What are the most common Ford F-350 problems?
According to Au7o's research across NHTSA recalls, manufacturer TSBs, and owner forum reports, the 2004 Ford F-350 has 10 documented issues. The most frequently reported are: 5R110W TorqShift Torque Converter Failure and Low/Reverse Planetary Pinion Walk-Out, Death Wobble - Violent Steering Oscillation, 6.0L Power Stroke Oil Cooler Plugging Leading to EGR Cooler Rupture. Of these, 4 are rated critical and should be addressed promptly.
Is the Ford F-350 reliable?
The 2004 Ford F-350 has 10 known issues compiled from NHTSA recalls, manufacturer TSBs, and owner forum reports. 4 issues are rated critical: 5R110W TorqShift Torque Converter Failure and Low/Reverse Planetary Pinion Walk-Out and Death Wobble - Violent Steering Oscillation and 6.0L Power Stroke Oil Cooler Plugging Leading to EGR Cooler Rupture and 6.0L Power Stroke Head Gasket Failure from Stretched Torque-to-Yield Head Bolts. Prospective buyers should inspect for these issues and factor potential repair costs into their purchase decision. Regular maintenance following the manufacturer's schedule helps prevent many common problems.
How much does it cost to fix common Ford F-350 problems?
Repair costs for known Ford F-350 issues range from $200 to $9,000, depending on the specific problem and whether you choose DIY or professional repair. The most critical issue, 5R110W TorqShift Torque Converter Failure and Low/Reverse Planetary Pinion Walk-Out, typically costs $2,800-$7,000 to repair. Au7o provides step-by-step DIY maintenance guides that can help reduce repair costs.
What is the 2003-2010 Ford F-350 5R110W TorqShift Torque Converter Failure and Low/Reverse Planetary Pinion Walk-Out?
The 5R110W TorqShift used in 2003-2010 F-350s has two documented failure modes that matter to heavy-duty owners. The stock torque converter uses a stamped-steel shell and a single-disc lockup clutch that is marginal behind a loaded F-350, particularly a dually pulling a gooseneck… Repairs typically run $2,800-$7,000. Severity: high.
What is the 1999-2025 Ford F-350 Death Wobble - Violent Steering Oscillation?
After hitting a bump at highway speed, the front end enters violent steering oscillation (death wobble) that requires slowing to a stop to recover. Caused by worn front-end components: track bar bushing, ball joints, tie rod ends, or steering damper. Repairs typically run $200-$1,500. Severity: high.
What is the 2003-2007 Ford F-350 6.0L Power Stroke Oil Cooler Plugging Leading to EGR Cooler Rupture?
On the 2003-2007 6.0L Power Stroke used in the F-350 Super Duty, the engine oil cooler is a stacked-plate unit with very small coolant passages that sits in the valley of the block. Casting sand left from block manufacture plus silicate dropout from degraded Ford Gold coolant pro… Repairs typically run $1,200-$3,000. Severity: high.
What is the 2003-2007 Ford F-350 6.0L Power Stroke Head Gasket Failure from Stretched Torque-to-Yield Head Bolts?
The 2003-2007 6.0L Power Stroke in the F-350 uses torque-to-yield head bolts in a high-cylinder-pressure engine with relatively few fasteners per cylinder. Under repeated heat cycles, and especially with the elevated cylinder pressures that come from towing at weight or from any… Repairs typically run $4,000-$9,000. Severity: high.
What is the 1999-2010 Ford F-350 Exhaust Manifold Bolt Breakage?
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. Repairs typically run $300-$1,200. Severity: medium.
What is the 2003-2007 Ford F-350 6.0L FICM (Fuel Injection Control Module) Voltage Decay Causing Hard Start and Misfire?
The 6.0L Power Stroke's Fuel Injection Control Module sits on top of the driver-side valve cover and must deliver a 48-volt pulse to fire each HEUI injector. The module is heat-soaked in that location and its internal power supply degrades over time; it is also killed outright by… Repairs typically run $350-$1,100. Severity: medium.
What is the 2003-2007 Ford F-350 6.0L Variable Geometry Turbo - Unison Ring and Vane Seizure from Soot and Rust?
The Garrett GT3782VA variable geometry turbocharger on the 2003-2007 6.0L Power Stroke controls boost by pivoting a set of vanes in the turbine housing, all tied to a single unison ring. Because the 6.0L routes heavy EGR flow and crankcase oil mist through the exhaust side, soot,… Repairs typically run $300-$2,200. Severity: medium.
What is the 1999-2016 Ford F-350 Dual-Rear-Wheel Rear Axle Bearing and Seal Failure on F-350 DRW (Dana 80 Full-Float)?
F-350 dually trucks run a full-floating Dana 80 rear axle whose hubs carry adjustable tapered inner and outer bearings with a seal riding on the innermost part of the spindle. Unlike a sealed unit bearing, this design is a maintenance item, and the loads a DRW F-350 carries - a p… Repairs typically run $300-$1,200. Severity: medium.
What is the 1999-2016 Ford F-350 Cab Corner, Rocker Panel and Rear Wheel Arch Rust-Through?
The 1999-2016 Super Duty cab has a double-wall rocker and cab-corner structure that traps water and road debris and rots from the inside out. On the F-350 the pattern is worse than on lighter trucks for two structural reasons: dual rear wheels throw far more salt spray and grit u… Repairs typically run $800-$4,000. Severity: medium.
What is the 2003-2007 Ford F-350 6.0L HEUI Injector Stiction - Cold-Start Misfire from Varnished Spool Valves?
The 6.0L Power Stroke uses hydraulically actuated, electronically controlled unit injectors (HEUI) that are fired by high-pressure engine oil. Oxidized oil leaves a varnish film on the injector spool valve, and when the engine is cold that film creates static friction (stiction)… Repairs typically run $900-$4,500. Severity: medium.
