definitely annoying
Crashes / Fires:
0 / 1
Injuries / Deaths:
0 / 0
Average Mileage:
32,614 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 #5

Apr 252009

F-350 8-cyl Diesel

  • Automatic transmission
  • 79,000 miles


The contact owns a 2004 Ford F350. The contact stated that smoke appeared from the egr cooler tube. She also smelled antifreeze in the cab of the vehicle. The vehicle was taken to the dealer and they stated that it was still safe to drive and to return if the failure worsened. Later, the contact noticed thick, black oil coming from the exhaust. The vehicle was taken to a repair shop and the mechanic replaced the egr cooler tube with a kit from Ford at the contact's expense. The failure mileage was 79,000. Updated 06/09/09.

- Shoreview, MN, USA

problem #4

Jan 072008

F-350 4WD 8-cyl Diesel

  • Automatic transmission
  • 41,070 miles
On 01-06-2008 I started to have significant problems with my 2004 Ford F-350. It has just over 41,000 miles on it. It was smoking and had significant loss of power problems while at low road speed. Problem would clear once truck was >40 mph in speed. Took it to local Ford dealer on 01-07-2008. Their investigation showed that the egr valve was sticking. The valve assembly had to be replaced. The service person stated that this problem is common enough that they are keeping a couple of extra egr valve assemblies in their stock room. I asked if there was any indication of a product recall in the works. He said that he did not know of one but that one might happen in the near future and that I should keep my invoice just in case. My question/concern(s) is this: How often or frequent should an egr valve stick and/or fail? if their failure rate is high (1 failure per vehicle every 50,000 or less) then shouldn't there be a redesign and recall to improve the performance and safety?

- Hartsville, SC, USA

problem #3

Oct 012006

F-350 4WD 6-cyl Diesel

  • Automatic transmission
  • 40,000 miles
The contact owns a 2004 Ford F350. While at a stop light, the engine would rev. Depending on the contact's reaction time, the vehicle would move 4-5 feet. There were no warning indicators. The RPM would increase to 1,000. The dealer replaced the control module, three turbos, three egr valves, and the back pressure sensor. However, the failure continues. The failure mileage was 40,000 and current mileage was 61,000. Updated 01/11/08. Updated

- Moyock, NC, USA

problem #2

May 042007

F-350 8-cyl Diesel

  • Automatic transmission
  • 3,000 miles
Vehicle had a stalling problem on accelleration. Vehicle idled fine, but frequently on acceleration from a stop after vehicle started to roll. Engine will misfire, shutter, or backfire for several seconds until clearing up. Also, vehicle misfired at highway speeds. Vehicle was taken to the dealer on several occations to find the cause of the problem, but they reported could not duplicate the problem. Dealer replaced several injectors and egr valve to no avail.

- Louisville, KY, USA

problem #1

Apr 172004

F-350 Diesel

  • miles
While driving, T he vehicle stalled several times. The consumer would restart the vehicle while in motion. The brakes would go out when this would occur. The problem seemed to be resolved. The dealer replaced the egr valve (exhaust gas-recirculation). The vehicle idled erratically. The injector pressure regulator was replaced. The ebp sensor and the egr valve did not work properly and both were replaced. The ebp signal remained to fluctuate. Also, the turbo charger was not working properly.

- Thurmont, MD, USA

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