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2004 Ford F-250 Recalls, Problems & Maintenance

The 2004 Ford F-250 has no open NHTSA recalls. Owners report 6 recurring issue clusters, led by “Spark plug ejection from cylinder head.” Ford uses the Intelligent Oil-Life Monitor (IOLM) to determine when oil changes are due based on actual driving load — not just mileage. Ford's published cap is 10,000 miles or 1 year, whichever comes first. The schedule below reflects Ford's Normal service intervals; F-Series trucks and Super Duty have additional towing-specific items.

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No open recalls on file. NHTSA lists no unrepaired safety recalls for this year, make and model. A recall can be issued at any time, and a specific car can still have one open — check yours by VIN at nhtsa.gov/recalls.

Known issues & problems for this vehicle

What drivers and federal regulators have officially reported about the 2004 Ford F-250.

Reported to NHTSA

Spark plug ejection from cylinder head

ENGINE

7 NHTSA complaints · 2009-06 → 2020-12

“THE THIRD FROM THE FRONT ON THE PASSENGER SIDE SPARK PLUG BLEW OUT AND A HELI COIL WAS REPLACED AND AFTER UNDER 500 MILES IT BLEW OUT AGAIN NOW THEY ARE REPLACING A SECOND HELI COIL AND I AM WORRIED ON IF IT WILL HOLD AND HOW DEPENDABLE IT WILL BE”
— Owner report, NHTSA ODI #10873006
“TL*THE CONTACT OWNS A 2004 FORD F250 SUPERDUTY. THE CONTACT STATED THAT WHILE DRIVING APPROXIMATELY 60 MPH, THE ENGINE EJECTED SPARK PLUGS. THE VEHICLE WAS TAKEN TO A LICENSED MECHANIC AND REPAIRED BY ADDING AN INSERT INTO THE ENGINE HEAD”
— Owner report, NHTSA ODI #10323356
“I HAVE A 2004 F 250 SUPER DUTY. I EXPERIENCED A BLOW OUT OF THE SPARK PLUG ON TWO OCCASIONS. THE FIRST I WAS ABLE TO PUT THE PLUG BACK IN AND RE-THREAD THE PLUG. IT JUST RECENTLY BLEW OUT THE SECOND TIME WHICH WILL RESULT IN A GREATER REPAIR”
— Owner report, NHTSA ODI #10272990

Read all complaints on NHTSA →

Tire tread separation and blowout

TIRES

11 NHTSA complaints · 2010-06 → 2018-06

“WHILE DRIVING WEST BOUND ON INTERSTATE HIGHWAY 80 EAST OF IMLAY, NV AT APPROXIMATELY 70 MPH IN LANE #2, THE LEFT REAR TIRE LOST ABOUT 80-85% OF IT'S TREAD IN ABOUT 10 SECONDS, EXTENSIVELY DAMAGING THE UNDERSIDE WHEEL WELL AREA NEAR THE TIRE AND THE BODY OF THE VEHICLE”
— Owner report, NHTSA ODI #10730811
“BF GOODRICH TA KM2 TIRES I HAVE THREE SEPARATE ON A TRIP THAT STARTED AUGUST 14,2015 THE TIRES HAVE 19000 MILES ON THEM. THE FIRST TIRE SEPARATED ON THE 14TH AND I PUT A SPARE ON IT. THE OTHER TWO TIRES SEPARATED ON THE 16TH AND NOW THE 4TH TIRE IS SHOWING SIGNS OF SEPARATION”
— Owner report, NHTSA ODI #10750415
“THIS IS THE 8TH SEPARATION OUT OF 11 TIRES THEY HAVE ALL HAPPENED AFTER ABOUT 2 HOURS OF HIGHWAY DRIVING THIS ONE BLOW AND CAUSED ABOUT 2300 DOLLARS OF DAMAGE TO MY TRUCK NOT INCLUDING THE TIRE 3 MILES SOUTH OF IOLA KANSAS COMING FROM INDEPENDENCE MISSOURI IT GAVE ABOUT 3 TO 5”
— Owner report, NHTSA ODI #10819354

Read all complaints on NHTSA →

Engine stalling and loss of power while driving

ELECTRICAL SYSTEM

75 NHTSA complaints · 2008-10 → 2025-06

“TL* THE CONTACT OWNS A 2004 FORD F250 SUPER DUTY. THE CONTACT WAS DRIVING APPROXIMATELY 60 MPH WHEN THE VEHICLE STALLED WITHOUT WARNING”
— Owner report, NHTSA ODI #10381552
“TL* THE CONTACT OWNS A 2004 FORD-250 SD. THE CONTACT WAS DRIVING 65 MPH WHEN THE ENGINE STALLED. THE VEHICLE WAS TAKEN TO THE DEALER WHERE THE DEALER CONFIRMED THAT THE FUEL INJECTOR MODULE NEEDED TO BE REPLACED”
— Owner report, NHTSA ODI #10437886
“TL* THE CONTACT OWNS A 2004 FORD F-250. WHILE DRIVING AT ANY SPEED, THE VEHICLE WOULD STALL WITHOUT WARNING. THE FAILURE RECURRED NUMEROUS TIMES. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE VEHICLE WAS NOT INCLUDED IN NHTSA CAMPAIGN NUMBER: 05V270000 (ELECTRICAL SYSTEM)”
— Owner report, NHTSA ODI #10733944

Read all complaints on NHTSA →

EGR cooler, oil cooler and head gasket failure, 6.0L diesel

ENGINE AND ENGINE COOLING

24 NHTSA complaints · 2009-06 → 2019-03

“2004 FORD 6.0 LITER DIESEL MOTOR- EGR COOLER CRACKING AND THUS CAUSING COOLANT LEAKS INTO THE EXHAUST SYSTEM AND ENGINE CYLINDERS. EGR COOLER FAILURE CAUSES COOLANT TO ENTER ENGINE CYLINDERS THUS INCREASING CYLINDER PRESSURES ON HEADS. HEAD BOLTS STRETCH AND HEAD GASKETS FAIL”
— Owner report, NHTSA ODI #10287147
“I HAVE A 2004 FORD F250 SUPER DUTY WITH A 6.0 DIESEL. THE EGR COOLER WAS REPLACE TWICE UNDER WARRANTY AND WITH THE TRUCK NOW OUT OF WARRANTY WITH 111,000 MILES ON IT, THE EGR COOLER WENT OUT ONCE MORE AND FORD WOULD NOT HELP ME OUT ON THE REPAIR SO I HAD TO PAY FOR IT MYSELF”
— Owner report, NHTSA ODI #10295895
“TL*THE CONTACT OWNS A 2004 FORD F250 SUPER DUTY. THE CONTACT STATED THAT THE EGR COOLER NEEDED TO BE REPLACED THREE TIMES. THE VEHICLE WOULD PRODUCE A LOT OF SMOKE AND FAIL TO ACCELERATE PROPERLY ONCE THE EGR FAILED”
— Owner report, NHTSA ODI #10275420

Read all complaints on NHTSA →

Front-end shake and steering wheel oscillation at speed

STEERING, SUSPENSION

7 NHTSA complaints · 2009-07 → 2025-07

“My 2004 F250 has developed the "Death Wobble" that is normally associated with newer models, but the shudder at or around 40-45mph is identical to the described problems of the newer models in the class action lawsuit and tech bulletins published by Ford”
— Owner report, NHTSA ODI #11673871
“FRONT END SHAKES VIOLENTLY AFTER HITTING A ROUGH SPOT ON PAVEMENT AT HIGHWAY SPEED. CONTINUES UNTIL SPEED IS REDUCED TO LESS THAN 50 MPH”
— Owner report, NHTSA ODI #10557862
“TRAVELING AT REGULAR MOTORWAY SPEEDS (55 - 70) THE TRUCK VIBRATES VIOLENTLY AND CONSTANTLY. IT STOPS ONCE THE VEHICLE SLOWS TO BELOW 30MPH. I HAVE CHECKED OTHER COMPLAINTS AND WILL BE CHECKING TIRE PRESSURE AND SEEING IT A STEERING DAMPENER CAN BE ADDED”
— Owner report, NHTSA ODI #10462909

Read all complaints on NHTSA →

Brake line, caliper and master cylinder failure

SERVICE BRAKES

7 NHTSA complaints · 2008-10 → 2019-11

“COMPLETE LOSS OF BRAKING DUE TO A BROKEN REAR BRAKE LINE. OCCURRED AFTER PULLING/ PARKING A 12000 LB 5TH WHEEL RV. BREAK ATTRIBUTED TO RUST BY FORD SERVICE DEPT”
— Owner report, NHTSA ODI #10919225
“THE CALIBER SUDDENLY BROKE AND I HAD NO BRAKES. ALL OF THE BRAKE FLUID LEAKED OUT”
— Owner report, NHTSA ODI #11277681
“THE VEHICLE IS A 2004 FORD F-250 SUPER DUTY I STEPPED ON MY BRAKES AND HEARD A POP. THE PEDAL WENT TO THE FLOOR. WHEN I GOT THE VEHICLE STOPPED, AND INVESTIGATED, I FOUND THAT ONE OF THE TWO BOLTS THAT MOUNT THE MASTER CYLINDER HAD BROKEN OFF”
— Owner report, NHTSA ODI #10246580

Read all complaints on NHTSA →

Issues on other model years

Source: NHTSA Office of Defects Investigation (ODI). Complaint data refreshed Sep 20, 2026. Investigation data refreshed Sep 20, 2026.

We display NHTSA's record with attribution; we don't editorialize on what these complaints mean for any specific vehicle.

Raw data + downloads for this vehicle →

Essential maintenance

Critical for safety and preventing major damage

Engine Oil & Filter

Every 7,500 mi

Replace synthetic-blend or full-synthetic Motorcraft oil per the IOLM, or every 7,500-10,000 miles. EcoBoost engines require full synthetic; Coyote 5.0L V8 specifies SAE 5W-30.

Estimated cost — typical U.S. ranges

Dealer

~$120–$160

Shop

~$85–$115

DIY

~$25–$55

Full synthetic costs more than conventional. 5-quart 0W-20 + filter is the typical bill.

Tire Rotation

Every 10,000 mi

Rotate tires every 10,000 miles, or with every other oil change. F-150 4x4 owners should rotate every 5,000-7,500 miles to even out drivetrain bias wear.

Estimated cost — typical U.S. ranges

Dealer

~$85

Shop

~$60

DIY

Free

Often free at the shop where you bought the tires — worth asking before paying.

Brake Inspection

Every 10,000 mi

Inspect brake pads, rotors, and brake fluid level every 10,000 miles. Front pads on F-150 and Explorer typically last 40,000-60,000 miles.

Estimated cost — typical U.S. ranges

Dealer

~$85

Shop

~$60

DIY

Free

Most shops do this free as a courtesy with any service. Don't pay separately if you can avoid it.

Brake Fluid

Every 45,000 mi

Ford specifies brake fluid replacement on an inspection basis, but moisture testing every 3 years is recommended. Replace if reading exceeds 3% water content.

Estimated cost — typical U.S. ranges

Dealer

~$180–$200

Shop

~$125–$140

DIY

~$10–$25

DOT 3 or 4 — match the cap. Vacuum bleeders make this a one-person DIY.

Important maintenance

Keeps your vehicle running smoothly and efficiently

Engine Air Filter

Every 30,000 mi

Replace the engine air filter every 30,000 miles. EcoBoost turbocharged engines are sensitive to airflow restriction — don't extend.

Estimated cost — typical U.S. ranges

Dealer

~$60–$95

Shop

~$45–$70

DIY

~$15–$40

5-minute job on most cars; the airbox lid usually has clips, no tools needed.

Automatic Transmission Fluid

Every 150,000 mi

Ford 6R80, 10R80, and 8F transmissions use Mercon LV fluid rated 150,000 miles under normal service. Severe service (towing, plowing) drops this to 60,000 miles.

Estimated cost — typical U.S. ranges

Dealer

~$330–$500

Shop

~$235–$355

DIY

~$60–$180

Some sealed transmissions have no dipstick — fill is precise and best left to a shop. Many drivers can still DIY drain-and-fill.

Transfer Case Fluid (4WD models)

Every 60,000 mi

On 4x4 models, replace transfer case fluid every 60,000 miles. Use Motorcraft XL-12 — do not substitute generic transfer case fluid.

Estimated cost — typical U.S. ranges

Dealer

~$105–$140

Shop

~$75–$100

DIY

~$15–$40

AWD/4WD vehicles only. Easy drain-and-fill on most platforms.

Rear Differential Fluid

Every 100,000 mi

F-Series and Expedition: replace rear axle fluid every 100,000 miles, or 50,000 miles if towing. Limited-slip rear ends require friction-modifier additive.

Estimated cost — typical U.S. ranges

Dealer

~$150–$195

Shop

~$105–$135

DIY

~$20–$50

Drain plug + fill plug — straightforward DIY. AWD vehicles have two; budget for both.

Spark Plugs

Every 100,000 mi

Iridium spark plugs on Coyote 5.0L, EcoBoost 2.7L/3.5L, and 2.3L are rated 100,000 miles. EcoBoost engines: never exceed the interval — gap erosion causes coil failure.

Estimated cost — typical U.S. ranges

Dealer

~$285–$390

Shop

~$200–$275

DIY

~$25–$100

Iridium plugs cost more but last 100k+ miles. V6/V8 access varies wildly — some are tough.

Engine Coolant

Every 50,000 mi

Motorcraft Orange (Dex-Cool compatible) coolant: first change at 100,000 miles, then every 50,000. Older trucks with Yellow Motorcraft coolant: 50,000 miles throughout.

Estimated cost — typical U.S. ranges

Dealer

~$285–$330

Shop

~$200–$235

DIY

~$25–$60

Use the manufacturer-specified coolant — wrong color/chemistry can damage the cooling system.

Recommended maintenance

Extends the life of your vehicle and improves comfort

Cabin Air Filter

Every 20,000 mi

Replace the cabin air filter every 20,000 miles. On F-150, located behind the glove box; on Escape and Explorer, accessed from the passenger footwell.

Estimated cost — typical U.S. ranges

Dealer

~$60–$95

Shop

~$45–$70

DIY

~$15–$40

Usually behind the glovebox. Shops charge labor for a 10-minute job — easy DIY win.

Fatal crash history & reported problems

Occupant deaths in fatal crashes (FARS)

1,680 crashes 1990–2024

How the 1,680 occupant deaths break down

1,274

driver deaths

404

passenger deaths

2

not recorded by seat

1,680

occupant deaths

Crash years covered: 1990–2024 This model year first appears in 2003 crashes. Older models have had more years on the road to appear in these crashes, so a higher count here does not by itself mean a vehicle is less safe.

FARS counts every occupant death in a fatal crash, whatever the cause — it does not mean the vehicle was at fault or defective. Counts are not adjusted for how many of each vehicle are on the road. How to read this number

FARS 2024 data is an annual report file. NHTSA revises these records when the final file is published, so this count can change.

Why we show driver deaths too

Every vehicle has exactly one driver seat, so driver deaths line up fairly when you compare one model to another. Occupant deaths include passengers, so a three row SUV can show a higher number than a two seat car simply because it carries more people.

Both figures are plain counts, not rates. A rate would need to know how many of each vehicle are on the road, and that registration data is not public, so we do not publish rates or scores of any kind.

IIHS publishes driver death rates using this same driver only idea, paired with a registered vehicle years denominator we do not have. Their rates and these counts answer different questions, so do not read either number here as a safety rating.

Owner-reported problem signals

Separate from the federal fatality data above: complaints owners filed with NHTSA about this year and model. These are reports of problems, unverified, and are counted here only as signals.

21

complaints mentioning a crash

16

complaints mentioning a fire

Reviewed known issues for this vehicle

Typical U.S. ranges. Actual quotes vary by shop, parts choice, and vehicle condition.

How we estimate: Dealer = OEM parts × 1.4 + labor × $165/hr. Shop = parts + labor × $115/hr. DIY = parts only.

This maintenance schedule for the 2004 Ford F-250 reflects Ford's published service intervals and the Intelligent Oil-Life Monitor system. Your actual service needs may vary based on driving conditions, climate, and vehicle usage. Always consult your owner's manual for model-specific recommendations.

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