Is the 2004 Ford F-350 SD a bad year?
285 owner complaints to NHTSA. Engine complaints: 123, 12× a quiet F-350 SD year.
Consider selling
Half of all engine complaints about the 2004 Ford F-350 SD were filed between 18k and 109k miles. You're at 67,000 miles.
The verdict moves with mileage: the same car reads differently at 30,000 and at 150,000 miles.
What 2004 F-350 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 67,000 miles.
| SYSTEM | COMPLAINTS | MIDDLE HALF FILED AT | TYPICAL US REPAIR BILLS |
|---|---|---|---|
| EngineSTANDS OUT | 121 (42%) | 18k–109k miles · around this mileage | Valve cover gasket replacement $110–$500 · Timing chain replacement $1,000–$4,000 |
| Electrical systemSTANDS OUT | 48 (17%) | 16k–104k miles · around this mileage | 12-volt battery replacement $100–$400 · Starter motor replacement $350–$1,200 |
| Fuel systemSTANDS OUT | 44 (15%) | 53k–121k miles · around this mileage | Fuel pump replacement $220–$1,500 · Fuel injector replacement (one injector) $300–$1,200 |
| Tires | 25 (9%) | 42k–80k miles · around this mileage | — |
| Steering | 15 (5%) | 20k–95k miles · around this mileage | Steering rack and pinion replacement $700–$2,100 |
| Suspension | 9 (3%) | 20k–78k miles · around this mileage | Ball joint replacement (one joint) $200–$500 · Control arm replacement (one arm) $200–$900 |
| Transmission and drivetrain | 24 (8%) | 4k–57k miles · mostly behind | — |
| Speed control | 19 (7%) | 10k–59k miles · mostly behind | — |
| Brakes | 16 (6%) | 6k–51k miles · mostly behind | — |
| Exhaust | 13 (5%) | 4k–58k miles · mostly behind | — |
| Body structure | 12 (4%) | 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 67,000 miles. Not a quote.
What owners reported alongside their complaints
Of 285 complaints: 16 mention a crash · 7 mention a fire · 9 report an injury · 2 say the car was towed.
No complaints in the last 12 months; the newest was filed in Apr 2025.
Counts of what owners wrote in their complaints, not verified by anyone.
In owners' own words
2004 Ford F350 crew cab diesel sat idle in driveway for approx. 6 weeks. A fire started in engine comp. While vehicle was off and unoccupied.
The engine stalled and would not restart. Vehicle was towed to a local repair shop and it was discovered tha t engine needed to be replaced.
Ford F-350 sd 6.0 l diesel, several times while driving, truck began to surge/cut-off. This happened under load while going uphill.
Unedited excerpts from complaints filed with NHTSA, chosen by mileage (nearest 67,000 miles), not by content. Unverified.
Recalls for the 2004 Ford F-350 SD: 5
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.
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 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-350 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-350 SD: 222 complaints, keep it, but watch the engine · 2005 F-350 SD: 331 complaints, keep it, but watch the engine.
Every Ford F-350 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-350 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-250 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-350 SD a bad year?
285 owner complaints to NHTSA. Engine complaints: 123, 12× a quiet F-350 SD year. At 67,000 miles the tool says: Consider selling. Half of all engine complaints about the 2004 Ford F-350 SD were filed between 18k and 109k miles. You're at 67,000 miles.
What are the most common problems with the 2004 Ford F-350 SD?
By owner complaints to NHTSA: engine (121), electrical system (48), fuel system (44), tires (25), steering (15). Half of the engine complaints were filed between 18k–109k miles.
How many recalls does the 2004 Ford F-350 SD have?
5 recall campaigns list this model year: Exterior lighting (NHTSA 11V-352), Wheels (NHTSA 07E106000), Equipment (NHTSA 07E066000), Electrical system (NHTSA 05V-270) 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.