2004 Ford F-250 Sd problems

Verdict · NHTSA data

One of the years to avoid

With 345 complaints filed to NHTSA — about 9.9 times the median F-250 Sd year — the 2004 model ranks #3 of 36 F-250 Sd years for complaint volume. It lands on the years-to-avoid list. Complainants reported 16 injuries in total across these filings.

Engine leads the complaint categories with 121 reports (35% of the total).

345

NHTSA complaints

Recalls

Investigations

Crash-involved

Fires reported

Injuries

Deaths

—

NCAP overall

How does 2004 compare to other F-250 Sd years?

F-250 Sd NHTSA complaints by model year, 2004 highlighted. Red bars are years to avoid.

See all F-250 Sd years to avoid →

What are the most common 2004 Ford F-250 Sd problems?

Component	Complaints	Share	vs prior year
Engine	121	35%	▲ up
Electrical System	62	18%	▲ up
Fuel System	38	11%	▲ up
Transmission	22	6%	— flat
Tires & Wheels	20	6%	— flat
Speed Control	17	5%	▲ up
Suspension	17	5%	▲ up
Steering	15	4%	— flat
Brakes	8	2%	▼ down
Body & Structure	7	2%	▲ up
Other	6	2%	▼ down
Airbags	5	1%	▲ up
Visibility & Wipers	2	1%	▲ up
Lighting	2	1%	— flat
Seat Belts	2	1%	▼ down
Seats	1	0%	— flat

Does the 2004 Ford F-250 Sd have recalls?

4 NHTSA recall campaigns on file. Recall repairs are free at franchised dealers.

11V352000LightingJuly 13, 2011 · 26,715 units

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) THAT MAY EXPERIENCE DEFORMATION. A MULTI-FUNCTION SWITCH WITH A DEFORMED SLIDER MAY MALFUNCTION CAUSING THE TURN SIGNAL, TAIL LIGHTS, HAZARD WARNING SIGNAL FLASHERS AND/OR BRAKE LIGHTS NOT TO ACTIVATE.

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.

07E106000Tires & WheelsDecember 17, 2007 · 130,000 units

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.

06E026000LightingMarch 23, 2006 · 61,944 units

Defect

CERTAIN PRO-A MOTORS CORNER LAMPS, TURN SIGNALS, AND HEADLIGHTS SOLD AS REPLACEMENT LAMPS FOR USE ON CERTAIN PASSENGER VEHICLES LISTED ABOVE. SOME COMBINATION LAMPS THAT ARE NOT EQUIPPED WITH AMBER SIDE REFLECTORS FAIL TO CONFORM TO FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 108, LAMPS, REFLECTIVE DEVICES, AND ASSOCIATED EQUIPMENT.

Consequence

WITHOUT THE AMBER REFLECTORS, THE VEHICLE WILL BE POORLY ILLUMINATED, POSSIBLY RESULTING IN A VEHICLE CRASH WITHOUT WARNING.

Remedy

PRO-A MOTORS WILL NOTIFY OWNERS AND OFFER TO REPURCHASE THE LAMPS. THE RECALL BEGAN ON APRIL 3, 2006. OWNERS MAY CONTACT PRO-A MOTORS AT 323-838-2988.

05V270000Electrical SystemJune 10, 2005 · 180,104 units

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.

Consumer complaints filed with NHTSA

Representative excerpts, cleaned of personal information. These are consumer statements, not verified defects.

“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. *TR”
Complaint filed with NHTSA · Engine · August 24, 2007 · crash

“THE CONSUMERS VEHICLE WAS NOT INCLUDED IN THE RECALL REGARDING THE BATTERY CABLE AND SUBSEQUENTLY THE VEHICLE CAUGHT FIRE. THE VEHICLE PROCEEDED TO BURN EVEN WHEN EXTINGUISHED WITH A FIRE EXTINGUISHER. THE CONSUMER WAS TOLD BY THE MANUFACTURE THE BATTERY CABLE RECALL DID NOT INCLUDE HIS VEHICLE.…”
Complaint filed with NHTSA · Electrical System · December 20, 2004 · fire

“THE ENGINE STALLS WITHOUT WARNING WHILE DRIVING. THERE IS ALREADY A RECALL BUT IT DID NOT INCLUDE MY VEHICLE. NHTSA CAMPAIGN ID NUMBER 05V270000 NHTSA ACTION NUMBER EA05003. THE PROBLEM WITH MY VEHICLE IS IDENTICAL TO THIS AND THE REMEDY WAS IDENTICAL HOWEVER, IT COST ME $350.00 BECAUSE MY VEHICLE…”
Complaint filed with NHTSA · Fuel System · June 24, 2010

“DT*: THE CONTACT STATED TWICE THE VEHICLE JUMPED INTO FOUR-WHEEL DRIVE ON ITS OWN CAUSING THE VEHICLE TO LOCK UP. WHEN THIS OCCURRED, THE STEERING WAS VERY DIFFICULT TO PUT INTO GEAR. THE FIRST TIME THIS OCCURRED, THE DEALERSHIP INSTALLED A VACUUM PUMP ASSEMBLY. THE SECOND TIME, THE DEALERSHIP…”
Complaint filed with NHTSA · Transmission · September 5, 2006

“DRIVING ON SH 239 IN REFUGIO COUNTY, TEXAS AT APPROX. 70 MPH BETWEEN TIVOLI, TX AND US HIGHWAY 77 SOUTH. RIGHT FRONT TIRE BLEW OUT WHICH IMMEDIATELY CAUSED THE TRUCK TO VEER OFF THE RIGHT SIDE OF THE HIGHWAY, OVER A METAL CULVERT, GO AIRBORNE THROUGH A BARBED WIRE FENCE AT THE CORNER POSTS, LAND IN…”
Complaint filed with NHTSA · Tires & Wheels · August 7, 2014 · crash

2004 Ford F-250 Sd — common questions

Is the 2004 Ford F-250 Sd reliable?

NHTSA data argues against it: 345 complaints put the 2004 model at #3 of 36 F-250 Sd years. It is one of the F-250 Sd years to avoid.

What are the most common 2004 F-250 Sd problems?

According to NHTSA complaint data, the leading problem areas are engine (121 complaints), electrical system (62 complaints), fuel system (38 complaints).

Does the 2004 Ford F-250 Sd have recalls?

Yes — NHTSA lists 4 recall campaigns affecting the 2004 Ford F-250 Sd. Recall repairs are free at franchised dealers; check the VIN at nhtsa.gov/recalls to confirm the work was done.

Is the 2004 Ford F-250 Sd under NHTSA investigation?

NHTSA opened 3 investigations into this model year; all are now closed.

Which Ford F-250 Sd years should you avoid?

Based on complaint rates and open investigations, the F-250 Sd years to avoid are 2005, 2006, 2004, 2001, 1999, 2002, 2000, 2003, 2011, 2008, 2017, 2012, 2007, 2023, 2015, 2018, 2016, 2019, 2020, 2021. The cleanest record among F-250 Sd years belongs to 1998.

Based on NHTSA ODI data through June 2026. Complaints are consumer-reported and unverified. Updated July 5, 2026.

Compiled by Sharon Ben-Moshe, Founder.

How does 2004 compare to other F-250 Sd years?

What are the most common 2004 Ford F-250 Sd problems?

Does the 2004 Ford F-250 Sd have recalls?

Consumer complaints filed with NHTSA

2004 Ford F-250 Sd — common questions

Is the 2004 Ford F-250 Sd reliable?

What are the most common 2004 F-250 Sd problems?

Does the 2004 Ford F-250 Sd have recalls?

Is the 2004 Ford F-250 Sd under NHTSA investigation?

Which Ford F-250 Sd years should you avoid?

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