2004 Ford F Super Duty problems, complaints & recalls
Most-reported problem areas: Electrical System (3) · Service Brakes (2) · Fuel System, Diesel (2)
🧭 Reliability snapshot
Compared against other Ford F Super Duty model years — complaint volume vs the model's median year, recalls and severity. How we score →
Safety recalls (0)
No recalls on record for this model year (campaigns announced since 2010).
Service bulletins (15)
Technical service bulletins are repair instructions manufacturers send dealers for known issues. Unlike recalls, the fix is not automatically free — but naming the bulletin at the service desk can save diagnosis time and support goodwill repairs.
Engine And Engine Cooling:exhaust System:manifold/Header/Muffler/Tail Pipe 2016-09-21 · SSM 46085 · Service Bulletin/Repair Instructions
the powertrain control/emissions diagnosis (pc/ed) manual has been revised for diagnosing electronic throttle bodies (etbs). the etc_act and etc_dsd pids should not used to diagnose possible etb concerns. the ids has a limited refresh rate when reading these pids and cannot display quickly enough to
Equipment Adaptive/Mobility 2014-02-01 · ASI-44408 · Service Bulletin/Repair Instructions
ford: the restraint control module (rcm) when using vcm ii, would have an error code 35 and diagnostic trouble code (dtc) b1035, and difficulty attempting programmable module installation (pmi). model 2001-2004 f-super duty. *pe
Engine 2012-07-10 · TSB-12-7-4 · Service Bulletin/Repair Instructions
ford/lincoln/mercury: if battery was disconnected or dead, vehicles/trucks may experience hard starts and engine idle rpm fluctuation and exhibit diagnostic trouble codes (dtcs) p0505, p0506, p2111 and p2112. *pe
Fuel System, Gasoline:fuel Injection System:injectors 2010-06-11 · TSB-10-12-6 · Service Bulletin/Repair Instructions
ford: runs rough, lacks power, hard start, no start. some vehicles and trucks equipped with 6.0l engine may exhibit a runs rough, lacks power, hard to start, no start concern with or without diagnostic trouble code (dtc) p0611 code or various injector circuit codes. *pe
Engine And Engine Cooling:exhaust System 2009-12-09 · TSB-09-15-6 · Service Bulletin/Repair Instructions
ford: some vehicles equipped with the 6.0l engine may experience a p006a, p132, p0401 or p0402 diagnostic trouble code (dtc) with a lack of power condition, surge, or turbocharger flutter after performing field service action (fsa) 06e17, or after recalibrating the vehicle with the inferred exhaust
Power Train:automatic Transmission:control Module (Tcm/Pcm/Tecm) 2009-08-19 · SB-09B09 · Service Bulletin/Repair Instructions
ford: certain vehicles with ambulance prep package ambulance class action settlement; pcm part number inspection. awareness communication dated 4/20/09. *pe
Showing the 6 most recent of 15 bulletins. Search all of them free at nhtsa.gov.
What owners report
2015-09-30 · Service Brakes · 91,103 mi“driving at approx. 30mph. applied brakes. very little pressure as pedal went to the floor. both front brake lines from abs pump to lf & rf brake hoses were rotted, as was 3rd line from abs pump to rear union. all 3 required replacement.…”
2015-09-23 · Engine · 12,100 mi“engine 6.0l, check engine light on, code p0299, 'underboost", car owned since new, odometer now has 12,100 mlesi ford dealership reporting that engine turbo-compressor may need replacement…”
2015-07-09 · Electrical System · 114,000 mi“as i'm driving, the horn will sometimes just start blowing by itself for no reason. this is an extremely unsafe as when i'm driving and this happens, it's will scare me completely and usually those around me. i have to quickly pull over and bang on the horn to get it to quit blowing. it seems to be in the airbag area. thank you. …”
2015-06-03 · Unknown Or Other · 54,687 mi“had 8 broken exhaust bolts on this 6.8 v10 only 54687 miles on the truck.…”
2015-02-13 · Electrical System · 140,000 mi“the truck stalled when i was going 70 mpg on the interstate in traffic and would not restart until it sat for 3 minutes. *tr…”
2015-01-07 · Fuel System, Diesel · 104,551 mi“engine,6.0 diesel was loosing water. took the vehicle to the dealer and was told that the head gaskets were blown and that the head bolts were soft and had stretched. this is a known fault with this engine according to the dealer. if it is a known fault, why hasn't there been a recall to fix this. i have never known an engine to have blown head gas…”
2014-07-07 · Service Brakes · 67,000 mi“brake line failed catastrophically due to corrosion resulting in loss of all brakes after only 9.5 years and 67000 miles. *js…”
2014-03-19 · Power Train · 40,000 mi“lack of power or runs rough condition, and/or the malfunction indicator light on with egr related diagnostic trouble codes (p0401, p0402, p0403, p0404, p0405, or p0406). engine and engine cooling:exhaust system:emission control:gas recirculation valve (egr valve). *tr…”
2014-03-07 · Suspension · 49,012 mi“right front wheel bearing and anti-lock system failed, crossed the center line in the town .stepping on the brakes only made matters worse; because now it pulled harder to the left. crain ford after replace every part on the right side. shortly after that it again the truck pulled to left and the brakes had to be replace because of a bent caliper. …”
2014-01-05 · Vehicle Speed Control · 140,000 mi“driving truck down road i hear the radio shut off, then all dash board lights are off. look at the dash board gauges and they are going nuts fuel , battery , temp gauges, and speed o would pin below 0 the tach gauges would pin as high as it would go then start moving up and down fast. . last a few mins then go back o normal. i pulled the truck in …”
Excerpts of consumer complaints filed with NHTSA, lightly truncated. They are owner statements, not verified findings.