2004 Ford F-350 Problems: 2 Issues Every Owner Should Know
2004 model year · 0+ owner reports · Updated April 2026
According to Au7o's analysis of 0+ owner reports, the 2004 Ford F-350 has 2 documented known issues. No issues are rated critical, indicating generally reliable ownership. Across all issues, repair costs range from $200 to $1,500. DIY maintenance guides at au7o.io.
All 2 Known Issues
On the 1999-2010 Ford F-350, the exhaust manifold bolts on the 6.0L and 7.3L Power Stroke diesel engines break due to thermal cycling, causing exhaust leaks with a ticking noise especially on cold starts. Broken bolts are very difficult to extract.
Common Symptoms
- Ticking noise on cold start
- Exhaust smell in cab
- Noise diminishes when warm
- Visible soot at manifold
How to Fix
Extract broken bolts and replace with updated studs and nuts. Use anti-seize on new hardware. In severe cases the manifold may need replacement if warped. Consider having a diesel specialist handle extraction.
What Owners Are Using
Parts and tips from 0+ owners who fixed this issue
- UpgradeDorman exhaust manifold — solves cracking issues on many models (Dorman Exhaust Manifold)
- UpgradeDorman exhaust manifold bolt and stud kit (Dorman Exhaust Manifold Hardware Kit)