2004 Ford F-350 engine problems

ENGINE

While driving at 40-50 MPH the vehicle will lose power and then then stalls while moving leading to loss of power. The loss power of affects the power steering posing a direct threat for an auto collision due to the difficult in steering the moving vehicle into an emergency lane. Avoided several accidents with this truck. Once it is stalled it can take numerous times to restart the vehicle. This issue seems to occur more on slopes going up hill. This does not seem to occur as often going downhill or on areas with no incline. Currently vehicle has 126,931.8 miles on it. Regularly serviced and otherwise running fine.

NHTSA complaint #11462676 — an unverified report by a vehicle owner.

ENGINE

MY TRUCK HAS MAJOR ENGINE DAMAGE BOUGHT IT AND THREE DAYS LATER THE EGR WENT OUT THEN NEXT THING YOU KNOW I GOT A BLOWN MOTOR

NHTSA complaint #11365419 — an unverified report by a vehicle owner.

ENGINE

TL* THE CONTACT OWNS A 2004 FORD F-350. WHILE DRIVING VARIOUS SPEEDS, THE VEHICLE SUDDENLY SHUT OFF. ALSO, WHILE IDLING, THE ENGINE RPMS REMAINED VERY HIGH AND THE VEHICLE WOULD ATTEMPT TO SURGE FORWARD. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC WHO REPLACED THE ICP SENSOR AND INJECTOR CONTROL SENSOR, BUT THE FAILURES CONTINUED. THE MANUFACTURER AND LOCAL DEALER WERE NOT NOTIFIED OF THE FAILURES. THE FAILURE MILEAGE WAS 200,000.

NHTSA complaint #11203466 — an unverified report by a vehicle owner.

ENGINE

TL* THE CONTACT OWNS A 2004 FORD F-350. WHILE DRIVING APPROXIMATELY 20 MPH, THE VEHICLE STALLED WITHOUT WARNING. THE CONTACT COASTED THE VEHICLE TO THE SHOULDER TO A COMPLETE STOP. THE VEHICLE WAS STARTED NORMALLY, BUT STALLED AGAIN THE SAME AFTERNOON. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE VIN WAS EXCLUDED FROM NHTSA CAMPAIGN NUMBER: 05V270000 (ENGINE). THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 133,307.

NHTSA complaint #10971851 — an unverified report by a vehicle owner.

ENGINE

TL*THE CONTACT OWNS A 2004 FORD F-350. THE CONTACT STATED THAT WHILE DRIVING AT APPROXIMATELY 55 MPH, THE VEHICLE STALLED. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC, WHO DISCOVERED THAT OIL WAS LEAKING FROM THE HEAD GASKET. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE WAS 210,000.

NHTSA complaint #10682591 — an unverified report by a vehicle owner.

ENGINE

TL* THE CONTACT OWNS A 2004 FORD F-350. THE CONTACT STATED THAT WHILE DRIVING AT APPROXIMATELY 15 MPH, THE VEHICLE STALLED WITHOUT WARNING. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE WAS 37,237.

NHTSA complaint #10654705 — an unverified report by a vehicle owner.

ENGINE

MY VEHICLE HAS BEEN BUCKING AND JERKING INTERMITTENTLY SINCE WAY BEFORE ABOVE.DATE IT STOPPED RUNNING AT A STOP SIGN THEN BUCKED AND JERKED SO IN 2013 IT GOT SO BAD THAT I FINALLY HAD IT CHECKED OUT. I THOUGHT IT WAS TRANSMISSION, HAD IT CHECKED AND WAS REFERRED TO LOCAL MECHANIC WHO WAS ACQUAINTED WITH THE PROBLEM AND HAS WORKED ON SEVERAL TRUCKS WITH THE 6.0 DIESEL ENGINE. HE SAID FOR $1200 YOU MIGHT REPAIR IT, NO GUARANTEES. HE SAID IT HAD TO DO WITH THE ELECTRONIC ACCELERATOR. I DIDN'T HAVE IT REPAIRED. IN AUGUST 2014 IT STOPPED AND JERKED AT STOPS SIGN MORE THAN ONCE. I TOOK IT TO THE SAME MECHANIC AND HE REPLACED A SENSOR LOCATED UNDER THE TURBO, FOR $600, AND THAT SOLVED THAT PROBLEM. IN OCTOBER 2014 I WAS TOWING A TRAILER AND THE TRUCK WOULD NOT SHIFT INTO 4TH GEAR. I STOPPED AND RESTARTED THE ENGINE AND IT WENT BACK TO NORMAL OPERATION, BUT IT STILL BUCKS AND JERKS TODAY I CALLED MY LOCAL FORD DEALER AND HE SAID THAT HE HAS NO RECALLS FOR MY VIN NUMBER. I ONLY DRIVE IT OCCASIONALLY. IT HAS 59,000 MILES ON IT NOW.

NHTSA complaint #10654220 — an unverified report by a vehicle owner.

ENGINE AND ENGINE COOLING:EXHAUST SYSTEM

TL* THE CONTACT OWNS A 2004 FORD F-350. THE CONTACT STATED THE EXHAUST SYSTEM WARNING LIGHT ILLUMINATED AND THE ENGINE LOSS POWER. THE VEHICLE RESTARTED. THE CONTACT MENTIONED THAT THE FAILURE RECURRED ON SEVERAL OCCASIONS. THE CONTACT REFERENCED NHTSA CAMPAIGN NUMBER: 07V139000 (POWER TRAIN). THE VEHICLE WAS TAKEN TO A DEALER. THE TECHNICIAN DIAGNOSED THAT THE EXHAUST SENSOR NEEDED TO BE REPLACED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS UNKNOWN.

NHTSA complaint #10643651 — an unverified report by a vehicle owner.

ENGINE

CAM POSITION SENSOR FAILURE, VEHICLE WILL NOT START, FOUND COOLANT IN OIL ON REPAIR.

NHTSA complaint #10640830 — an unverified report by a vehicle owner.

ENGINE

CRACKED HEAD, RESULTING IN COOLANT IN ENGINE OIL, HARD STARTING OR FAILURE TO START.

NHTSA complaint #10640833 — an unverified report by a vehicle owner.

ENGINE

VEHICLE HARD STARTING CAUSED BY FAILURE OF HIGH PRESSURE OIL PUMP, REPLACED ICP REGULATOR, REPLACED EGR VALVE AND INTAKE GASKETS.

NHTSA complaint #10640835 — an unverified report by a vehicle owner.

ENGINE

CHECK ENGINE LIGHT/NO POWER/HARD STARTING- REPLACED EXHAUST BACK PRESSURE SENSOR- VEHICLE FAILURE OF AMBULANCE RESPONDING TO A CALL.

NHTSA complaint #10640854 — an unverified report by a vehicle owner.

ENGINE

WHILE DRIVING VEHICLE HAS INTERMITTENT LOSS OF POWER, DIAGNOSED AND SERVICED EGR VALVE, REPLACED EGR THROTTLE VALVE AND SEALED THE BOOST INLET TUBE.

NHTSA complaint #10640860 — an unverified report by a vehicle owner.

ENGINE

VEHICLE WILL NOT START, CRANKS BUT DOES NOT START. DIAGNOSED AND REPLACED CAM POSITION SENSOR.

NHTSA complaint #10640863 — an unverified report by a vehicle owner.

ENGINE

TL* THE CONTACT OWNS A 2004 FORD F-350. THE CONTACT STATED WHILE DRIVING VARIOUS SPEEDS THE VEHICLE WOULD SUDDENLY HESITATE AND THE SPEED WOULD DECELERATE. THE VEHICLE WAS TAKEN TO THE DEALER WHO DIAGNOSED THAT THE INJECTOR CONTROL PRESSURE SENSOR WAS FAULTY. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE WAS 100,000.

NHTSA complaint #10598607 — an unverified report by a vehicle owner.

ENGINE

TL* THE CONTACT OWNS A 2004 FORD F-350. THE CONTACT STATED THAT THE VEHICLE STALLED WITHOUT WARNING WHILE DRIVING 65 MPH. THE VEHICLE WAS TOWED TO THE CONTACT'S RESIDENCE WHERE AN INDEPENDENT MECHANIC PERFORMED A DIAGNOSTIC. THE FAILURE WAS LOCATED AT THE FUEL INJECTION PRESSURE SENSOR. THE MANUFACTURER WAS CONTACTED AND ADVISED THAT THE VIN WAS NOT INCLUDED IN NHTSA CAMPAIGN NUMBER 05V270000 (ELECTRICAL SYSTEM). THE VEHICLE WAS NOT REPAIRED. THE APPROXIMATE FAILURE AND CURRENT MILEAGE WAS 85,000.

NHTSA complaint #10524196 — an unverified report by a vehicle owner.

ENGINE AND ENGINE COOLING:ENGINE:DIESEL

TL* THE CONTACT OWNS A 2004 FORD F-350. THE CONTACT STATED THAT COOLANT WAS OBSERVED LEAKING FROM THE VEHICLE. THE VEHICLE WAS TAKEN TO THE DEALER WHERE THE DEALER CONFIRMED THAT THE HEAD GASKET NEEDED TO BE REPLACED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE VEHICLE WAS NOT REPAIRED. THE FAILURE MILEAGE WAS 60,000 AND THE CURRENT MILEAGE IS 73,047. ..UPDATED 04/19/12 *BF UPDATED 04/25/12

NHTSA complaint #10452685 — an unverified report by a vehicle owner.

ENGINE AND ENGINE COOLING

TL* THE CONTACT OWNS A 2004 FORD F-350. THE CONTACT STATED THAT THE VEHICLE ENGINE FAILED. THE ENGINE BLOCK WAS CORRODED DUE TO DEFECTIVE MATERIAL AND LEAKED CAUSED COOLANT TO LEAK. THE VEHICLE WAS TAKEN TO THE DEALER WHO ADVISED THE CONTACT THAT THE ENGINE WOULD NEED TO BE REPLACED. THE MANUFACTURER DENIED ASSISTANCE WITH THE REPAIRS, STATING THAT THE WARRANTY WAS EXPIRED. THE VEHICLE WAS NOT REPAIRED. THE FAILURE AND THE CURRENT MILEAGE WAS 26,000.

NHTSA complaint #10446359 — an unverified report by a vehicle owner.

ENGINE AND ENGINE COOLING

MY 2004 FORD F-350 6.0 DIESEL. HESITATE OR SURGES WHILE DRIVING, AND/OR THE ENGINE MAY STALL WHILE DRIVING AT ALL SPEEDS INCLUDING HIGHWAY SPEED, WILL LOSE POWER STEERING AND BRAKES AND WHEN AT A STOP IT WILL LUNGE FORWARD. THE ENGINE MAY OR MAY NOT RESTART AFTER STALL. I FEEL THAT THIS IS A GREAT SAFETY CONCERN I HAVE ALMOST LOST CONTROL OF MY VEHICLE ON A FEW OCCASIONS WHILE TOWING MY BOAT AND GOING AROUND CORNERS. I HAVE HEARD OF OTHER PEOPLE HAVING THE SAME PROBLEMS WITH THEIR 2004 6.0 DIESELS. PLEASE HELP!

NHTSA complaint #10445520 — an unverified report by a vehicle owner.

ENGINE AND ENGINE COOLING

TL* THE CONTACT OWNS A 2004 FORD F-350. THE CONTACT STATED THAT WHILE DRIVING 45 MPH, THE VEHICLE DECELERATED TO APPROXIMATELY 5 MPH AND THE LIMP HOME MODE MESSAGE APPEARED ON THE INSTRUMENT PANEL. THE VEHICLE WAS SAFELY DRIVEN TO AN AUTHORIZED DEALER, WHERE THE CONTACT WAS INFORMED THAT THE EGR AND OIL COOLERS NEEDED TO BE REPLACED. THE CONTACT WAS ALSO INFORMED THAT THE FAILURE WAS COMMON. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE, BUT OFFERED NO ASSISTANCE. THE FAILURE MILEAGE WAS 72,000.

NHTSA complaint #10432555 — an unverified report by a vehicle owner.

ENGINE AND ENGINE COOLING

LOSS OF COOLANT, WHITE SMOKE EXITING OUT OF EXHAUST. ENGINE OVER HEATING. CAN LEAD TO BLOWN HEAD GASKETS.

NHTSA complaint #10430818 — an unverified report by a vehicle owner.

ENGINE AND ENGINE COOLING

TL* THE CONTACT OWNS A 2004 FORD F-350. THE CONTACT STATED THE CHECK ENGINE LIGHT ILLUMINATED ON THE INSTRUMENT PANEL AND THE VEHICLE BEGAN TO FUNCTION WITH DIFFICULTY. THE VEHICLE WAS TAKEN TO THE DEALER AND THE GRV VALVE, OIL COOLER AND THE TURBO HAD TO BE DISASSEMBLED AND REBUILT. THE DEALER STATED THE HOSES WERE TOO SMALL TO CONTROL THE OIL FLOW AND THAT WAS WHY IT HAD TO BE REBUILT. THE DEALER STATED THE VEHICLE WAS DESIGNED BY MANUFACTURER IN THAT WAY. THE VIN WAS NOT AVAILABLE. THE FAILURE MILEAGE WAS 80,000 AND THE CURRENT MILEAGE WAS 85,000.

NHTSA complaint #10430638 — an unverified report by a vehicle owner.

ENGINE AND ENGINE COOLING:ENGINE

OWN A 2004 FORD F-350 SD. FOR YEARS HAVE HAD SURGING PROBLEMS WHEN DRIVING. HAVE TAKEN INTO SHOP AND THEY CANNOT DETERMINE REASON. IT HAPPENS WHILE STOPPED OR DRIVING, SURGING AND TRYING TO JUMP BECAUSE OF THE SURGE. TURBO CHARGER HAS NOT BEEN REPLACED.

NHTSA complaint #10402042 — an unverified report by a vehicle owner.

ENGINE AND ENGINE COOLING

TL* THE CONTACT OWNS A 2004 FORD F-350. THE CONTACT WAS DRIVING APPROXIMATELY 50 MPH WHEN THE VEHICLE SUDDENLY STALLED WITHOUT WARNING. THE VEHICLE WAS ABLE TO BE RESTARTED AND WAS TAKEN TO THE DEALER. THE VEHICLE WAS DIAGNOSED AS THE FICM WIRING HARNESS NEEDING REPLACEMENT. THE DEALER ADVISED THAT THE FAILURE OF THE FICM WIRING HARNESS CAUSED THE FUEL PUMP AND INJECTOR TO FAIL. THE VEHICLE WAS REPAIRED. THE MANUFACTURED WAS CONTACTED AND OFFERED NO ASSISTANCE. THE FAILURE MILEAGE WAS APPROXIMATELY 98,800.

NHTSA complaint #10384491 — an unverified report by a vehicle owner.

ENGINE AND ENGINE COOLING

TL* THE CONTACT OWNS A 2004 FORD F350. THE CONTACT WAS DRIVING AT APPROXIMATELY 40 MPH WHEN THE VEHICLE SUDDENLY BEGAN TO SHAKE AND JERK FORWARD. THE VEHICLE WAS TAKEN TO A LOCAL MECHANIC WHO INFORMED THE CONTACT THAT THE EGR COOLER AND THREE FUEL INJECTORS WERE THE CAUSE FOR THE FAILURE. THE VEHICLE WAS REPAIRED AT THAT TIME. LATER, THE HIGH OIL PRESSURE PUMP AND OIL COOLER FAILED. THE VEHICLE WAS AWAITING FURTHER REPAIRS AT THE TIME OF THE COMPLAINT. THE CONTACT CALLED THE MANUFACTURER BUT WAS TOLD THAT SHE WOULD HAVE TO ASSUME ALL REPAIR COSTS AT HER EXPENSE. THE FAILURE MILEAGE APPROXIMATELY WAS 121,000. THE CURRENT MILEAGE WAS APPROXIMATELY 130,000.

NHTSA complaint #10322358 — an unverified report by a vehicle owner.

ENGINE AND ENGINE COOLING:ENGINE

SINCE NEW VEHICLE PURCHASE, MY FORD F350 DIESEL P/U EXPERIENCED ENGINE SURGING (200-250 RPM) WHILE STOPPED WITH THE AUTOMATIC TRANSMISSION IN DRIVE. THE SURGE WAS SIGNIFICANT ENOUGH TO LURCH THE TRUCK FORWARD WITH THE BRAKE APPLIED, SUCH AS AT A STOPLIGHT. IN SEVERAL CASES, I ALMOST REAR ENDED OTHER VEHICLES BEFORE APPLYING THE BRAKE HARD ENOUGH TO STOP THE TRUCK FROM MOVING FORWARD. I LATER LEARNED TO ANTICIPATE THE SURGE USING THE BRAKES TO MINIMIZE MOVEMENT OF THE TRUCK WHILE STOPPED. MY SURGING PROBLEM WAS CONFIRMED ON MULTIPLE OCCASIONS BY TECHNICIANS DURING TEST RIDES, BUT THEY COULD NOT DUPLICATE THE PROBLEM IN THE SHOP. IN ALL CASES, THE FIRST STEP WAS TO REFLASH THE ECM WHICH MASKED THE PROBLEM FOR SEVERAL DAYS WHILE THE TRUCK RELEARNED MY DRIVING HABITS AND PREVENTED A DIAGNOSIS. THE ENGINE HAD TO BE OPERATED AT FULL TEMPERATURE IN ROAD CONDITIONS BEFORE THE PROBLEM DEVELOPED. IN THE SHOP, IDLING THE ENGINE TO WARM UP TO NORMAL OPERATING TEMPERATURE WAS NOT SUFFICIENT TO REPLICATE THE PROBLEM. FORD DEALERS MADE MULTIPLE ATTEMPTS (10 OR MORE) TO DIAGNOSE THE PROBLEM: REPLACING INJECTOR CONTROL PRESSURE (ICP) MODULE, EGR VALVE, AND ICP WIRING CONNECTORS TO NO AVAIL. THE PROBLEM WAS FINALLY DIAGNOSED AND CORRECTED, OUT OF WARRANTY AT APPROX. 44,500 MILES, BY REPLACING THE ENGINE WIRING HARNESS. I FOUND A DEALER WHO WAS WILLING TO SEND A TECHNICIAN ON A TEST RIDE WITH ME AND HOOK UP AN ONBOARD COMPUTER LAPTOP THAT IDENTIFIED THE PROBLEM BEFORE REFLASHING THE COMPUTER ECM. A NUMBER OF SURGING COMPLAINTS FROM OTHER OWNERS OF FORD F350 ARE POSTED IN ONLINE FORUMS DOCUMENTING SIMILAR CIRCUMSTANCES AND FRUSTRATION. THE INCIDENT DATE PROVIDED IS THE APPROXIMATE DATE OF THE FIRST OCCURRENCE. IN MY CASE, THE SURGING OCCURRED ON A NEAR DAILY BASIS, ALTHOUGH INTERMITTENTLY, FOR 41000 MILES OF DRIVING WITHOUT ANY RESOLUTION FROM FORD. THE ENGINE WIRING HARNESS WAS REPLACED IN FEB 2009 WHICH CORRECTED THE SURGING IN MY TRUCK. I PAID A $100 DEDUCTIBLE.

NHTSA complaint #10314198 — an unverified report by a vehicle owner.

ENGINE AND ENGINE COOLING:EXHAUST SYSTEM

2004 F350 DIESEL 6.0 ,EGR COOLER WENT OUT. I WAS IN THE MIDDLE OF THE HWY WHEN THIS OCCURED. CLOUDS OF SMOKE WENT OUT THE TAILPIPE, ENGINE OVERHEATING STRANDING ME IN THE CENTER LANE STOPPED BEFORE I COULD GET OVER TO THE SHOULDER. PASSERBY'S HELP ME PUSH MY TRUCK OFF A BUSY HWY. SMOKE WAS SO THICK I COULDNT NOR COULD OTHER DRIVERS SEE AROUND ME. FORD HAS HAD NUMEROUS COMPLAINTS ON THIS ENGINE AND PART,BUT HAVE FAILED TO RESPOND,OR THEY WAITING FOR A DEATH TO OCCUR. THE INTERNET IS FULL OF COMPLAINTS FOR THE EXACT SAME THING. LETTERS TO FORD MOTOR CO. AND MY LOCAL DEALER LEIF JOHNSON FORD WERE UNSUCCESSFUL. I'M NOT ABLE TO PAY THE ALMOST $3000 THE DEALER WANTS TO FIX THE PROBLEM. THIS IS AN OBVIOUS DEFECT ON FORD'S PART. VERY FUSTRATED AS I HAVE A EXPENSIVE TRUCK JUST PARKED FOR SEVERAL MONTHS IN MY DRIVEWAY. UPDATED 2/17/10 *CN UPDATED 02/22/10

NHTSA complaint #10299874 — an unverified report by a vehicle owner.

ENGINE AND ENGINE COOLING:ENGINE:DIESEL

2004 F350 DIESEL 6.0 ,EGR COOLER WENT OUT. I WAS IN THE MIDDLE OF THE HWY WHEN THIS OCCURED. CLOUDS OF SMOKE WENT OUT THE TAILPIPE, ENGINE OVERHEATING STRANDING ME IN THE CENTER LANE STOPPED BEFORE I COULD GET OVER TO THE SHOULDER. PASSERBY'S HELP ME PUSH MY TRUCK OFF A BUSY HWY. SMOKE WAS SO THICK I COULDNT NOR COULD OTHER DRIVERS SEE AROUND ME. FORD HAS HAD NUMEROUS COMPLAINTS ON THIS ENGINE AND PART,BUT HAVE FAILED TO RESPOND,OR THEY WAITING FOR A DEATH TO OCCUR. THE INTERNET IS FULL OF COMPLAINTS FOR THE EXACT SAME THING. LETTERS TO FORD MOTOR CO. AND MY LOCAL DEALER LEIF JOHNSON FORD WERE UNSUCCESSFUL. I'M NOT ABLE TO PAY THE ALMOST $3000 THE DEALER WANTS TO FIX THE PROBLEM. THIS IS AN OBVIOUS DEFECT ON FORD'S PART. VERY FUSTRATED AS I HAVE A EXPENSIVE TRUCK JUST PARKED FOR SEVERAL MONTHS IN MY DRIVEWAY. UPDATED 2/17/10 *CN UPDATED 02/22/10

NHTSA complaint #10299874 — an unverified report by a vehicle owner.

ENGINE AND ENGINE COOLING

2004 F350 6.0 POWERSTROKE BOGGS WHEN TAKING OFF. SOMETIMES WILL ACT LIKE YOU TURNED OFF SWITCH WHEN YOU PUSH DOWN THE PEDAL THERE IS NO EFFECT. MOSTLY WHEN DRIVING UP THE MOUNTAIN ITS LIKE IT DON'T GO PAST IDLE HAS NOT STALLED YET. 8 INJECTORS REPLACED FRONT AND REAR INJECTOR HARNESS REPLACED HIGH PRESSURE PUMP FUEL MILEAGE 13 MPG. HEAD GASKETS REPLACED EGR COOLER REAR MAIN SEAL ALL UNDER 65,000 MILES.

NHTSA complaint #10268988 — an unverified report by a vehicle owner.