2004 FORD F-350 Electrical System Problems

The contact owns a 2004 Ford F-350. The contact stated that while driving approximately 76 MPH with his wife in the front passenger seat, the vehicle shuddered uncontrollably and stalled. The contact and his wife were concerned for their safety. There was no warning light illuminated. The contact was able to regain control of the vehicle and pulled over to the side of the road. The vehicle failed to restart and was towed to the residence. The contact stated that as an independent mechanic, he used a code reader to retrieve diagnostic trouble codes for the fuel control module wiring harness failure. The contact related to the failure to NHTSA Campaign Number: 05V270000 (Electrical System). The contact stated that the fuel control module wiring harness failure had caused warning lights to fail to illuminate as needed. The dealer was notified of the failure and informed the contact that the vehicle had previously been repaired under the recall. The manufacturer was notified of the failure and informed the contact that an elbow vacuum tubing connector was previously replaced under the recall; however, the contact advised the manufacturer that the recall involved replacing the entire fuel control module wiring harness. The manufacturer informed the contact that the recall was already marked completed and no further repairs could be covered. The contact stated that the dealer and the manufacturer had failed to honor the recall repair. The vehicle was not repaired. The failure mileage was 190,019.

Mileage: 190,019

TL* THE CONTACT OWNS A 2004 FORD F-350. WHILE DRIVING THE VEHICLE, IT EXPERIENCED A COMPLETE LOSS OF POWER. THE VEHICLE WAS TAKEN TO THE DEALER WHERE IT WAS DIAGNOSED THAT THE WIRING HARNESS WAS DEFECTIVE AND NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. PRIOR TO THE FAILURE, THE VEHICLE WAS REMEDIED UNDER NHTSA CAMPAIGN NUMBER: 07E066000 (EQUIPMENT). THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE WAS APPROXIMATELY 100,000.

Mileage: 100,000

TL* THE CONTACT OWNS A 2004 FORD F-350. THE CONTACT STATED THAT WHILE DRIVING AT VARIOUS SPEEDS, THE VEHICLE WOULD SUDDENLY SHUT OFF AND ON SEVERAL OCCASIONS WOULD NOT START. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC, WHO DETERMINED THAT THE FUEL INJECTION CONTROL MODULE WIRE HARNESS NEEDED TO BE REPLACED. THE CONTACT NOTIFIED THE MANUFACTURER, WHO EXPLAINED THAT THE HARNESS WAS REPLACED IN 2005 UNDER NHTSA CAMPAIGN NUMBER: 05V270000 (ELECTRICAL SYSTEM). THE FAILURE MILEAGE WAS 83,000.

Mileage: 83,000

SHORTLY AFTER STARTING FROM A STOP THE VEHICLE LOST POWER AND HAD TO BE TOWED TO REPAIR SHOP. PROBLEM DIAGNOSED AND REPAIRED AS REPLACING THE PCM AND REFLASH OF THE ONBOARD COMPUTER. *TR

Mileage: 176,253

TL* THE CONTACT OWNS A 2004 FORD F-350. THE CONTACT STATED THAT WHILE AT A STOP, THE VEHICLE SURGED FORWARD. THE CONTACT ALSO STATED EXCESSIVE FORCE WAS APPLIED TO THE BRAKE PEDAL WHEN MAKING A STOP. IN ADDITION, THE VEHICLE STALLED ON MULTIPLE OCCASIONS. THE VEHICLE WAS ABLE TO RESTART. THE VEHICLE WAS TAKEN TO AN AUTHORIZED DEALER, WHO DIAGNOSED THAT AN OIL CHANGE AND THE ICP SENSOR NEEDED TO BE REPLACED. THE VEHICLE WAS REPAIRED BUT THE FAILURE RECURRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE AND STATED THAT THE VEHICLE WAS NOT INCLUDED IN NHTSA CAMPAIGN ID NUMBER: 05V270000 (ELECTRICAL SYSTEM). THE APPROXIMATE FAILURE MILEAGE WAS 18,000. UPDATED 9/12/14*CN UPDATED 1/27/15 *JS

Mileage: 18,000

TL* THE CONTACT OWNS A 2004 FORD F-350. THE CONTACT STATED THAT THE VEHICLE FAILED TO START. THE CONTACT TOOK THE VEHICLE TO THE DEALER, WHO STATED THAT THE COMPUTER MODULE WOULD NEED TO BE REPLACED. THE VEHICLE WAS REPAIRED HOWEVER, THE FAILURE RECURRED THE FOLLOWING DAY AND THE VEHICLE WAS TAKEN BACK TO THE DEALER WHERE THE COMPUTER MODULE WAS REPLACED A SECOND TIME BUT TO NO AVAIL. THE DEALER THEN REPLACED THE FUSE BOX AS BUT THE REPAIR DID NOT PREVENT THE FAILURE FROM RECURRING. ADDITIONALLY, THE TURN SIGNALS, DAYTIME RUNNING LIGHTS AND THE TAIL LIGHTS HAD BECOME INOPERABLE. THE CONTACT CALLED THE MANUFACTURE IN REGARD TO NHTSA CAMPAIGN ID NUMBER: 11V352000 (EXTERIOR LIGHTING) AND WAS ADVISED THAT THE VEHICLE WAS NOT INCLUDED IN THE RECALL. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURES. THE FAILURE MILEAGE WAS 140,000.

Mileage: 140,000

FOR UNKNOWN REASONS ON 12/20/13 AT 0030 HRS MY TRUCK CAUGHT ON FIRE AS IT SAT IN MY DRIVEWAY. I DROVE THE TRUCK LAST ON 12/14/13. THE FIRE STARTED IN THE ENGINE COMPARTMENT ON THE DRIVERS SIDE. I HAVE OWNED THE TRUCK FOR ABOUT 8 MONTHS AND IT HAD 105000 MILES ON IT WHEN I PURCHASED IT. THE FIRE DEPARTMENT ADVISED IT COULD BE DUE TO SOME TYPE OF ELECTRICAL ISSUE NEAR THE MASTER CYLINDER. I TOLD THEM THAT I HAVE NOT DONE ANY WORK UNDER THE HOOD IN MONTHS AND THAT WAS OIL/FILTER CHANGE. STILL UNDER INVESTIGATION. *TR

Mileage: 111,000

MY 2004 FORD F-350 6.0 DIESEL. HESITATE OR SURGES WHILE DRIVING, AND/OR THE ENGINE MAY STALL WHILE DRIVING AT ALL SPEEDS INCLUDING HIGHWAY SPEED, WILL LOSE POWER STEERING AND BRAKES AND WHEN AT A STOP IT WILL LUNGE FORWARD. THE ENGINE MAY OR MAY NOT RESTART AFTER STALL. I FEEL THAT THIS IS A GREAT SAFETY CONCERN I HAVE ALMOST LOST CONTROL OF MY VEHICLE ON A FEW OCCASIONS WHILE TOWING MY BOAT AND GOING AROUND CORNERS. I HAVE HEARD OF OTHER PEOPLE HAVING THE SAME PROBLEMS WITH THEIR 2004 6.0 DIESELS. PLEASE HELP! *TR

Mileage: 89,000

SINCE NEW VEHICLE PURCHASE, MY FORD F350 DIESEL P/U EXPERIENCED ENGINE SURGING (200-250 RPM) WHILE STOPPED WITH THE AUTOMATIC TRANSMISSION IN DRIVE. THE SURGE WAS SIGNIFICANT ENOUGH TO LURCH THE TRUCK FORWARD WITH THE BRAKE APPLIED, SUCH AS AT A STOPLIGHT. IN SEVERAL CASES, I ALMOST REAR ENDED OTHER VEHICLES BEFORE APPLYING THE BRAKE HARD ENOUGH TO STOP THE TRUCK FROM MOVING FORWARD. I LATER LEARNED TO ANTICIPATE THE SURGE USING THE BRAKES TO MINIMIZE MOVEMENT OF THE TRUCK WHILE STOPPED. MY SURGING PROBLEM WAS CONFIRMED ON MULTIPLE OCCASIONS BY TECHNICIANS DURING TEST RIDES, BUT THEY COULD NOT DUPLICATE THE PROBLEM IN THE SHOP. IN ALL CASES, THE FIRST STEP WAS TO REFLASH THE ECM WHICH MASKED THE PROBLEM FOR SEVERAL DAYS WHILE THE TRUCK RELEARNED MY DRIVING HABITS AND PREVENTED A DIAGNOSIS. THE ENGINE HAD TO BE OPERATED AT FULL TEMPERATURE IN ROAD CONDITIONS BEFORE THE PROBLEM DEVELOPED. IN THE SHOP, IDLING THE ENGINE TO WARM UP TO NORMAL OPERATING TEMPERATURE WAS NOT SUFFICIENT TO REPLICATE THE PROBLEM. FORD DEALERS MADE MULTIPLE ATTEMPTS (10 OR MORE) TO DIAGNOSE THE PROBLEM: REPLACING INJECTOR CONTROL PRESSURE (ICP) MODULE, EGR VALVE, AND ICP WIRING CONNECTORS TO NO AVAIL. THE PROBLEM WAS FINALLY DIAGNOSED AND CORRECTED, OUT OF WARRANTY AT APPROX. 44,500 MILES, BY REPLACING THE ENGINE WIRING HARNESS. I FOUND A DEALER WHO WAS WILLING TO SEND A TECHNICIAN ON A TEST RIDE WITH ME AND HOOK UP AN ONBOARD COMPUTER LAPTOP THAT IDENTIFIED THE PROBLEM BEFORE REFLASHING THE COMPUTER ECM. A NUMBER OF SURGING COMPLAINTS FROM OTHER OWNERS OF FORD F350 ARE POSTED IN ONLINE FORUMS DOCUMENTING SIMILAR CIRCUMSTANCES AND FRUSTRATION. THE INCIDENT DATE PROVIDED IS THE APPROXIMATE DATE OF THE FIRST OCCURRENCE. IN MY CASE, THE SURGING OCCURRED ON A NEAR DAILY BASIS, ALTHOUGH INTERMITTENTLY, FOR 41000 MILES OF DRIVING WITHOUT ANY RESOLUTION FROM FORD. THE ENGINE WIRING HARNESS WAS REPLACED IN FEB 2009 WHICH CORRECTED THE SURGING IN MY TRUCK. I PAID A $100 DEDUCTIBLE. *TR

Mileage: 3,000

WHEN TRUCK ORIGINALLY PURCHASED BUBBLE ON TIRE, AND DEALER SAID THEY ALL COME THAT WAY, TIRE WENT FLAT WHILE PARKED ABOUT A MONTH LATER, NO HOLES, WE WERE TOLD TIRE WAS NO GOOD, HAD TO BE REPLACED. TRUCK KEPT STALLING, LOSS OF BRAKES AND STEERING WHILE NAVIGATING DOWNHILL, SOLENOID ASSEMBLY REPLACED. 2 DAYS LATER KEPT STALLING. DEALER HAD TRUCK 21 DAYS TO REBUILD TRANSMISSION, AGAIN SOLENOID ASSEMBLY REPLACED AFTER THAT REPLACED WIRING HARNESS. SINCE THEN, CALIPER BROKE AND BRAKES WENT, TURBO HAS BEEN REPLACED. VEHICLE HAS REPEATEDLY STALLED, NOISES FROM REAR END WITH NO DX. NOW ENGINE SMOKING, LOSS OF POWER, RPMS JUMP WHILE IDLING. TRUCK HAS ALSO REPEATEDLY CHANGED GEARS AUTOMATICALLY, IE WHILE AT RED LIGHT TRUCK WOULD JUMP TO 3RD AND THEN TRUCK WOULD STALL. *JB

Mileage: 4,000

WHEN TRUCK ORIGINALLY PURCHASED BUBBLE ON TIRE, AND DEALER SAID THEY ALL COME THAT WAY, TIRE WENT FLAT WHILE PARKED ABOUT A MONTH LATER, NO HOLES, WE WERE TOLD TIRE WAS NO GOOD, HAD TO BE REPLACED. TRUCK KEPT STALLING, LOSS OF BRAKES AND STEERING WHILE NAVIGATING DOWNHILL, SOLENOID ASSEMBLY REPLACED. 2 DAYS LATER KEPT STALLING. DEALER HAD TRUCK 21 DAYS TO REBUILD TRANSMISSION, AGAIN SOLENOID ASSEMBLY REPLACED AFTER THAT REPLACED WIRING HARNESS. SINCE THEN, CALIPER BROKE AND BRAKES WENT, TURBO HAS BEEN REPLACED. VEHICLE HAS REPEATEDLY STALLED, NOISES FROM REAR END WITH NO DX. NOW ENGINE SMOKING, LOSS OF POWER, RPMS JUMP WHILE IDLING. TRUCK HAS ALSO REPEATEDLY CHANGED GEARS AUTOMATICALLY, IE WHILE AT RED LIGHT TRUCK WOULD JUMP TO 3RD AND THEN TRUCK WOULD STALL. *JB

Mileage: 4,000

DT: THE VEHICLE STALLED ON THREE DIFFERENT OCCASIONS. THE VEHICLE HAD BEEN TAKEN TO THE DEALERSHIP NUMEROUS TIMES. THE CONSUMER WAS NOT SURE IF THEY HAD REPLACED ANYTHING ON THE VEHICLE. THE VEHICLE WOULD SURGE AT TIMES OR WOULD COMPLETELY STALL. THIS STARTED ON MARCH 1, 2004. THERE WAS NO WARNING OR NOISE UNTIL THE PROBLEM HAD ACTUALLY OCCURRED. THE CONSUMER CONTACTED THE MANUFACTURER, AND THE MANUFACTURER REFERRED HIM TO THE DEALER. THE DEALER STATED THAT THIS WAS AN ELECTRONIC PROBLEM. *SC . *AK

FORD F-350 DIESEL-2004 CAR SHUT DOWN IN THE PASSING LANE ON PA TURNPIKE. TOWED TO FORD...NO INSULATION ON WIRING HARNESS, SHORTED OUT THE TRUCK. THE TRUCK STOPPED DEAD IN THE ROAD..NOW THE FORD DEALER FIXED IT BY PUTTING INSULATION OVER IT TO GET ME BACK ON THE ROAD. IT HAD BEEN IN THE SHOP THE WEEK BEFORE, AND THE WEEK BEFORE THAT BECAUSE I COMPLAINED OF LOSING POWER ON THE ROAD WHEN I TRAVEL. I DON'T WANT TO HAVE A FIRE WITH MY FAMILY! *NM

Mileage: 63,285

DT: UNDER ACCELERATION BETWEEN 25 AND 45 MPH THE VEHICLE LOSES POWER. THERE IS HESITATION WHEN VEHICLE ACCELERATES. IT IS AS THOUGH IT BOGS DOWN AND CAN NOT GAIN ANY SPEED. ALSO, A LARGE AMOUNT OF BLACK SMOKE WAS EXPELLED FROM THE EXHAUST. WHEN THIS OCCURS THE TRUCK COMES TO CRAWL IN MIDDLE OF TRAFFIC, AND HAPPENS MOSTLY IN STOP AND GO TRAFFIC, AS WELL AS ON INTERSTATE. TOOK VEHICLE TO A DEALER 4 TIMES FOR THIS PROBLEM WITHIN 28,000 MILES. DEALERSHIP COULD NOT FIND ANYTHING WRONG, BUT DID TROUBLE SHOOTING REPAIRS TO THE COMPUTER, AND THEN REPLACED THE TURBO. DEALER ADMITTED THEY DID NOT KNOW HOW TO FIX OR DIAGNOSE THIS PROBLEM. CONSUMER HAS NOT CONTACTED THE MANUFACTURER AT THIS TIME. NO OTHER REPAIRS WERE DONE OR ISSUES OUTSIDE OF THIS PROBEKM OCCURRED. *AK

Mileage: 1,000

2004 FORD F350 DEVELOPED PROBLEMS WITH THE ENGINE.***NO ANSWER REQUIRED***. *MR THE VEHICLE WOULD RUN ROUGH. THE STARTER BURNED OUT CAUSING THE VEHICLE NOT TO START. THE VEHICLE HAD MULTIPLE FUEL SYSTEM PROBLEMS. THE REAR WINDOW LATCH ASSEMBLY BROKE. THE STEERING DAMPNER CHAFED. THE LONG DRAG LINK WAS REPLACED BECAUSE IT WAS WEAK. STEERING STABILIZER WAS INSTALLED BECAUSE IT WASN'T INSTALLED AT FACTORY. *NM

Mileage: 60,942

2004 F-350 BEGAN HAVING STALLING PROBLEMS AT <2000 MILES. AFTER SEVERAL ATTEMPTS TO FIX THE VEHICLE, WE ASKED FOR A REPLACEMENT. WHILE WAITING ON ACTION FROM FORD, WE WERE IN AN ACCIDENT ON APRIL 15,2005 AFTER THE TRUCK FAILED WHILE CROSSING AN INTERSECTION.

THE BOLTS THAT HOLD THE BRACKETS FOR THE TOP SUPPORT OF THE AIR SUSPENSION SYSTEM CONTINUOUSLY BREAK. THIS OCCURRED IN FIVE VEHICLE (AMBULANCES) SO FAR, VIN NUMBERS: [XXX], [XXX], [XXX], [XXX], AND [XXX]. TOOK THE VEHICLES TO BE REPAIRED AT FORD DEALERSHIP. *AK THERE WERE 2 UNITS WITH BRACKET FAILURE, ALSO HAD BROKEN BRAKE LINES WHICH CAUSED THE BRAKES TO FAIL. THE BRAKE LIGHT ON THE DASH AND THE BRAKE LINE WAS NOT ATTACHED PROPERLY. THE REAR SUSPENSION BRACKET HAD BROKEN. *SC INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6). *TR

Mileage: 7,000

WHILE DRIVING AT ANY SPEED VEHICLE STALLED. CONSUMER WAS UNABLE TO RESTART VEHICLE, AND IT WAS TOWED TO THE DEALER FOR INSPECTION NUMEROUS TIMES. MECHANIC DETERMINED THAT COMPUTER NEEDED TO BE REPLACED, AND REPLACED IT. HOWEVER, PROBLEM RECURRED. *AK

Mileage: 8,000

WHILE DRIVING 30 MPH THE VEHICLE STALLED WITHOUT WARNING. THIS CAUSED LOST OF STEERING AND BRAKES. THE DEALER TOLD THE CONSUMER THAT HE WAS USING THE WRONG GAS BUT THE CONSUMER IS USING HIGH DIESEL OCTANE. PLEASE PROVIDE ANY ADDITIONAL INFORMATION. *NM THE CONSUMER STATED THERE WAS A TECHNICAL SERVICE BULLETIN WHICH STATED THERE WAS A PROBLEM WITH WIRE CHAFFING. *JB

Mileage: 400

WHILE DRIVING 62 MPH, THE VEHICLE STALLED. THE DRIVER WAS ABLE TO RESTART THE VEHICLE AND DROVE TO THE DEALER FOR ANALYSIS. THE MECHANIC COULD NOT RESOLVE THE PROBLEM. *AK THE CRUISE CONTROL WAS ENGAGED WHEN THE VEHICLE STALLED. THE DEALER WAS UNABLE TO DUPLICATE THE PROBLEM. *SC *JB

Mileage: 23,000