2004 Ford F-350 Super Duty

Alright, here is a comprehensive breakdown of common issues and complaints for the 2004 Ford F-350 Super Duty, categorized by component and including engine and transmission options.

The 2004 Ford F-350 Super Duty is a heavy-duty pickup truck known for its towing and hauling capabilities. Engine options included the 5.4L Triton V8 (300 hp, 365 lb-ft torque), the 6.8L Triton V10 (310 hp, 425 lb-ft torque), and the 6.0L Power Stroke Diesel V8 (325 hp, 570 lb-ft torque). Transmission options consisted of either a 5-speed manual or a 4-speed automatic. Owners generally appreciate the truck’s ruggedness and workhorse capability, but common complaints revolve around reliability issues, particularly with the 6.0L diesel engine.

Engine

6.0L Power Stroke Diesel V8

• EGR Cooler Failure
  • Description/Symptoms: The EGR cooler cracks, leaking coolant into the intake manifold. This can cause white smoke from the exhaust, coolant loss, and potentially hydro-lock the engine.
  • Solution: Replace the EGR cooler with an updated design, potentially upgrade the oil cooler to prevent recurrence.
  • Estimated Cost to Fix: $800 - $1500+
  • Recalls: None Found
• Oil Cooler Failure
  • Description/Symptoms: The factory oil cooler is prone to clogging, restricting oil flow and leading to overheating. This can lead to further engine damage.
  • Solution: Replace the oil cooler with an updated, larger capacity design.
  • Estimated Cost to Fix: $500 - $1200+ (often done in conjunction with EGR cooler replacement)
  • Recalls: None Found
• Injector Failure
  • Description/Symptoms: Faulty fuel injectors can cause rough running, misfires, poor fuel economy, and excessive smoke.
  • Solution: Replace the faulty injectors. It’s often recommended to replace all injectors at once for consistent performance.
  • Estimated Cost to Fix: $300 - $500 per injector + labor
  • Recalls: None Found
• Head Gasket Failure
  • Description/Symptoms: This is a very common and serious issue. The head bolts stretch, leading to head gasket failure. Symptoms include white smoke, coolant loss, and overheating.
  • Solution: Replace the head gaskets with updated gaskets and ARP head studs to prevent future failure.
  • Estimated Cost to Fix: $3000 - $6000+ (major engine repair)
  • Recalls: None Found
• FICM (Fuel Injection Control Module) Failure
  • Description/Symptoms: The FICM controls the fuel injectors. When it fails, the engine may not start, run poorly, or stall.
  • Solution: Replace the FICM.
  • Estimated Cost to Fix: $400 - $800+
  • Recalls: None Found

5.4L Triton V8

• Spark Plug Thread Failure
  • Description/Symptoms: The spark plug threads in the aluminum cylinder head are weak and prone to stripping, making spark plug changes difficult or impossible.
  • Solution: Repair the spark plug threads with thread repair inserts (Heli-Coil or similar).
  • Estimated Cost to Fix: $200 - $800+ (depending on the number of plugs and shop)
  • Recalls: None Found

6.8L Triton V10

• Exhaust Manifold Bolts Breaking
  • Description/Symptoms: Exhaust manifold bolts rust and break, leading to exhaust leaks that sound like a ticking noise, especially when cold.
  • Solution: Replace the broken bolts and potentially the exhaust manifold if it is warped.
  • Estimated Cost to Fix: $300 - $1000+
  • Recalls: None Found

Transmission

4R100 4-Speed Automatic (All Engine Options)

• Valve Body Issues
  • Description/Symptoms: Shift flares, harsh shifting, slipping between gears, or failure to shift.
  • Solution: Replace or rebuild the valve body with updated components.
  • Estimated Cost to Fix: $500 - $1500+
  • Recalls: None Found
• Torque Converter Failure
  • Description/Symptoms: Shuddering at certain speeds, poor acceleration, or complete loss of drive.
  • Solution: Replace the torque converter.
  • Estimated Cost to Fix: $400 - $1000+
  • Recalls: None Found

ZF5 5-Speed Manual (All Engine Options)

• Clutch Failure
  • Description/Symptoms: Slipping clutch, difficulty shifting, or grinding noises.
  • Solution: Replace the clutch disc, pressure plate, and throwout bearing. Consider resurfacing or replacing the flywheel.
  • Estimated Cost to Fix: $500 - $1200+
  • Recalls: None Found

Suspension

• Leaf Spring Sagging/Cracking
  • Description/Symptoms: Rear of the truck sags, especially when loaded. Ride quality deteriorates, and the truck may bottom out easily. Cracked or broken leaf springs are a safety hazard.
  • Solution: Replace the leaf springs with new or heavy-duty springs.
  • Estimated Cost to Fix: $500 - $1500+ (per axle)
  • Recalls: None Found
• Ball Joint Failure
  • Description/Symptoms: Loose steering, clunking noises from the front end, uneven tire wear.
  • Solution: Replace the ball joints. It’s usually recommended to replace upper and lower ball joints at the same time.
  • Estimated Cost to Fix: $300 - $800+ (per side)
  • Recalls: None Found

Electrical

• Alternator Failure
  • Description/Symptoms: Dimming lights, slow starting, or a completely dead battery.
  • Solution: Replace the alternator.
  • Estimated Cost to Fix: $200 - $500+
  • Recalls: None Found
• Glow Plug Relay Failure (Diesel)
  • Description/Symptoms: Hard starting, especially in cold weather.
  • Solution: Replace the glow plug relay.
  • Estimated Cost to Fix: $100 - $300+
  • Recalls: None Found

Exterior

• Rust on Cab Corners and Rocker Panels
  • Description/Symptoms: Rust bubbles and holes appearing on the lower cab corners and rocker panels, especially in areas with road salt.
  • Solution: Cut out the rusted metal and weld in new panels, then repaint.
  • Estimated Cost to Fix: $500 - $2000+ (per side, depending on the extent of the damage)
  • Recalls: None Found

Interior

• Cracked Dashboard
  • Description/Symptoms: Cracks developing in the dashboard, especially in sun-exposed areas.
  • Solution: Replace the dashboard or install a dashboard cover.
  • Estimated Cost to Fix: $200 - $800+
  • Recalls: None Found
• Power Window Motor Failure
  • Description/Symptoms: Window moves slowly, erratically, or not at all.
  • Solution: Replace the power window motor.
  • Estimated Cost to Fix: $150 - $400+ (per window)
  • Recalls: None Found

Summary

The 2004 Ford F-350 Super Duty is a capable truck, but it’s prone to several significant issues. The 6.0L Power Stroke diesel engine is particularly problematic, with head gasket failure, EGR cooler failure, and oil cooler failure being common and expensive repairs. Other issues, such as spark plug thread failure on the 5.4L, or exhaust manifold bolts on the 6.8L, are less severe but still require attention. Rust is also a concern, especially in colder climates. Potential buyers should be aware of these common problems and factor in potential repair costs when considering a purchase. The severity of the issues can range from minor inconveniences to major engine repairs costing thousands of dollars.