2004 Ford F-250 Super Duty
The 2004 Ford F-250 Super Duty is a heavy-duty pickup truck known for its robust capabilities and durability, a popular choice for towing and hauling. Engine options for the 2004 F-250 included the 5.4L Triton V8 (300 hp and 365 lb-ft of torque), the 6.8L Triton V10 (310 hp and 425 lb-ft of torque), and the 6.0L Power Stroke Turbo Diesel V8 (325 hp and 560 lb-ft of torque). Transmission choices were typically a 5-speed manual or a 4-speed automatic depending on the engine. Owners often praise the F-250 for its workhorse performance and ruggedness, but common complaints revolve around fuel economy, maintenance costs, and specific issues related to the diesel engine.
Engine
6.0L Power Stroke Turbo Diesel V8
- EGR Cooler Failure
- Description/Symptoms: Overheating, coolant loss, white smoke from exhaust, potential for head gasket failure due to increased cylinder pressure.
- Solution: Replace the EGR cooler with an updated version or delete the EGR system (check local emissions regulations).
- Estimated Cost to Fix: $800 - $2000+
- Recalls: None Found
- Fuel Injector Issues
- Description/Symptoms: Rough running, misfires, white or black smoke, poor fuel economy.
- Solution: Diagnose faulty injectors and replace as needed. Can be caused by oil intrusion from failing high pressure oil pump (HPOP).
- Estimated Cost to Fix: $300 - $800+ per injector
- Recalls: None Found
- High Pressure Oil Pump (HPOP) Failure
- Description/Symptoms: Hard starting, stalling, loss of power, check engine light.
- Solution: Replace the HPOP.
- Estimated Cost to Fix: $800 - $1500+
- Recalls: None Found
- Turbocharger Problems
- Description/Symptoms: Lack of power, excessive smoke, whistling noises, check engine light. Variable geometry turbochargers (VGTs) are prone to sticking due to soot buildup.
- Solution: Clean or replace the turbocharger.
- Estimated Cost to Fix: $1000 - $2500+
- Recalls: None Found
5.4L Triton V8
- Spark Plug Ejection/Failure
- Description/Symptoms: Misfires, loud popping noise, loss of power. The 2-valve 5.4L Triton engine is known for spark plugs seizing in the cylinder heads and sometimes ejecting.
- Solution: Use penetrating oil and careful removal techniques. Re-thread the cylinder head if necessary. Install new spark plugs and use anti-seize compound on the threads.
- Estimated Cost to Fix: $200 - $1000+ depending on the severity of the damage.
- Recalls: None Found
- Manifold Leaks
- Description/Symptoms: Ticking noise from the engine, especially when cold.
- Solution: Replace the exhaust manifold and gaskets.
- Estimated Cost to Fix: $300 - $800+
- Recalls: None Found
6.8L Triton V10
- Spark Plug Ejection/Failure
- Description/Symptoms: Misfires, loud popping noise, loss of power.
- Solution: Use penetrating oil and careful removal techniques. Re-thread the cylinder head if necessary. Install new spark plugs and use anti-seize compound on the threads.
- Estimated Cost to Fix: $200 - $1000+ depending on the severity of the damage.
- Recalls: None Found
- Manifold Leaks
- Description/Symptoms: Ticking noise from the engine, especially when cold.
- Solution: Replace the exhaust manifold and gaskets.
- Estimated Cost to Fix: $300 - $800+
- Recalls: None Found
Transmission
4R100 4-Speed Automatic Transmission
- Torque Converter Failure
- Description/Symptoms: Shuddering during acceleration, stalling, transmission slipping.
- Solution: Replace the torque converter.
- Estimated Cost to Fix: $800 - $1500+
- Recalls: None Found
- Shift Flare
- Description/Symptoms: A delay or hesitation during gear changes, particularly between 2nd and 3rd gear.
- Solution: Often related to worn valve body components or solenoids. Can also be caused by low fluid or incorrect fluid type. Replacement or rebuild of the transmission may be required for severe cases.
- Estimated Cost to Fix: $300 - $2500+ depending on the severity of the problem.
- Recalls: None Found
Suspension
- Ball Joint Failure
- Description/Symptoms: Clunking noises, loose steering, uneven tire wear.
- Solution: Replace worn ball joints.
- Estimated Cost to Fix: $300 - $800+ per side
- Recalls: None Found
- Leaf Spring Sagging/Cracking
- Description/Symptoms: Reduced load carrying capacity, rear end sagging, rough ride.
- Solution: Replace or add-a-leaf to the leaf springs.
- Estimated Cost to Fix: $400 - $1200+
- Recalls: None Found
Electrical
- Instrument Cluster Issues
- Description/Symptoms: Intermittent gauge failures, flickering lights, complete cluster failure.
- Solution: Repair or replace the instrument cluster.
- Estimated Cost to Fix: $200 - $800+
- Recalls: None Found
- Alternator Failure
- Description/Symptoms: Battery light on, dimming headlights, stalling, failure to start.
- Solution: Replace the alternator.
- Estimated Cost to Fix: $200 - $500+
- Recalls: None Found
Exterior
- Rust (Cab Corners, Rocker Panels)
- Description/Symptoms: Visible rust on cab corners, rocker panels, and other body panels.
- Solution: Repair or replace rusted panels.
- Estimated Cost to Fix: $500 - $3000+ depending on the extent of the damage.
- Recalls: None Found
Interior
- Cracked Dashboard
- Description/Symptoms: Cracks appearing on the dashboard, especially in areas exposed to sunlight.
- Solution: Dash cover or dashboard replacement
- Estimated Cost to Fix: $100-$800+
- Recalls: None Found
Summary
The 2004 Ford F-250 Super Duty is a capable truck, but owners need to be aware of potential issues. The 6.0L Power Stroke diesel engine is prone to problems like EGR cooler failure, fuel injector issues, and turbocharger problems, which can lead to significant repair costs. The gas engines can have spark plug ejection issues. The transmission and suspension components can also suffer from wear and tear over time, leading to costly repairs. Overall, potential buyers should thoroughly inspect the vehicle and be prepared for potential maintenance expenses. The severity and cost of repairs vary widely depending on the specific issue and the condition of the truck.