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2004 Ford F750

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By Research the Car 7 min read

The 2004 Ford F-750 is a medium-duty truck designed for commercial applications, offering a robust platform for various vocational needs. It’s generally appreciated for its dependability, workhorse capabilities, and relative ease of maintenance compared to some of its contemporaries. However, like any vehicle of this age and class, the 2004 F-750 is susceptible to certain issues. Available engines include the Caterpillar 3126 diesel engine producing approximately 300 horsepower and around 860 lb-ft of torque, the Cummins ISB diesel engine with similar output, and the Ford 7.3L Powerstroke diesel engine with similar output. Transmission options include the Allison automatic transmissions, the Eaton Fuller manual transmissions, and the Ford TorqShift transmission. Owners often find the cab comfortable for its class, but some dislike the truck’s relatively large turning radius.

Engine

Caterpillar 3126

  • Injector Failure
    • Description/Symptoms: Hard starting, rough idling, excessive black smoke, reduced power, and eventual engine stalling. This is particularly common in engines that haven’t had regular injector maintenance.
    • Solution: Replace the faulty injectors. It’s often recommended to replace all injectors at the same time to ensure balanced engine performance.
    • Estimated Cost to Fix: $400 - $800+ per injector (parts and labor)
    • Recalls: None Found
  • HEUI (Hydraulically Actuated Electronically Controlled Unit Injector) Pump Failure
    • Description/Symptoms: Engine misfires, loss of power, and potentially a complete engine shutdown. This pump provides the high-pressure oil required for injector operation.
    • Solution: Replace the HEUI pump. Ensure proper diagnosis to confirm the pump failure and not other related components.
    • Estimated Cost to Fix: $1,500 - $3,000+ (parts and labor)
    • Recalls: None Found
  • Turbocharger Issues
    • Description/Symptoms: Loss of power, excessive black smoke, whistling noises, and increased oil consumption. These can be caused by worn bearings or damaged turbine wheels.
    • Solution: Replace or rebuild the turbocharger. Inspect the oil supply lines for blockages.
    • Estimated Cost to Fix: $1,000 - $2,500+ (parts and labor)
    • Recalls: None Found

Cummins ISB

  • Fuel Injector Issues
    • Description/Symptoms: Rough idle, white smoke, poor fuel economy, and potential engine misfires. Fuel injectors can become clogged or fail over time.
    • Solution: Replace or rebuild the fuel injectors. Ensure the fuel system is clean to prevent future issues.
    • Estimated Cost to Fix: $300 - $700+ per injector (parts and labor)
    • Recalls: None Found
  • Lift Pump Failure
    • Description/Symptoms: Hard starting, loss of power, and eventual engine stalling. The lift pump supplies fuel to the high-pressure injection pump.
    • Solution: Replace the lift pump. Consider upgrading to a higher-flow pump for improved reliability.
    • Estimated Cost to Fix: $300 - $600+ (parts and labor)
    • Recalls: None Found
  • Turbocharger Wastegate Issues
    • Description/Symptoms: Overboost or underboost conditions, leading to reduced performance or potential engine damage. The wastegate controls turbocharger pressure.
    • Solution: Replace or repair the wastegate actuator or the turbocharger itself, depending on the specific failure.
    • Estimated Cost to Fix: $500 - $1,500+ (parts and labor)
    • Recalls: None Found

Ford 7.3L Powerstroke Diesel

  • Cam Position Sensor (CPS) Failure
    • Description/Symptoms: Stalling, rough running, and difficulty starting. This sensor is critical for engine timing.
    • Solution: Replace the CPS. It’s a relatively inexpensive and straightforward repair.
    • Estimated Cost to Fix: $100 - $200+ (parts and labor)
    • Recalls: None Found
  • Injector Driver Module (IDM) Failure
    • Description/Symptoms: Engine misfires, rough running, and stalling. The IDM controls the fuel injectors.
    • Solution: Replace the IDM. Ensure proper diagnosis to confirm the IDM failure.
    • Estimated Cost to Fix: $400 - $800+ (parts and labor)
    • Recalls: None Found
  • Exhaust Back Pressure Valve (EBPV) Problems
    • Description/Symptoms: Whistling noise, reduced power, and potentially poor fuel economy. The EBPV is used to warm the engine in cold weather.
    • Solution: Disconnect or remove the EBPV, or replace the faulty components.
    • Estimated Cost to Fix: $300 - $700+ (parts and labor)
    • Recalls: None Found

Transmission

Allison Automatic Transmission

  • Torque Converter Failure
    • Description/Symptoms: Slipping during acceleration, shuddering, and reduced power transfer.
    • Solution: Replace the torque converter. Inspect the transmission fluid for contamination.
    • Estimated Cost to Fix: $1,500 - $3,000+ (parts and labor)
    • Recalls: None Found
  • Shift Solenoid Issues
    • Description/Symptoms: Erratic shifting, failure to shift, and transmission getting stuck in gear.
    • Solution: Replace the faulty shift solenoids. Ensure proper diagnosis to identify the specific solenoid causing the problem.
    • Estimated Cost to Fix: $500 - $1,200+ (parts and labor)
    • Recalls: None Found

Eaton Fuller Manual Transmission

  • Clutch Failure
    • Description/Symptoms: Slipping clutch, difficulty shifting, and grinding noises.
    • Solution: Replace the clutch assembly (disc, pressure plate, and throw-out bearing).
    • Estimated Cost to Fix: $1,000 - $2,500+ (parts and labor)
    • Recalls: None Found
  • Shift Fork Wear
    • Description/Symptoms: Difficulty shifting into specific gears, grinding noises, and potential gear lockup.
    • Solution: Replace the worn shift forks. This often requires a transmission disassembly.
    • Estimated Cost to Fix: $800 - $2,000+ (parts and labor)
    • Recalls: None Found

Ford TorqShift Transmission

  • Valve Body Issues
    • Description/Symptoms: Harsh shifting, delayed engagement, and slipping between gears. The valve body controls fluid pressure and shift timing.
    • Solution: Replace or rebuild the valve body. Sometimes, individual solenoids within the valve body can be replaced.
    • Estimated Cost to Fix: $800 - $2,000+ (parts and labor)
    • Recalls: None Found
  • Transmission Fluid Leaks
    • Description/Symptoms: Visible fluid leaks, low transmission fluid level, and potential transmission damage. Leaks can occur at seals, gaskets, and the transmission pan.
    • Solution: Replace the leaking seals or gaskets. Ensure proper torque specifications during reassembly.
    • Estimated Cost to Fix: $100 - $500+ (parts and labor, depending on the location of the leak)
    • Recalls: None Found

Suspension

  • Leaf Spring Sagging/Cracking
    • Description/Symptoms: Vehicle leaning to one side, rough ride, and reduced load-carrying capacity.
    • Solution: Replace the worn or damaged leaf springs. Consider upgrading to heavier-duty springs for increased capacity.
    • Estimated Cost to Fix: $500 - $1,500+ per spring (parts and labor)
    • Recalls: None Found
  • Shock Absorber Wear
    • Description/Symptoms: Bouncing ride, poor handling, and excessive body roll.
    • Solution: Replace the worn shock absorbers.
    • Estimated Cost to Fix: $200 - $600+ per axle (parts and labor)
    • Recalls: None Found

Electrical

  • Wiring Harness Issues
    • Description/Symptoms: Intermittent electrical problems, such as lights flickering, gauges malfunctioning, and starting issues.
    • Solution: Repair or replace the damaged sections of the wiring harness. Check for corrosion and chafing.
    • Estimated Cost to Fix: $200 - $1,000+ (parts and labor, depending on the extent of the damage)
    • Recalls: None Found
  • Alternator Failure
    • Description/Symptoms: Dimming lights, battery not charging, and eventual engine stalling.
    • Solution: Replace the alternator.
    • Estimated Cost to Fix: $300 - $700+ (parts and labor)
    • Recalls: None Found

Exterior

  • Rust
    • Description/Symptoms: Rust formation on body panels, frame, and undercarriage components. This is particularly common in areas with harsh winters and road salt.
    • Solution: Repair or replace rusted panels. Apply rust inhibitors and protective coatings to prevent further corrosion.
    • Estimated Cost to Fix: Varies greatly depending on the extent of the rust.
    • Recalls: None Found

Interior

  • HVAC Issues
    • Description/Symptoms: Inconsistent heating or cooling, blower motor failure, and issues with the blend door actuator.
    • Solution: Replace the faulty components (blower motor, blend door actuator, or heater core).
    • Estimated Cost to Fix: $200 - $800+ (parts and labor, depending on the specific issue)
    • Recalls: None Found

Summary The 2004 Ford F-750, while a dependable workhorse, can present several potential issues primarily related to its diesel engines and transmissions, especially given its age. Engine-related problems such as injector failure, HEUI pump issues (for the Caterpillar 3126), CPS failure (for the 7.3L Powerstroke), and turbocharger problems can be costly, ranging from hundreds to thousands of dollars. Transmission issues, including torque converter failure and valve body problems, also contribute to potential significant repair costs. Suspension and electrical problems are also common due to the vehicle’s age. While some fixes are relatively inexpensive, such as replacing the CPS sensor or repairing minor wiring issues, major repairs such as replacing injectors or rebuilding the transmission can be substantial expenses. The severity of these issues can range from minor inconveniences to major operational disruptions, making thorough inspection and regular maintenance essential for maintaining the vehicle’s reliability.

Ford, F750
Ford F750 2004
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