VehicleVerdict

2004 Ford F-550 Sd problems

Verdict · NHTSA data

One of the years to avoid

With 67 complaints filed to NHTSA — about 13.4 times the median F-550 Sd year — the 2004 model ranks #3 of 34 F-550 Sd years for complaint volume. It lands on the years-to-avoid list.

Fuel System leads the complaint categories with 26 reports (39% of the total).

67

NHTSA complaints

3

Recalls

1

Investigations

1

Crash-involved

5

Fires reported

4

Injuries

0

Deaths

—

NCAP overall

How does 2004 compare to other F-550 Sd years?

F-550 Sd NHTSA complaints by model year, 2004 highlighted92 complaints1993: 0 complaints1994: 0 complaints1995: 0 complaints1996: 0 complaints1997: 2 complaints1998: 0 complaints1999: 92 complaints2000: 85 complaints2001: 35 complaints2002: 31 complaints2003: 40 complaints2004: 67 complaints2005: 41 complaints2006: 55 complaints2007: 25 complaints2008: 31 complaints2009: 1 complaints2010: 2 complaints2011: 4 complaints2012: 8 complaints2013: 3 complaints2014: 10 complaints2015: 18 complaints2016: 4 complaints2017: 5 complaints2018: 0 complaints2019: 4 complaints2020: 7 complaints2021: 15 complaints2022: 15 complaints2023: 1 complaints2024: 5 complaints2025: 3 complaints2026: 3 complaints
F-550 Sd NHTSA complaints by model year, 2004 highlighted. Red bars are years to avoid.

See all F-550 Sd years to avoid →

What are the most common 2004 Ford F-550 Sd problems?

ComponentComplaintsShare
Fuel System2639%
Engine1725%
Electrical System913%
Transmission710%
Speed Control23%
Tires & Wheels23%
Body & Structure11%
Suspension11%
Brakes11%
Airbags11%

Does the 2004 Ford F-550 Sd have recalls?

3 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.

07E066000Electrical SystemAugust 28, 2007 · 175 units

Defect

CERTAIN CEQUENT 90 DEGREE 7-WAY RIGHT ANGLE ADAPTORS SOLD BY DISTRIBUTORS IN TOW PACKAGES FOR AFTERMARKET SALES TO TOW 5TH WHEEL RV TRAVEL TRAILERS. DUE TO INCORRECT WIRING OF THE HARNESS, THE TRAILER LIGHTS MAY NOT OPERATE PROPERLY.

Consequence

IF THE TRAILER LIGHTS ARE NOT WORKING PROPERLY, A VEHICLE CRASH CAN OCCUR.

Remedy

ALL OF THE DEFECTIVE TOW PACKAGES ARE STILL AT THE DISTRIBUTOR LEVEL AND HAVE NOT BEEN SOLD TO ANY CONSUMERS.

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.

“VEHICLE (2004 DIESEL F550 TRUCK) WAS TRAVELING ON I-405 DURING RUSH HOUR TRAFFIC WHEN THE VEHICLE STALLED. DEALER SAYS THAT THE PAINT/LAMINATE INSIDE THE FUEL TANK IS CORRODING AND PIECES OF DEBRIS ARE BEING FED INTO THE FUEL SYSTEM CAUSING SUDDEN STALLING OF VEHICLE. NO OFF-ROAD DIESEL HAS EVER…”

Complaint filed with NHTSA · Fuel System · December 21, 2011

“TRUCK WAS TAKEN TO DEALER FOR OVERHEATING PROBLEM. ON THE FIRST TRIP OUT WITH THE TRUCK AFTER BEING PICKED UP FROM THE DEALERSHIP, THE TRUCK OVERHEATED AND CAUGHT FIRE. EXTENSIVE DAMAGE AND NEITHER DEALERSHIP OR FORD WANT TO INVESTIGATE SOURCE OF FIRE. TRUCK WAS UNDER WARRANTY AT THE TIME OF THE…”

Complaint filed with NHTSA · Engine · October 24, 2005 · fire

“TL* THE CONTACT OWNS A 2004 FORD F-550. THE CONTACT STATED THAT THE VEHICLE WOULD NOT START. THE DEALER DIAGNOSED THAT THE FUEL INJECTOR WIRE WAS MELTING ON THE ENGINE. THE VEHICLE WAS REPAIRED AND RECURRED. THE MANUFACTURER WAS NOTIFIED, BUT DENIED ANY ASSISTANCE WITH REPAIRS. THE FAILURE MILEAGE…”

Complaint filed with NHTSA · Electrical System · June 16, 2011 · fire

“WHILE SHIFTING, THE TRANSMISSION DOWN SHIFTED ON ITS OWN. THE TRANSMISSION SURGED, AND THE VEHICLE BLEW OUT BLUE SMOKE. THE CONSUMER DROVE VEHICLE TO THE DEALER, AND THE MECHANIC DETERMINED THAT EBP SENSOR NEEDED TO BE REPLACED. *AK THE ENGINE LOADED UP WITH FUEL, SMOKE, SURGING WHEN DOWN SHIFTED…”

Complaint filed with NHTSA · Transmission · October 5, 2004

“I PURCHASED A NEW MOTORHOME BUILT ON A FORD CHASSIS AND FOUND ONE OF THE WHEELS (STEEL RIM) TO BE THE WRONG SIZE. IT IS UNDER-RATED IN WEIGHT CARRYING CAPACITY FOR THE SIZE OF THE VEHICLE. FORD IS REFUSING TO CORRECT THIS SAFETY DEFECT. *NM”

Complaint filed with NHTSA · Tires & Wheels · September 11, 2006

2004 Ford F-550 Sd — common questions

Is the 2004 Ford F-550 Sd reliable?

NHTSA data argues against it: 67 complaints put the 2004 model at #3 of 34 F-550 Sd years. It is one of the F-550 Sd years to avoid.

What are the most common 2004 F-550 Sd problems?

According to NHTSA complaint data, the leading problem areas are fuel system (26 complaints), engine (17 complaints), electrical system (9 complaints).

Does the 2004 Ford F-550 Sd have recalls?

Yes — NHTSA lists 3 recall campaigns affecting the 2004 Ford F-550 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-550 Sd under NHTSA investigation?

NHTSA opened one investigation into this model year; all are now closed.

Which Ford F-550 Sd years should you avoid?

Based on complaint rates and open investigations, the F-550 Sd years to avoid are 1999, 2000, 2004, 2006, 2005, 2003, 2001, 2002, 2008, 2015, 2021, 2020, 2017, 2019, 2016, 2018. The cleanest record among F-550 Sd years belongs to 1998.

Related

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

Compiled by Sharon Ben-Moshe, Founder.