank problem. For ten years I complained about this and ford finally sent me a notice for a recall in 2004. Was I suppose to recall my truck from the junk yard?.. Its a great disservice to ford customers.
Tl*the contact owns a 2004 ford f250 super duty diesel. The contact stated that the check engine indicator illuminated on the instrument panel. The dealer advised her to immediately bring in the vehicle for repair and they found an oil leak that leaked into the icp sensor. The contact paid over $600 to have the vehicle repaired. The current and failure mileages were less than 47,000. Updated 12/09/09 *bf the dealer informed the consumer that the problem will continue to happen due to a desgin flaw. The flaw was correcte in later models. Updated 12/10/09.
Tl*the contact owns a 2004 ford f250 super duty. While attempting to start the vehicle, it shut off. In addition, the engine shuts off when driving downhill at various speeds. The contact must pull over and restart the vehicle again. He inspected the vehicle himself with a computer diagnostic machine and determined that the camshaft sensor was failing. The vehicle was previously repaired according to a recall for the camshaft sensor. The vehicle was taken to the dealer for inspection, but they refused to inspect or repair the vehicle because the warranty was expired. The contact called the manufacturer and was informed to take the vehicle to the dealer. If the failure was related to the camshaft sensor, they would not cover the cost because the vehicle was already repaired for that failure. Any parts and labor fees would have to be covered by the contact. The federal safety agency campaign id number was unknown. The failure mileage was 143,930 and current mileage was 143,984.
My 2004 ford f-250 5.4l was making a ticking noise for a couple of days then today a big pop and terrible noise from under the hood. I have discovered that it blew a spark plug out of the head. From what I have read this is a common problem with this engine. I am looking at a several thousand dollar repair.
I have a 2004 ford f-250 with a triton 5.4 liter engine. I went out to start the truck and heard a loud boom and then the truck sounded like I had lost the exhaust system. As it turns out the engine pressure blew a spark plug out of the head and also broke the coil pack on top of it. After doing some research on the internet it seems this is a fairly common problem yet ford has not offered to do anything about it blaming it on many issues that simply do not make sense. The government to this point has also not forced a recall on this issue which I find very disheartening as this is a major safety issue. Not everyone driving a truck is a mechanic and may not be aware of the fact that this type of problem could lead to a major fire or explosion in the engine compartment.
I own a 2004 ford f250 sd diesel and on 10/11/08 took a trip to sante fe nm which approx 55 miles and from what they tell me a fuel injector stuck and let fuel into the cyl thus ruining the engine. I believe that this related to the shop replacing the turbo which blew up into pieces and went into the exhaust and possibly into the fuel system jamming up the injector causing the damage. This was the second turbo with in the last 3000 miles. This vehicle has only 35400 miles I feel the engine should be covered by warranty due to miles on vehicle and also the original warranty not even a month past.
Egr cooler has been replaced 4 times in less than 30,000 miles.
For the past 4 months we have had our truck in the shop three times, because of the egr valve. Truck constantly blows out black smoke and has no pick up speed. Still having issues the day after the truck was taken into the shop.
Exhaust manifold bolts broken, leading to carbon monoxide (as well as other exhaust gases) being released into passenger compartment.
Exhaust manifold bolts rusted/corroded & broken off + rust/corrosion related crack in exhaust manifold itself. This is obviously an ongoing problem with no specific date as to when it happened only when it was discovered. I believe this to be an emissions issue.
I have a 2004 f250 diesel. The turbo charger was replaced 6/2007 because it was causing the vehicle to surge while driving. The turbo is again causing the vehicle to surge. This is a serious safety problem.
2004 f250 crew cab diesel 4x4 check engine light cam on at 7,800 mi after truck died when driving took it in they said nothing was wrong, 200 miles later I started loosing power , and stalling kept recurring, they got a code that read internal failure, erratic back pressure in exhaust . They put a new sensor in it made no difference still stalling 20,000 mi took it in again, for stalling , lack of power bad fuel mpg, hesitating on take off . Check engine light on , and a loud clunking in the front passenger side . They put a new sensor in , an no difference at 26,000 they replaced the turbo it ran good for a week or so but fuel mpg never improved and it slowly lost power again , and all the other issues still remain the same. I got under the truck and had to locate the problem and found that the leaf spring was loose and caused the bushings to be destroyed, they wouldn't fix any of it , and I paid for a 2000 extended warranty . Im currently trying to get other owners of the 6.0 diesel motors to get together a file a class action suit .
Vehicle loss of power and whine noise from motor and /or turbo causing truck to have major hesitation and lack of power at freeway and surface street speeds--several time this happens when driving on a regular basis.
2004 king ranch, 6.0 diesel, turbo problems, again. Now truck surges at low speeds, in parking lot and at stop light. If my foot is not on the brake, the truck will move forward! Almost hit a lady in the shopping center parking lot. Serviced for problems 8 times over 36 months. Can't fix?
Engine surges and will increase speed by 700 rpms with no contact to pedal. Taken to dealership several times numerous recalls and repairs to wireharness and erg valve have not cured problem. Vehicle lurched forward while being parked bumper striking light pole minor damage.
I have owned the truck for approx. 9 months, (third owner). While towing my travel trailer or going uphill unloaded, the turbo will howl loudly and the truck will experience a significant power loss (cannot maintain adequate speed above 45 MPH). Also I average only 9 mpg city and 11.9 mpg highway unloaded weight. I have taken the truck to antelope valley ford as well as the previous owner and get the same response, "cannot duplicate. It seems as if ford has instructed their technicians to "cannot duplicate" all complaints in an effort to avoid fixing under warranty.
Tl*the contact owns a 2004 ford f250 super duty. While driving 35 MPH, the vehicle shut down. The vehicle was towed to the dealer and repaired. The dealer stated that the oil pressure tied to fuel injector # 2 was low, which is a common failure. The dealer warned the contact that other injectors may also malfunction. The current mileage is 24,000 and failure mileage was 21,000.
2004 ford f250 sd 6.0l . Engine stalls at highway speeds put doesn't die. In 2005 wiring harness was replaced. In may 2007 took to southern ford in manvel, tx they replaced egr valve & performed software update on ECM. Problem is worse from a stop accelerator will be depressed but truck will move only 3-5 MPH. Pumping the pedal a few times will bring back acceleration. Happens intermittently almost caused accident as I tried to merge into traffic and engine lost power.
2004 ford 6.0 diesel - turbo hose keeps coming off when towing. Have had it in the shop at least a dozen times- hose and clamps have all been replaced at great cost each time - still the same problem - dealer says no other fix available - multiple people with same problem reporting on the internet.
Ford super duty trucks with the 6-liter diesel engine, generally while towing a heavy trailer uphill, experience a high rate of turbo hoses blowing off. This creates a low power situation that leaves the truck without enough power to safely exit the roadway. On two-lane highways this is a serious safety concern. I have this truck, as do three of my acquaintances. Three out of four of us have had this happen. A search of ford warranty repair records will confirm that this is a very common problem. Several acquaintances have had the problem more than once, in spite of ford having done the repairs. The incident below involves a friend, not my own experience. I feel that this is a safety hazard that should be corrected with a recall of affected vehicles.
Tl*- the contact owns a 2004 ford f250 superduty 6.0l. The contact stated that while driving 50 MPH he lost turbo charge trying to accelerate to get onto the freeway. This happened when the vehicle overheated as well. Also, the contact stated that the engine stalled. He had taken the vehicle to the dealership, where they have made repairs 5 times to date. This had been an ongoing problem since the vehicle was purchased. The failure mileage was 15,000, and the current mileage was 23,000.
I have an ongoing problem with my 2004 f250 with the 6.0l powerstroke diesel engine. The vehicle has a problem in the mornings after it has not run for several hours, it smokes, runs rough, and has severe hesitation. Forb has a tsb regarding this issue but they were unable to fix it. The smoking and rough running is merely an inconvenience, but the hesitation is a huge safety concern. The vehicle will operate at idle speeds but once the throttle is depressed the vehicle will not accelerate. This condition can last as long as several minutes. I have had a number of near accidents upon leaving my driveway or parking lots and pulling into traffic. Once in traffic the vehicle wouldn't accelerate. This condition occurs nearly every morning, especially in the winter, and has resulted in a number of near crashes. The tsb states that this is a common problem that mainly occurs after the vehicles have 15000 miles. I first reported my problem to ford at 17,000 miles. I have had the vehicle back to the dealer numerous times and they just don't know what else to do but the dealer admits there is a problem. Feel free to contact me for more questions. The service manager, dean, at rio valley ford has extensive knowledge on my truck also.
Tl*- the contact owns a 2004 ford f-250 super duty and stated that while driving between 40-50 MPH, the vehicle stalled without prior warning. The stalling seemed to occur when the engine had not warmed up completely. He did research online and felt that this vehicle should be covered under recall the federal safety agency campaign id number: 05v270000 concerning electrical system: wiring. He took it to the dealer, and they stated that the vehicle did not fall within the recall due to the VIN. The current and failure mileage were 112000.*ak the consumer stated an accident occurred. The consumer attempted to stoop the vehicle, but the brakes and steering became stiff. Updated 03/07/07.
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