Huge win for car owners! All TSBs to be made public. The Center for Auto Safety just made the NHTSA (US Government) make public the full text of all TSBs from now on. They are the same organization that has petitioned the NHTSA & filed lawsuits to protect car owners over exploding gas tanks & other major safety issues. Whenever you drive in your car, you are safer thanks in part to a lot of work over the years by this small but very effective consumer advocacy group.

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really awful
Crashes / Fires:
0 / 0
Injuries / Deaths:
3 / 0
Average Mileage:
20,517 miles

About These NHTSA Complaints:

This data is from the NHTSA — the US gov't agency tasked with vehicle safety. Complaints are spread across multiple & redundant categories, & are not organized by problem.

So how do you find out what problems are occurring? For this NHTSA complaint data, the only way is to read through the comments below. Any duplicates or errors? It's not us.

2004 Ford F-350 exhaust system problems

exhaust system problem

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2004 Ford F-350 Owner Comments

problem #6

Jun 022014


  • miles


The contact owns a 2004 Ford F-350. The contact stated the exhaust system warning light illuminated and the engine loss power. The vehicle restarted. The contact mentioned that the failure recurred on several occasions. The contact referenced NHTSA campaign number: 07V139000 (power train). The vehicle was taken to a dealer. The technician diagnosed that the exhaust sensor needed to be replaced. The manufacturer was notified of the failure. The approximate failure mileage was unknown.

- Meridian, ID, USA

problem #5

Jun 012009

F-350 8-cyl Diesel

  • Automatic transmission
  • 86,000 miles
2004 F350 diesel 6.0, egr cooler went out. I was in the middle of the hwy when this occured. Clouds of smoke went out the tailpipe, engine overheating stranding me in the center lane stopped before I could get over to the shoulder. Passerby's help me push my truck off a busy hwy. Smoke was so thick I couldnt nor could other drivers see around me. Ford has had numerous complaints on this engine and part, but have failed to respond, or they waiting for a death to occur. The internet is full of complaints for the exact same thing. Letters to Ford Motor Co. And my local dealer leif johnson Ford were unsuccessful. I'm not able to pay the almost $3000 the dealer wants to fix the problem. This is an obvious defect on Ford's part. Very fustrated as I have a expensive truck just parked for several months in my driveway. Updated 2/17/10 updated 02/22/10

- Elgin, TX, USA

problem #4

Sep 102004

F-350 4WD Diesel

  • Automatic transmission
  • 4,000 miles
When truck originally purchased bubble on tire, and dealer said they all come that way, tire went flat while parked about a month later, no holes, we were told tire was no good, had to be replaced. Truck kept stalling, loss of brakes and steering while navigating downhill, solenoid assembly replaced. 2 days later kept stalling. Dealer had truck 21 days to rebuild transmission, again solenoid assembly replaced after that replaced wiring harness. Since then, caliper broke and brakes went, turbo has been replaced. Vehicle has repeatedly stalled, noises from rear end with no dx. Now engine smoking, loss of power, rpms jump while idling. Truck has also repeatedly changed gears automatically, ie while at red light truck would jump to 3rd and then truck would stall.

- Scranton, PA, USA

problem #3

Apr 252004

F-350 4WD 8-cyl Diesel

  • Automatic transmission
  • 1,000 miles


Under acceleration between 25 and 45 mph the vehicle loses power. There is hesitation when vehicle accelerates. It is as though it bogs down and can not gain any speed. Also, a large amount of black smoke was expelled from the exhaust. When this occurs the truck comes to crawl in middle of traffic, and happens mostly in stop and go traffic, as well as on interstate. Took vehicle to a dealer 4 times for this problem within 28,000 miles. Dealership could not find anything wrong, but did trouble shooting repairs to the computer, and then replaced the turbo. Dealer admitted they did not know how to fix or diagnose this problem. Consumer has not contacted the manufacturer at this time. No other repairs were done or issues outside of this probekm occurred.

- Chantilly, VA, USA

problem #2

Sep 012004

F-350 4WD 8-cyl Diesel

  • Automatic transmission
  • 1,100 miles
There are toxic fumes coming through the defroster when it is turned on. Which is distracting the driver on the road. Manufacturer had been contacted by consumer. The consumer purchased a carbon monoxide detector in which the vehicle registered 40 ppm. As the weather turned cold, the consumer was unable to use the defroster or heater due to the diesel fumes from the exhaust system. The consumer suffered nose bleeds and his mother-in-law had become ill while riding in the vehicle. Two dealerships stated that they could not find anything wrong with the vehicle. The engine died while going down hill to a stop at times, the vehicle stuck in 4X4 low, driver door molding was coming a loose, head light was inoperative at times and the switch was replaced, the rear door did not line properly and leaked air therefore both rear door upper seals were adjusted.

- Quincy, CA, USA

problem #1

Apr 152004

F-350 8-cyl Diesel

  • Automatic transmission
  • 31,000 miles
Vehicle is experiencing a problem with the exhaust fumes which seem to be getting into the cab of the pickup. Vehicle has been to the dealers on several occasions. Also, contacted the manufacturer. However, they did not help the owner with this problem. The exhaust fumes were coming through the air conditioner and heat vents. When driving, the exhaust fumes burned the driver's eyes, and gave owner a headache. Updated 12/27/2005 - the vehicle has also been having injector problems

- Live Oak, FL, USA

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