2004 Ford F-250 Fuel system Problems

I purchased this truck in January 2023. Drove just fine for 2 months and started having this issue. While driving my 2004 f250 sd 6.0l turbodiesel 4x4, (egr deleted, bulletproofed and studded engine, cold air intake, oil cooler, sct x4 tuner) a "fizzle" noise was heard more on passenger side; acting like fuel wasn't reaching engine; and truck stalled right after noise was heard. Wouldn't restart on a hot engine. Crank-no start. Drained both batteries attempting to restart. Restarted after cold engine but would stalled out and not be able to restart while hot engine. Replaced both fuel filters, fuel pump, some module in front bumper relating to fuel system. A friend that knows diesel engines has been trying to find out why its operating the way it is. I treated the gas tank to (2) SEAFOAM for trucks and had valvoline in Ferndale, WA do an oil change after purchasing it. Recalls say that they've been done, but could this issue be caused by the FICM recall?

NHTSA ID

11536759

Incident

Mar 1, 2023

I was driving in nampa around 5pm when my truck lost power my fuel peddle had 0 response tried to pull off the road almost had an accident because truck died losing steering power and brakes was hard to push truck had lost the voltage board in the ficm. Upon going over forums this is a major common issue amongst many ford owners. I also have a ground short from unknown location not sure as to what has caused this but assuming it has to do with the wiring harnesses to the ficm. I feel Ford should be in repair of this due to the large amount of issues across the nation of 6.0 owners but this is a very dangerous situation for owners. Not having steering control in such a large truck is extremely dangers. Previous owner had same issue and replaced the ficm and said it shouldn’t ever be an issue I feel there is a wiring issue that needs to be addressed.

NHTSA ID

11457900

Incident

Mar 2, 2022

VEHICLE LOSES ALL POWER-STALLS AND LOSES FUNCTION WHEN IDLING. HAS OCCURRED WHEN EXITING FREEWAY WAY AND IN A REGULAR NEIGHBORHOOD STREETS. NEED TO RESTART AFTER STALL.

NHTSA ID

11387696

Incident

Jan 2, 2021

Mileage

200,000 mi

REDUCED POWERED UNDER A GRADE/LOAD. REDUCED ACCELERATION. BOGS DOWN, CANNOT REACH SPEEDS HIGHER THAN 40-45 MPH, UP HILL.

NHTSA ID

11271433

Incident

Aug 15, 2019

Mileage

136,000 mi

TL* THE CONTACT OWNS A 2004 FORD F-250. THE CONTACT STATED THAT A CONE FRACTURED IN THE FUEL PICKUP SENDER UNIT. THE FAILURE RECURRED NUMEROUS TIMES. ALSO, THE VEHICLE STALLED WHILE DRIVING WITHOUT WARNING. THE CONTACT COASTED TO THE SIDE OF THE ROAD AND THE VEHICLE WOULD NOT RESTART. THE CONTACT STATED THAT THE VEHICLE WAS TOWED MORE THAN ONCE TO GRIECO FORD OF DELRAY BEACH (3000 S FEDERAL HWY, DELRAY BEACH, FL 33483, (561) 278-0303) WHERE IT WAS DIAGNOSED THAT THE CONE DISINTEGRATED IN THE FUEL TANK AND NEEDED TO BE REPLACED. THE VEHICLE WAS REPAIRED. THE TECHNICIAN REPLACED THE CONE UNIT, FUEL FILTER, FUEL LINES, AND INJECTOR. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE AND PROVIDED CASE NUMBER: CAS-24538661. THE FAILURE MILEAGE WAS APPROXIMATELY 59,000.

NHTSA ID

11269219

Incident

Oct 11, 2019

Mileage

59,000 mi

TL* THE CONTACT OWNS A 2004 FORD F-250. WHILE DRIVING APPROXIMATELY 45 MPH, THE VEHICLE STALLED AND THE CHECK ENGINE WARNING INDICATOR ILLUMINATED. THE CONTACT HAD TO MANEUVER THE VEHICLE TO THE SHOULDER. AFTER APPROXIMATELY HALF AN HOUR, THE VEHICLE RESTARTED, BUT STALLED AGAIN SIX MILES LATER. THE VEHICLE WAS TOWED TO THE CONTACT'S RESIDENCE. THE VEHICLE WAS DIAGNOSED BY AN INDEPENDENT MECHANIC WHO STATED THAT THE CLOGGED INJECTOR PUMPS FAILED AND NEEDED REPLACEMENT. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE VIN WAS INVALID. THE APPROXIMATE FAILURE MILEAGE WAS 195,000.

NHTSA ID

10914316

Incident

Sep 30, 2016

Mileage

195,000 mi

TL* THE CONTACT OWNS A 2004 FORD F-250. THE CONTACT STATED THAT THE FUEL LINES WERE SEVERELY CORRODED AND WERE LEAKING. AS A RESULT, THE TRANSMISSION FAILED WHILE DRIVING AT 40 MPH, CAUSING THE CONTACT TO USE EXCESSIVE FORCE IN ORDER TO DRIVE THE VEHICLE. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE CONTACT REPLACED THE POWER STEERING FUEL LINE, ONE BRAKE LINE, AND ONE TRANSMISSION FUEL LINE. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE WAS 180,000. UPDATE 01/13/16 MA

NHTSA ID

10779797

Incident

Sep 5, 2015

Mileage

180,000 mi

ENGINE ACCELERATES SPORADICALLY ON ITS OWN. ENGINE OCCASIONALLY DIES AT STOP LIGHTS. MUST KEEP BRAKE PEDAL FIRMLY PUSHED AT STOP AS ENGINE WILL SUDDENLY ACCELERATE. I HAVE ALREADY REPLACED THE TURBO. THE DEALER SAYS IT COULD BE MANY DIFFERENT THINGS WRONG. THE 2003-2007 DIESELS ARE NOTORIOUS FOR BAD TURBO, FUEL INJECTORS AND A HEAD BOLT PROBLEM THAT REQUIRES REMOVING THE CAB. I PURCHASED THIS TRUCK NEW AND IT NOW HAS 39000 MILES ON IT. THIS IS A SERIOUS SAFETY CONCERN. *TR

NHTSA ID

10618762

Incident

Mar 6, 2013

Mileage

35,000 mi

TL* THE CONTACT OWNS A 2004 FORD F-250 TDI. THE CONTACT STATED THAT WHILE DRIVING 10 MPH UPHILL AND TOWING A BOAT, THE VEHICLE STALLED WITHOUT WARNING. THE VEHICLE WAS TAKEN TO THE DEALER. THE TECHNICIAN WAS UNABLE TO DIAGNOSE THE FAILURE BUT STATED THAT HE FOUND PERMATEX GASKET MATERIAL IN THE FUEL SYSTEM, CAUSING THE INJECTOR O-RING TO BLOW. THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURE. THE VEHICLE WAS NOT REPAIRED. THE FAILURE MILEAGE WAS 140,000 AND THE CURRENT MILEAGE WAS 1637,000.

NHTSA ID

10543979

Incident

Mar 6, 2012

Mileage

140,000 mi

MY VEHICLE HAS BEING STALLING WHILE DRIVING AT 1ST START UP IN THE MORNING FOR OVER 3 WEEKS. THE PROBLEM IS NOW GETTING DAILY. I UNDERSTAND THERE IS A RECALL 05S34 THAT HAS THIS PROBLEM WITH THE FORD DIESELS. MY VEHICLE IN CURRENTLY BROKEN DOWN ABOUT 60 MILES FROM MY HOME. THE AUTO REPAIR SHOP THINKS ITS A HIRING HARNESS TO THE FICM. *TR

NHTSA ID

10490409

Incident

Dec 24, 2012

Mileage

124,000 mi

TL* THE CONTACT OWNS A 2004 FORD F-250. THE CONTACT STATED THAT THE VEHICLE WOULD NOT START. THE VEHICLE WAS TOWED TO DEALER FOR DIAGNOSIS WHERE THE STATED THAT THEY NEEDED TO REPLACE THE HEAD GASKET. THE VEHICLE WAS REPAIRED BUT THE VEHICLE STILL WOULD NOT START. THE DEALER THEN ADVISED THE CONTACT THAT THE FUEL MODULE NEEDED TO BE REPLACED. THE VEHICLE WAS NOT FURTHER REPAIRED. THE MANUFACTURER WAS CONTACTED BUT PROVIDED NO ASSISTANCE, STATING THAT THE VEHICLE WAS NOT UNDER RECALL. THE FAILURE AND THE CURRENT MILEAGE WAS 173,000.

NHTSA ID

10472917

Incident

Aug 15, 2012

Mileage

173,000 mi

TL* THE CONTACT OWNS A 2004 FORD F-250. WHILE TRAVELING 60 MPH, THE VEHICLE STALLED WITHOUT WARNING. THE VEHICLE WAS TAKEN TO THE DEALER WHERE THE CONTACT WAS INFORMED THAT THE FUEL INJECTION CONTROL MODULE NEEDED TO BE REPLACED. THE VEHICLE WAS REPAIRED. THE CURRENT AND FAILURE MILEAGES WERE 126,000.

NHTSA ID

10457495

Incident

May 28, 2011

Mileage

126,000 mi

ABOUT 9/15/2010 THE VEHICLE, WHILE STOPPED AT A RED LIGHT FAILED TO ACCELERATE WHEN LIGHT CHANGED AND THE GAS PEDAL WAS DEPRESSED. THE TRUCK THEN STALLED AND TOOK UP TO 5 MINUTES TO RESTART. THE INCIDENT DID NOT REPEAT FOR SEVERAL MONTHS. THE NEXT INCIDENT THE TRUCK FAILED TO ACCELERATE AFTER SLOWING TO NEAR STOP AT A YIELD AT A HIGHWAY CROSSING NEARLY CAUSING AN ACCIDENT. REPLACED FUEL FILTER AND HAD A TUNE UP ALTHOUGH IT HAD RECENTLY BEEN DONE AND IT DIDN'T HAPPEN AGAIN FOR A FEW WEEKS. AFTER A FEW WEEKS OF HARD DRIVING WITH NO INCIDENCE THE TRUCK AGAIN FAILED TO ACCELERATE ON HIGHWAY ENTRANCE RAMP NEARLY CAUSING ANOTHER ACCIDENT. AFTER PULLING OVER AND TURNING OFF THE ENGINE AND RESTARTING IT DROVE ON THE HIGHWAY FINE, BUT STALLED WHEN EXITING THE HIGHWAY. THE LATEST INCIDENT, DRIVING ON THE HIGHWAY THE TRUCK DROVE FINE, UNTIL EXITING. IT FAILED TO RESPOND TO PRESSURE ON THE GAS PEDAL AND STALLED LEAVING A WOMAN AND CHILD ON THE SIDE OF THE ROAD FOR 2 HOURS WAITING FOR A TOW. DURING THAT TIME IT WOULD NOT START. TOWED TO DEALERSHIP AND AFTER HAVING THE VEHICLE FOR A WEEK, THEY STATED THEY PULLED CODES SHOWING FUEL INJECTOR WAS BAD, EGR VALVE STICKING, NEEDS SOME SORT OF WIRING HARNESS, TURBO NEEDS CLEANING AND SOME SORT OF CHIP TOTAL COST OVER $2000.

NHTSA ID

10444317

Incident

Sep 15, 2010

Mileage

95,000 mi

THE PROBLEM BEGAN IN JULY 2011. I OWN AND BOUGHT NEW, A 2004 F-250 SUPER DUTY CREW CAB FOUR-WHEEL DRIVE TRUCK WITH A 6.0 LITER ENGINE. THE PROBLEM STARTED WITH HARD COLD STARTS. WHEN IT DID START AFTER THREE TO FOUR ATTEMPTS, THE ENGINE RAN EXTREMELY ROUGH. AFTER A FEW MINUTES, IT WOULD EVENTUALLY LEVEL OFF. THROUGHOUT THE DAY, THE ENGINE WOULD START AND STOP WITHOUT ANY PROBLEMS. BUT AFTER BEING PARKED OVERNIGHT, THE TRUCK WOULD BE HARD TO START. THIS CONTINUED FOR SEVERAL WEEKS. ON THE EVENING OF AUGUST 11, 2011, AFTER THE ENGINE WAS OFF FOR ONLY THREE HOURS, IT WAS HARD TO START. THE ENGINE WOULD LOPE, IT WOULD NOT LEVEL OFF FOR A FEW MINUTES AND BLEW BLACK SMOKE OUT THE EXHAUST. EVENTUALLY, IT DID LEVEL OFF AND DROVE HOME. I DID NOT ATTEMPT TO START IT UP AGAIN UNTIL THE MORNING OF AUGUST FIFTEEN. IT WOULD NOT START. WHEN I TURNED THE KEY, IT CRANKED, ACTED LIKE IT WAS GOING TO START, THEN BACK TO JUST CRANKING. I ATTEMPTED SEVEN TIMES AND STOPPED CONCERNED I WOULD DRAIN THE BATTERY, DAMAGE THE STARTER, OR SOME OTHER PART. I CONTACTED THE DEALER. IT HAD TO BE TOWED TO THEIR SERVICE CENTER. THEY RAN DIAGNOSTICS AND DETERMINED IT WAS THE FICM (FUEL INJECTOR CONTROL MODULE) AND WAS GOING TO COST ME $1,300 TO FIX. THIS IS OUR ONLY SOURCE OF TRANSPORTATION, SO I RELUCTANTLY GAVE THEM THE GO AHEAD TO FIX IT. THE DAY IT WENT IN FOR SERVICE IT ONLY HAD 55,079 MILES. I DON'T UNDERSTAND. THIS TRUCK IS ONLY SEVEN YEARS OLD. I HESITATED IN SWITCHING TO DIESEL, BUT AFTER RESEARCHING AND LISTENING TO FRIENDS AND RELATIVES ABOUT THE LOWER FUEL COSTS, LOWER MAINTENENCE, HIGHER PERFORMANCE, I SWITCHED. I AM DISAPPOINTED THAT IN ONLY SEVEN YEARS, I'M HAVING TO SPEND OVER A THOUSAND DOLLARS TO REPLACE A PART THAT CANNOT BE REPAIRED. POOR DESIGN OR POOR QUALITY? AMERICAN MADE CARS AND TRUCKS USED TO BE BUILT TO OUTLAST THEIR OWNERS. THIS EVENT HAS QUESTIONED MY TRUST IN THE "BUILT FORD TOUGH" STATEMENT. RECALL SHOULD BE THE WORD FOR THIS SITUATION.*KB

NHTSA ID

10419752

Incident

Jul 20, 2011

Mileage

55,079 mi

TL* THE CONTACT OWNS A 2004 FORD F-250 EQUIPPED WITH A DIESEL ENGINE. THE CONTACT WAS DRIVING AT APPROXIMATELY 65 MPH, WHEN THE VEHICLE SUDDENLY SHUT OFF COMPLETELY WITH NO POWER STEERING. HE WAS ABLE TO GET THE VEHICLE SAFELY TO THE SIDE OF THE ROAD AND HAD IT TOWED TO A REPAIR SHOP. THE MECHANIC AT THE REPAIR SHOP REPLACED THE WIRING HARNESS AND ONE OF THE FUEL INJECTORS. HOWEVER, THE WIRING HARNESS SHORTED OUT AGAIN AND A FUEL INJECTOR IN ANOTHER AREA BLEW. THE CONTACT THEN TOOK THE VEHICLE TO THE DEALERSHIP WHERE HE WAS INFORMED THAT THE WIRING HARNESS AND THE FUEL INJECTION MODULE HAD FAILED. HE WAS ALSO ADVISED TO REPLACE THE WIRING HARNESS AND THE MODULE. THE CURRENT AND FAILURE MILEAGES WERE APPROXIMATELY 170,000.

NHTSA ID

10322680

Incident

Feb 28, 2010

Mileage

170,000 mi

WHILE DRIVING AT ANY SPEED VEHICLE STALLED. CONSUMER HAD THE VEHICLE TOWED. DEALERSHIP WAS NOTIFIED, BUT DID NOT RESOLVE THE PROBLEM. *AK THE CONSUMER MULTIPLE FAILURES DUE TO REMOTE START, FUEL SENSORS, AND FUEL COMPONENTS. THE CONSUMER STATED THAT WHEN THE VEHICLE STALLS IT LOOSES ALL POWER. *TC

NHTSA ID

10111524

Incident

Oct 13, 2004

Mileage

10,000 mi

VEHICLE SUDDENLY STALLED UPON PULLING UP TO AN INTERSECTION. VEHICLE WAS THEN TOWED TO A DEALERSHIP FOR INSPECTION, AND DEALERSHIP INDICATED THAT FUEL INJECTION CLIP BROKE AND FELL APART, AND THE HIGH PRESSURE OIL SIDE WAS LEAKING. THE BROKEN CLIP WAS REPLACED. A SERVICE PERSON TEST DROVE THE VEHICLE AND IT STALLED AGAIN. CONSUMER TRADED THE VEHICLE IN BECAUSE THE DEALERSHIP WAS UNABLE TO CORRECT THE PROBLEM.*AK

NHTSA ID

10105306

Incident

Oct 19, 2004

Mileage

4,445 mi

2004 FORD F250 SUPER DUTY KING RANCH. AFTER REFLASH TO REPAIR AN IDLE PROBLEM TRUCK DEVELOPED THREE VERY DANGEROUS CONDITIONS. 1. CRUISE STALLED - GOING DOWN HILL AT APPROX 55-58 THE TRUCK WILL STALL WITHOUT WARNING. NO POWER STEERING OR BRAKES. REPRODUCABLE ON DEMAND. 2. DOWNSHIFT LOCKUP - TRUCK WILL LOCKUP REAR TIRES IN EXCESS OF 30 FEET IF TOW/HAUL MODE IS USED. ON FIRST OCCASION IT ALMOST CAUSED A MAJOR ACCIDENT ON HIGHWAY, CAME WITHIN INCHES OF A HEAD ON WITH A LARGE DUMP TRUCK WHILE TOWING A BOAT. REPRODUCABLE ON DEMAND. 3. COAST STALL. INTERMITTENTLY STALLS USUALLY AT OFF RAMPS AFTER CRUISE HAS BEEN RELEASED. EXTREMLY DANGEROUS TO TAKE OFFRAMPS IN SUCH A LARGE VEHILCE WITH NO POWER.*AK

NHTSA ID

10074959

Incident

May 1, 2004

Mileage

800 mi

THE CONSUMER OWNED A NEW 2004 FORD, F250 WITH A 6.0 LITER DIESEL ENGINE. ON MARCH 7, 2004 WHILE DRIVING AT 65 MPH AND WITHOUT ANY WARNING, THE VEHICLE LOST PRESSURE. THE VEHICLE WAS TAKEN TO THE DEALER AND THE SERVICE TECHNICIAN DETERMINED THAT ONE OF THE FUEL INJECTORS MALFUNCTIONED. TWO DAYS LATER WHILE DRIVING ON THE HIGHWAY ANOTHER FUEL INJECTOR FAILED, WHICH CAUSED WATER TO LEAK ONTO ONE OF THE PISTONS, THEREFORE THE ENGINE WAS BURNING WATER. THE DEALER INDICATED THAT THEY WERE AWARE OF THE PROBLEM. *AK *SC *JB

NHTSA ID

10064675

Incident

Mar 23, 2004

Mileage

38,800 mi