2004 Ford F650

Here is a comprehensive list of common issues and complaints associated with the 2004 Ford F-650, broken down by category. This information is compiled from owner reports, forums, and repair data, focusing on specific issues beyond normal wear and tear.

The 2004 Ford F-650 is a medium-duty truck known for its robustness and versatility. It’s generally appreciated for its towing capacity and durability but criticized for its size and fuel consumption. Engine options include the Caterpillar 3126 diesel engine, which produces approximately 300-330 horsepower and 860 lb-ft of torque depending on its configuration. It has a reputation of being a dependable engine, but is not without its problems. Transmission options typically include a manual transmission or an Allison automatic.

Engine

Caterpillar 3126 Diesel

• Injector Failure
  • Description/Symptoms: Rough running, misfires, excessive smoke (white or black), reduced power, and potential fuel dilution of the engine oil. Can eventually lead to engine damage if not addressed.
  • Solution: Replace the faulty injectors. It’s often recommended to replace all injectors at the same time for balanced performance.
  • Estimated Cost to Fix: $2,000 - $4,000+ (depending on labor and parts cost for injectors).
  • Recalls: None Found
• HEUI (Hydraulic Electronic Unit Injector) Pump Failure
  • Description/Symptoms: Hard starting, loss of power, stalling, and a generally rough-running engine. The HEUI pump provides the high-pressure oil necessary for the injectors to function correctly.
  • Solution: Replace the HEUI pump.
  • Estimated Cost to Fix: $1,500 - $3,000+
  • Recalls: None Found
• Turbocharger Issues
  • Description/Symptoms: Whining noises from the turbo, black smoke, reduced power, and potential oil leaks. Can be caused by worn bearings, damaged turbine blades, or issues with the wastegate.
  • Solution: Inspect the turbocharger for damage or wear. Repair or replace the turbocharger as needed.
  • Estimated Cost to Fix: $1,000 - $3,000+ (depending on whether it’s a repair or replacement)
  • Recalls: None Found

Transmission

Allison Automatic Transmissions

• Shifting Problems/Slipping
  • Description/Symptoms: Delayed shifts, harsh shifts, slipping between gears, or failure to shift at all. Can be caused by worn clutches, valve body issues, or low fluid levels.
  • Solution: Diagnose the cause of the shifting problems. Could involve a transmission fluid flush and filter change, valve body repair or replacement, or a complete transmission rebuild.
  • Estimated Cost to Fix: $300 (fluid/filter) to $5,000+ (rebuild)
  • Recalls: None Found
• Torque Converter Failure
  • Description/Symptoms: Shuddering at low speeds, poor acceleration, and unusual noises coming from the transmission area.
  • Solution: Replace the torque converter.
  • Estimated Cost to Fix: $1,500 - $3,000+
  • Recalls: None Found

Suspension

• Leaf Spring Sagging/Failure
  • Description/Symptoms: Vehicle sitting lower than normal, especially in the rear, rough ride quality, and potential cracking or breaking of the leaf springs.
  • Solution: Replace the worn or damaged leaf springs.
  • Estimated Cost to Fix: $1,000 - $2,500+ (depending on the number of springs replaced and labor)
  • Recalls: None Found
• Air Suspension Problems (if equipped)
  • Description/Symptoms: Vehicle leaning to one side, air compressor running constantly, and a rough ride. Can be caused by leaks in the air bags, faulty air compressor, or issues with the ride height sensors.
  • Solution: Inspect the air suspension system for leaks or damage. Repair or replace the air bags, compressor, or sensors as needed.
  • Estimated Cost to Fix: $500 - $2,000+
  • Recalls: None Found

Electrical

• Wiring Harness Issues
  • Description/Symptoms: Intermittent electrical problems, such as lights not working, gauges malfunctioning, or starting issues. Can be caused by corrosion, chafing, or loose connections.
  • Solution: Inspect the wiring harness for damage. Repair or replace damaged wires or connectors.
  • Estimated Cost to Fix: $200 - $1,000+ (depending on the extent of the damage)
  • Recalls: None Found
• Alternator Failure
  • Description/Symptoms: Dim headlights, battery not charging, and the battery warning light illuminating on the dashboard.
  • Solution: Replace the alternator.
  • Estimated Cost to Fix: $300 - $700+
  • Recalls: None Found

Exterior

• Rust (Especially in Northern Climates)
  • Description/Symptoms: Rust formation on body panels, frame, and undercarriage components. Can weaken the structure of the vehicle over time.
  • Solution: Address rust promptly by sanding, treating, and repainting affected areas. For severe rust, panel replacement or frame repair may be necessary.
  • Estimated Cost to Fix: $300+ (for minor rust repair) to $3,000+ (for extensive repair)
  • Recalls: None Found

Interior

• HVAC Blower Motor Failure
  • Description/Symptoms: The HVAC blower motor not working, resulting in no air blowing from the vents.
  • Solution: Replace the blower motor.
  • Estimated Cost to Fix: $200 - $500+
  • Recalls: None Found

Summary

The 2004 Ford F-650 has some common issues. The most pressing issues relate to the Caterpillar 3126 diesel engine and the Allison transmission. These issues can be moderate to severe in terms of repair cost and potential downtime. Addressing these problems promptly will help ensure the longevity and reliability of the truck.