Is the 2004 Ford F-250 SD a bad year?
408 owner complaints to NHTSA. Engine complaints: 159, 9.9× a quiet F-250 SD year.
Consider selling
Half of all engine complaints about the 2004 Ford F-250 SD were filed between 9k and 100k miles. You're at 50,000 miles.
The verdict moves with mileage: the same car reads differently at 30,000 and at 150,000 miles.
What 2004 F-250 SD owners report, by mileage
Each system owners named in five or more complaints, with the mileage range where the middle half of those complaints were filed. Read at 50,000 miles.
| SYSTEM | COMPLAINTS | MIDDLE HALF FILED AT | TYPICAL US REPAIR BILLS |
|---|---|---|---|
| EngineSTANDS OUT | 155 (38%) | 9k–100k miles · around this mileage | Valve cover gasket replacement $110–$500 · Timing chain replacement $1,000–$4,000 |
| Electrical systemSTANDS OUT | 92 (23%) | 25k–138k miles · around this mileage | 12-volt battery replacement $100–$400 · Starter motor replacement $350–$1,200 |
| Fuel systemSTANDS OUT | 57 (14%) | 50k–128k miles · around this mileage | Fuel pump replacement $220–$1,500 · Fuel injector replacement (one injector) $300–$1,200 |
| Transmission and drivetrain | 33 (8%) | 6k–94k miles · around this mileage | CV axle / CV joint replacement (one side) $300–$1,500 · Automatic transmission replacement $2,500–$7,000 |
| Tires | 27 (7%) | 30k–101k miles · around this mileage | — |
| Steering | 25 (6%) | 29k–80k miles · around this mileage | Steering rack and pinion replacement $700–$2,100 |
| Exhaust | 22 (5%) | 8k–66k miles · around this mileage | Exhaust leak repair $200–$1,500 · Catalytic converter replacement $500–$4,000 |
| Suspension | 17 (4%) | 23k–63k miles · around this mileage | Ball joint replacement (one joint) $200–$500 · Control arm replacement (one arm) $200–$900 |
| Brakes | 15 (4%) | 22k–107k miles · around this mileage | Brake pad replacement (one axle) $115–$390 · Brake pads and rotors replacement (one axle) $200–$1,084 |
| Body structure | 11 (3%) | 25k–88k miles · around this mileage | — |
| Speed control | 36 (9%) | 2k–43k miles · mostly behind | — |
| Air bags | 9 (2%) | too few with a mileage | — |
| Equipment | 9 (2%) | too few with a mileage | — |
Bills are typical US ranges from the sources named in the tool (J.D. Power, Kelley Blue Book, CarParts.com and others), printed only for systems that stand out or sit at or ahead of 50,000 miles. Not a quote.
What owners reported alongside their complaints
Of 408 complaints: 21 mention a crash · 16 mention a fire · 14 report an injury · 4 say the car was towed.
1 complaint was filed in the last 12 months, the newest in Sep 2026.
Counts of what owners wrote in their complaints, not verified by anyone.
In owners' own words
My Ford F-250 superduty with 6.0 diesel has a hard starting issue and then the engine go from low idle to high idle causing to have to really apply the brakes in order to keep the vehicle from taking off.
1.) we were driving in the pet Smart parking lot and the vehicle lurched forward on it"S own and almost ran over a lady and her little dog!
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.
Unedited excerpts from complaints filed with NHTSA, chosen by mileage (nearest 50,000 miles), not by content. Unverified.
Recalls for the 2004 Ford F-250 SD: 10
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. Non-functioning lights could increase the risk of a crash.
These headlamps fail to conform to the requirements of federal motor vehicle safety standard no. 108, "Lamps, reflective devices, and associated equipment." These lamps do not contain the required amber side reflectors. Decreased lighting visibility may result in a vehicle crash.
These headlamps fail to conform to the requirements of federal motor vehicle safety standard no. 108, "Lamps, reflective devices, and associated equipment." These lamps do not contain the required amber side reflectors. Decreased lighting visibility may result in a vehicle crash.
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. Wheel separation can result in a vehicle crash.
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. If the trailer lights are not working properly, a vehicle crash can occur.
Certain eagle eyes headlamps, p/nos. FR208-B101R, FR208-B101L, FR208-B001R, and FR208-B001L, sold for use as replacement equipment for the passenger vehicles listed above. Decreased lighting visibility may result in a vehicle crash.
Certain ck motorsports combination headlights, clear corner, bumper, and side marker lights sold as replacement lamps for use on the passenger vehicles listed above. Without the amber reflectors, the vehicle will be poorly illuminated, possibly resulting in a vehicle crash without warning.
Certain pro-a motors corner lamps, turn signals, and headlights sold as replacement lamps for use on certain passenger vehicles listed above. Without the amber reflectors, the vehicle will be poorly illuminated, possibly resulting in a vehicle crash without warning.
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. Should the engine stall, a vehicle crash could occur.
Certain lariat and king ranch model pickup trucks fail to comply with the requirements of federal motor vehicle safety standard no. 120, "Tire selection and rims for motor vehicles other than passenger cars." Some trucks were inadvertently equipped with an incorrect load range tire. If a tire was operated in an over-loaded or over-inflated condition, the tire may rupture resulting in a rapid air loss, which can cause a crash without warning.
A recall may cover only some cars of a model year; the campaign size counts every model and year it lists. Enter your VIN at nhtsa.gov/recalls: dealers fix open recalls free.
Service bulletins from Ford: 6
Repair instructions Ford sent its dealers for symptoms seen in the shop on the 2004 Ford F-250 SD. Ask a dealer or mechanic for a bulletin by its number.
When shifting between park, reverse and/or during 2-3 shift, an intermittent clunk occurs with a torqshift transmission
Some vehicles may exhibit concern during or after programing the VSM
The restraint control module (RCM) when using vcm II, would have an error code 35 and diagnostic trouble code (DTC) B1035…
NHTSA defect investigations: 3
Spark plug ejection from cylinder head
Engine stalling
Engine stalling
Neighbouring years
2003 F-250 SD: 293 complaints, keep it, but watch the engine · 2005 F-250 SD: 439 complaints, keep it, but watch the engine.
Every Ford F-250 SD year
2000 · 2001 · 2002 · 2003 · 2004 · 2005 · 2006 · 2007 · 2008 · 2009 · 2010 · 2011 · 2012 · 2013 · 2014 · 2015 · 2016 · 2017 · 2018 · 2019 · 2020 · 2021 · 2022 · 2023 · 2024 · 2025 · 2026 · All F-250 SD years side by side
Other Ford models: Ford 500 · Ford Bronco · Ford Bronco Sport · Ford C-Max · Ford Contour · Ford Crown Victoria · Ford E-150 · Ford E-250 · Ford E-350 · Ford E-450 · Ford EcoSport · Ford Edge · Ford Escape · Ford Escape Hybrid · Ford Escort · Ford Excursion · Ford Expedition · Ford Explorer · Ford Explorer Sport · Ford Explorer Sport Trac · Ford F SD · Ford F-150 · Ford F-150 Hybrid · Ford F-150 Lightning BEV · Ford F-350 SD · Ford F-450 SD · Ford F-550 SD · Ford Fiesta · Ford Five Hundred · Ford Flex · Ford Focus · Ford Focus Electric · Ford Ford · Ford Freestar · Ford Freestyle · Ford Fusion · Ford Fusion Energi · Ford Fusion Hybrid · Ford Maverick · Ford Maverick Hybrid · Ford Mustang · Ford Mustang GT · Ford Mustang Mach-E · Ford Ranger · Ford Taurus · Ford Taurus X · Ford Thunderbird · Ford Transit · Ford Transit Connect · Ford Windstar. All makes and models.
Questions
Is the 2004 Ford F-250 SD a bad year?
408 owner complaints to NHTSA. Engine complaints: 159, 9.9× a quiet F-250 SD year. At 50,000 miles the tool says: Consider selling. Half of all engine complaints about the 2004 Ford F-250 SD were filed between 9k and 100k miles. You're at 50,000 miles.
What are the most common problems with the 2004 Ford F-250 SD?
By owner complaints to NHTSA: engine (155), electrical system (92), fuel system (57), transmission and drivetrain (33), tires (27). Half of the engine complaints were filed between 9k–100k miles.
How many recalls does the 2004 Ford F-250 SD have?
10 recall campaigns list this model year: Exterior lighting (NHTSA 11V-352), Exterior lighting (NHTSA 09E025000), Exterior lighting (NHTSA 09E012000), Wheels (NHTSA 07E106000) and more. A recall may cover only some cars; check by VIN at nhtsa.gov/recalls.
Method: counts of unverified owner complaints filed with NHTSA, compared only with other years of the same model (sales volumes are unknown, so no failure rate is computed). A system stands out at 40+ complaints and at least twice the model's quiet (lower-quartile) year, or twice the share across every vehicle of that model year. The mileage range is the 25th to 75th percentile of the mileages owners reported. Data received by NHTSA through November 5, 2026. Repair prices are typical US ranges from named sources, not quotes. Not a diagnosis and not financial advice. PulsCar is not affiliated with NHTSA. Check this car at your own mileage.