2004 Ford F-550 SD: problems, recalls and reliability
3 recalls and 49 owner complaints on record; the weakest area is fuel system, diesel (31% of complaints); the 2002 model year looks more trouble-free.
Data updated weekly · latest recall Jul 2011
All counts are reports filed with NHTSA in the United States - US market only, not worldwide totals.
Common problems
Computed from 49 owner complaints filed with NHTSA for this exact model year.
“Tl* the contact owns a 2004 ford f-550 sd. While driving approximately 55 mph, the vehicle stalled without warning. The vehicle restarted; however, the failure recurred approximately one mile later. The vehicle did not restart and was towed to the contact's job. The vehicle was taken to the dealer where it was diagnosed that the wiring harness was faulty, melted, and needed to be replaced. The vehicle was not repaired. The manufacturer was made aware of the failure and stated that the VIN was not included in NHTSA campaign number: 05v270000 (electrical system). The approximate failure mileage was 155,862.”Owner report · Electrical System · Feb 2016
“Tl* the contact owns a 2004 ford f-550 super duty. While the link was in the air with a worker located in the bucket, the link fractured without warning. The worker's bucket came down with force causing injury to his head, back, and pelvic area. The worker received medical attention. The vehicle was not diagnosed. The contact stated that the VIN was included in an equipment manufacturer recall for a link failure, but the contact did not receive a notification. The vehicle was not repaired. The failure mileage and recall number were not available.”Owner report · Structure · Sep 2015
“2004 f550 diesel. Consumer states vehicle has a faulty head-gasket *tgw the consumer stated the truck would only run for 20 minutes before it overheated. The consumer was informed it cost close to 10,000 to fix the truck. *jb”Owner report · Engine And Engine Cooling · Jul 2012
Show 7 more owner reports
“Tl* the contact owns a 2004 ford f-550 sd. While driving approximately 5 mph, the engine stalled without prior warning. The vehicle failed to restart and it was towed to an independent mechanic who stated the failure was contributed to the high pressure oil pump. The vehicle was repaired. The manufacturer was notified of the problem. The approximate failure mileage was 30,000. Updated 8/8/12 *cn updated 08/15/2012 *js”Owner report · Engine · May 2012
“Vehicle (2004 diesel f550 truck) was traveling on I-405 during rush hour traffic when the vehicle stalled. Dealer says that the paint/laminate inside the fuel tank is corroding and pieces of debris are being fed into the fuel system causing sudden stalling of vehicle. No off-road diesel has ever been used in the tanks--standard diesel fuel only. *tr”Owner report · Fuel System, Diesel · Dec 2011
“Tl* the contact owns a 2004 ford f-550. The contact stated that the vehicle would not start. The dealer diagnosed that the fuel injector wire was melting on the engine. The vehicle was repaired and recurred. The manufacturer was notified, but denied any assistance with repairs. The failure mileage was 116,000 and the current mileage was 121,164.”Owner report · Electrical System · Jun 2011
“Tl*the contact owns a 1997 ford f-550 super duty. The contact stated the vehicle would stall while driving at various speeds. The vehicle was taken to an authorized dealer where the contact was informed the vehicle was stalling due to delamination of the fuel tank. The vehicle was not repaired. The failure mileage was unknown and the current mileage was 144,250.”Owner report · Fuel System, Diesel · Jun 2011
“Tl*the contact owns a 2004 ford f-550 superduty. While driving approximately 35 mph the vehicle stalled. It was towed to another location where the driver was able to get it restarted. The vehicle was then taken to an authorized dealer where the driver was informed the fuel tank was de-laminating due to rust and corrosion. It was not repaired. The failure and current mileages were 80,978.”Owner report · Fuel System, Diesel · Aug 2010
“We own a fleet of ford diesel engine trucks which continue to experience fuel delivery problems. The problem is engine cut-off and surging and hard starting. Ford says not their problem and charges us. I don't think we have the only ones. Toyota is not the only company not dealing with this problem. Think only the government will make them fix it. *tr”Owner report · Fuel System, Diesel · May 2010
“Tl*the contact owns a 2004 ford f550. Two hours after the vehicle was parked, it caught fire. The contact stated that it was an electrical fire inside the cab that did not seem to affect the engine. The fire was not reported to the fire department or police. The contact used water and a fire extinguisher to extinguish the flames. The vehicle has not been taken to a dealer or mechanic and has not left the scene of the fire. The current and failure mileages were 50,000.”Owner report · Electrical System · Jun 2009
When filing, owners marked a crash in 1 of these complaints and injuries in 4 - self-reported to NHTSA, not verified accident statistics.
Recalls - 3 campaigns
CERTAIN PICKUP TRUCKS, SPORT UTILITY VEHICLES AND VANS EQUIPPED WITH 6.0L DIESEL ENGINES MAY EXPERIENCE STALLING WITHOUT WARNING WHILE DRIVING AND MAY OR MAY NOT RESTART.
Remedy: DEALERS WILL UPGRADE THE FUEL INJECTION CONTROL MODULE (FICM) WIRE HARNESS OR REPLACED, AND/OR HAVE A NEW INJECTION CONTROL PRESSURE (ICP)) SENSOR CONNECTOR INSTALLED FREE OF CHARGE. THE RECALL BEGAN ON JULY 22, 2005. OWNERS MAY CONTACT FORD AT 1-800-392-3673.
FORD IS RECALLING CERTAIN MODEL YEAR 2011 RANGER TRUCKS BUILT FROM JANUARY 25, 2011, THROUGH APRIL 25, 2011 AT THE TWIN CITIES ASSEMBLY PLANT, AND SERVICE PARTS DISTRIBUTED TO DEALERS FOR CERTAIN 2004 THROUGH 2011 MODEL YEAR RANGER TRUCKS, 2002 THROUGH 2005 MODEL YEAR EXCURSION VEHICLES, AND 2002 THROUGH 2007 MODEL YEAR F-250, F-350, F-450, AND F-550 TRUCKS FOR FAILING TO COMPLY WITH THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 108, "LAMPS, REFLECTIVE DEVICES, AND ASSOCIATED EQUIPMENT." THE MULTI-FUNCTION SWITCH WAS SHIPPED WITH A SUBCOMPONENT (SLIDER) THAT MAY EXPERIENCE DEFORMATION. A MULTI-FUNCTION SWITCH WITH A DEFORMED SLIDER MAY MALFUNCTION CAUSING THE TURN SIGNAL, TAIL LIGHTS, HAZARD WARNING SIGNAL FLASHERS AND/OR BRAKE LIGHTS NOT TO ACTIVATE.
Remedy: DEALERS WILL REPLACE THE SWITCHES FREE OF CHARGE. THE SAFETY RECALL BEGAN ON AUGUST 15, 2011. OWNERS MAY CONTACT FORD MOTOR COMPANY CUSTOMER RELATIONSHIP CENTER AT 1-866-436-7332.
CERTAIN CEQUENT 90 DEGREE 7-WAY RIGHT ANGLE ADAPTORS SOLD BY DISTRIBUTORS IN TOW PACKAGES FOR AFTERMARKET SALES TO TOW 5TH WHEEL RV TRAVEL TRAILERS. DUE TO INCORRECT WIRING OF THE HARNESS, THE TRAILER LIGHTS MAY NOT OPERATE PROPERLY.
Remedy: ALL OF THE DEFECTIVE TOW PACKAGES ARE STILL AT THE DISTRIBUTOR LEVEL AND HAVE NOT BEEN SOLD TO ANY CONSUMERS.
How other years compare
Check your exact F-550 SD by VIN
Recalls and equipment differ between individual vehicles. Decode your VIN to see what applies to yours.
Open VIN decoderFrequently asked questions
Is the 2004 Ford F-550 SD reliable?
NHTSA has 49 owner complaints and 3 recall campaigns on record for the 2004 Ford F-550 SD. The most complained-about area is fuel system, diesel (31% of complaints).
At what mileage do 2004 Ford F-550 SD problems usually appear?
Half of the complaints that mention mileage were filed at 41,000 miles or less.
Does the 2004 Ford F-550 SD have open recalls?
3 recall campaigns have been issued, the latest concerning electrical system:wiring. Check your specific vehicle by VIN - recall repairs are free at franchised dealers.
Source: NHTSA recall campaigns and owner complaints (public domain). Counts reflect reports on file and are not a defect rate.