2004 Ford F-350

The 2004 Ford F-350 Super Duty is a heavy-duty pickup truck known for its towing and hauling capabilities. Available engine options include the 5.4L Triton V8, the 6.8L Triton V10, and the 6.0L Power Stroke Turbo Diesel V8. The 5.4L V8 produces around 300 horsepower and 365 lb-ft of torque. Transmission options are primarily a 5-speed manual and a 4-speed automatic. People generally like the F-350 for its robust build, towing capacity, and reliability when properly maintained. Common dislikes include fuel economy, potential maintenance costs associated with the diesel engine, and ride quality compared to lighter-duty trucks.

Engine

6.0L Power Stroke Turbo Diesel V8

• EGR Cooler Failure
  • Description/Symptoms: The EGR (Exhaust Gas Recirculation) cooler can crack and leak coolant into the exhaust system, leading to white smoke from the exhaust, coolant loss, and potential overheating.
  • Solution: Replace the EGR cooler with an updated version or delete it (check local regulations before deleting).
  • Estimated Cost to Fix: $500 - $1500+
  • Recalls: None Found
• Fuel Injector Issues
  • Description/Symptoms: The fuel injectors can fail, causing rough idling, poor performance, and black smoke from the exhaust.
  • Solution: Replace the faulty fuel injectors.
  • Estimated Cost to Fix: $200 - $400 per injector, $800 - $3200+ for a set.
  • Recalls: None Found
• High Pressure Oil Pump (HPOP) Failure
  • Description/Symptoms: The HPOP supplies high-pressure oil to the fuel injectors. Failure can lead to no-start conditions, stalling, and poor performance.
  • Solution: Replace the HPOP.
  • Estimated Cost to Fix: $800 - $2000+
  • Recalls: None Found
• Turbocharger Problems
  • Description/Symptoms: The turbocharger can experience issues such as sticking vanes (variable geometry turbochargers), oil leaks, and bearing failures, leading to reduced power and increased exhaust smoke.
  • Solution: Repair or replace the turbocharger.
  • Estimated Cost to Fix: $1000 - $3000+
  • Recalls: None Found

5.4L Triton V8

• Spark Plug Ejection
  • Description/Symptoms: The spark plugs can sometimes be ejected from the cylinder heads due to stripped threads, especially on earlier 2-valve engines. This results in a loud popping noise, misfire, and loss of power.
  • Solution: Repair the spark plug threads using a thread repair kit (e.g., Time-Sert) or replace the cylinder head.
  • Estimated Cost to Fix: $300 - $1500+ depending on the severity and repair method.
  • Recalls: None Found
• Broken Exhaust Manifold Studs
  • Description/Symptoms: Exhaust manifold studs can break, leading to exhaust leaks, a ticking noise (especially when cold), and reduced fuel efficiency.
  • Solution: Replace the broken exhaust manifold studs.
  • Estimated Cost to Fix: $300 - $800+
  • Recalls: None Found

6.8L Triton V10

• Broken Exhaust Manifold Studs
  • Description/Symptoms: Exhaust manifold studs can break, leading to exhaust leaks, a ticking noise (especially when cold), and reduced fuel efficiency.
  • Solution: Replace the broken exhaust manifold studs.
  • Estimated Cost to Fix: $300 - $800+
  • Recalls: None Found

Transmission

4R100 4-Speed Automatic Transmission

• Shift Flare/Slipping
  • Description/Symptoms: The transmission may experience a delay or “flare” during shifts, or slip out of gear, especially under heavy load.
  • Solution: Rebuild or replace the transmission.
  • Estimated Cost to Fix: $1500 - $4000+
  • Recalls: None Found
• Torque Converter Failure
  • Description/Symptoms: Torque converter failure can cause shuddering, stalling, and difficulty shifting.
  • Solution: Replace the torque converter.
  • Estimated Cost to Fix: $500 - $1500+
  • Recalls: None Found

ZF5 5-Speed Manual Transmission

No Issues Found

Suspension

• Worn Ball Joints
  • Description/Symptoms: Clicking or popping noises from the front suspension, especially when turning or going over bumps. Excessive tire wear can also be a symptom.
  • Solution: Replace the worn ball joints.
  • Estimated Cost to Fix: $300 - $800+ per side.
  • Recalls: None Found
• Worn Leaf Spring Bushings
  • Description/Symptoms: Squeaking or clunking noises from the rear suspension, especially when going over bumps.
  • Solution: Replace the worn leaf spring bushings.
  • Estimated Cost to Fix: $200 - $600+ per side.
  • Recalls: None Found
• Sagging Leaf Springs
  • Description/Symptoms: The rear of the truck sags, especially when loaded, reducing ride height and potentially affecting handling.
  • Solution: Replace the leaf springs.
  • Estimated Cost to Fix: $500 - $1500+ per side.
  • Recalls: None Found

Electrical

• Alternator Failure
  • Description/Symptoms: Battery not charging, dimming lights, and eventual electrical system failure.
  • Solution: Replace the alternator.
  • Estimated Cost to Fix: $200 - $600+
  • Recalls: None Found
• Instrument Cluster Issues
  • Description/Symptoms: Gauges may stop working or display inaccurate readings.
  • Solution: Repair or replace the instrument cluster.
  • Estimated Cost to Fix: $200 - $800+
  • Recalls: None Found
• 4x4 Actuator Problems
  • Description/Symptoms: The 4-wheel drive system may fail to engage or disengage properly.
  • Solution: Replace the 4x4 actuator motor.
  • Estimated Cost to Fix: $200 - $500+
  • Recalls: None Found

Exterior

• Rust on Body Panels
  • Description/Symptoms: Rust forming on the lower body panels, especially around the wheel wells and rocker panels.
  • Solution: Repair or replace the rusted panels.
  • Estimated Cost to Fix: Varies greatly depending on the extent of the rust.
  • Recalls: None Found
• Tailgate Handle Failure
  • Description/Symptoms: The tailgate handle breaks or becomes difficult to operate.
  • Solution: Replace the tailgate handle assembly.
  • Estimated Cost to Fix: $50 - $200+
  • Recalls: None Found

Interior

• Cracked Dashboard
  • Description/Symptoms: The dashboard can crack, especially in hot climates.
  • Solution: Replace the dashboard or install a dashboard cover.
  • Estimated Cost to Fix: $200 - $1500+ depending on the method.
  • Recalls: None Found
• Power Window Motor Failure
  • Description/Symptoms: Power windows stop working or operate slowly.
  • Solution: Replace the power window motor.
  • Estimated Cost to Fix: $150 - $400+ per window.
  • Recalls: None Found
• HVAC Blend Door Actuator Failure
  • Description/Symptoms: The temperature of the air blowing from the vents is inconsistent or stuck on hot or cold.
  • Solution: Replace the HVAC blend door actuator.
  • Estimated Cost to Fix: $150 - $500+
  • Recalls: None Found

Summary

The 2004 Ford F-350, particularly models equipped with the 6.0L Power Stroke diesel engine, can suffer from a range of issues, some of which can be costly to repair. The diesel engine’s issues, such as EGR cooler failure, fuel injector problems, and HPOP failure, can lead to significant expenses. The 5.4L V8 and 6.8L V10 can have issues with spark plugs and exhaust manifolds, respectively. Suspension issues like worn ball joints and leaf springs are common due to the truck’s heavy-duty nature. Electrical issues such as alternator failure and instrument cluster problems can also occur. Overall, potential buyers should thoroughly inspect the truck and be prepared for potential maintenance costs, especially with diesel-equipped models.