2004 Ford F Super Duty: common problems

Owners of the 2004 Ford F Super Duty filed 14 complaints with NHTSA, most often about electrical system and engine. Details by component below, with sources.

Key figures

Owner complaints: 14

What fails most often

1 Electrical system 29% of all complaints
2 Engine 29% of all complaints
3 Service brakes 21% of all complaints
4 Engine and cooling 14% of all complaints
5 Fuel system 14% of all complaints
6 Exterior lighting 7% of all complaints
7 Powertrain 7% of all complaints
8 Steering 7% of all complaints

Circle size and colour show each component’s share of NHTSA complaints. Schematic only, not a drawing of the exact model.

Electrical system: 4 complaints (29% of all).
Engine: 4 complaints (29% of all).
Service brakes: 3 complaints (21% of all).
Engine and cooling: 2 complaints (14% of all).
Fuel system: 2 complaints (14% of all).

Symptoms owners describe

How many of the 14 NHTSA complaints mention each symptom (automatic count from complaint text; one complaint can mention several).

stalls while driving2 · 14%
warning lights, check engine2 · 14%
windows, sunroof2 · 14%
loss of power / limp mode1 · 7%
rust, corrosion1 · 7%
infotainment or screen glitches1 · 7%
steering or power steering problems1 · 7%

Components owners complain about

Component	Owner complaints	involving a crash	Technical service bulletins (TSB)
Electrical system	4	0	0
Engine	4	0	0
Service brakes	3	0	0
Engine and cooling	2	0	0
Fuel system	2	0	0
Exterior lighting	1	0	0
Powertrain	1	0	0
Steering	1	0	0
Suspension	1	0	0
Tires	1	0	0
Vehicle speed control	1	0	0
Other	2	0	0

What owners report

Short excerpts of NHTSA complaints in the original wording. These are owner statements not verified by NHTSA; personal data removed.

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.
Service brakes · 2015-09-30 · NHTSA complaint #10778611
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
Engine · 2015-09-23 · NHTSA complaint #10775379
The truck stalled when I was going 70 mpg on the interstate in traffic and would not restart until it sat for 3 minutes.
Electrical system · 2015-02-13 · NHTSA complaint #10683144
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.
Engine · 2015-01-07 · NHTSA complaint #10670813
Brake line failed catastrophically due to corrosion resulting in loss of all brakes after only 9.5 years and 67000 miles.
Service brakes · 2014-07-07 · NHTSA complaint #10608732
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).
Engine · 2014-03-19 · NHTSA complaint #10573470
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.
Service brakes · 2014-03-07 · NHTSA complaint #10567758
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. .
Electrical system · 2014-01-05 · NHTSA complaint #10558523

When owners complained

NHTSA complaints by filing year. The peak shows at what age the problems show up most.

20081
20091
20111
20131
20144
20156

Comparison

By complaint count this model year ranks 9,552 of 36,659 model years in the NHTSA data (top 26% most complained about).

On average one model year of the F Super Duty has 20 complaints (21 years in the data). This year has 14, below average.

What to check before buying

Electrical system. Scan all modules, test the battery and alternator, inspect connectors near the impact zone.
Engine. Cold start, unusual noises, oil leaks and engine codes.
Service brakes. Pedal feel, ABS operation, leaks, discs and hoses.
Engine and cooling. Radiator and fan after a frontal hit, coolant level and condition, overheating.

Other years of this model

Questions and answers

What are the most common problems with the 2004 Ford F Super Duty?

Owner complaints to NHTSA most often mention: electrical system, engine, service brakes. Total complaints: 14. The most frequent symptoms in complaint texts: stalls while driving (14%), warning lights, check engine (14%), windows, sunroof (14%).

How many service bulletins (TSB) were issued for the 2004 Ford F Super Duty?

NHTSA lists 0 manufacturer service bulletins for this year. A bulletin tells dealers how to diagnose or fix a known issue; it is not a recall.

Should I buy a 2004 Ford F Super Duty from a US auction?

Owner complaints describe defects, not crash damage. Before bidding, check the components listed above and review the lot photos: VinWind builds a report of visible and hidden damage by VIN.

Other 2004 models

Read also

Sources: public NHTSA data (USA): service bulletins and owner complaints; YouTube: links to videos credited to their authors. Complaints are owner statements not verified by NHTSA, and describe defects rather than crash damage. Data updated 2026-11-06.