Vehicle Data Hub

2004 Ford F-250 SD exhaust system problems

17 complaints about exhaust system have been filed for the 2004 Ford F-250 SD, which is 5% of all its NHTSA complaints.

At a glance

Complaints
17 5% of this year's complaints
Typical mileage
40,000 miles 15 complaints with mileage
Crashes and fires
0 and 1
Injuries and deaths
0 and 0

Source: NHTSA owner complaints

When exhaust system problems show up

Exhaust system complaints by mileage, 2004 Ford F-250 SD Complaints by odometer reading in 20,000-mile steps. The median is about 40,000 miles. 0k to 20k miles: 7 complaints 20k to 40k miles: 1 complaints 40k to 60k miles: 1 complaints 60k to 80k miles: 3 complaints 80k to 100k miles: 1 complaints 100k to 120k miles: 1 complaints 120k to 140k miles: 1 complaints 140k to 160k miles: 0 complaints 160k to 180k miles: 0 complaints 180k to 200k miles: 0 complaints 200k+ miles: 0 complaints 040k80k120k160k200k miles Typical: 40,000 miles
Based on 15 complaints that include mileage. 60% were reported before 60,000 miles. The amber marker shows the median: half of these complaints happened before that mileage.
View the numbers
MileageComplaints
0k to 20k miles7
20k to 40k miles1
40k to 60k miles1
60k to 80k miles3
80k to 100k miles1
100k to 120k miles1
120k to 140k miles1
140k to 160k miles0
160k to 180k miles0
180k to 200k miles0
200k+ miles0

What the data shows

Of the 15 exhaust system complaints that report mileage, the median is about 40,000 miles, and 60% were reported before 60,000 miles.

These complaints mention 1 fire.

What owners wrote

Tl*the contact owns a 2004 ford f250 super duty. The contact stated that the egr cooler needed to be replaced three times. The vehicle would produce a lot of smoke and fail to accelerate properly once the egr failed. The dealer stated that the manufacturer would not assume liability for the repairs. There was a factory warranty that covered the part for twelve months or 12,000 miles, whichever came first. The failure always occurred outside of the warranty. The VIN was unknown.

Reported at 99,000 miles, June 2009 Fire

Exhaust manifold bolts rusted/corroded & broken off + rust/corrosion related crack in exhaust manifold itself. This is obviously an ongoing problem with no specific date as to when it happened only when it was discovered. I believe this to be an emissions issue.

Reported at 60,000 miles, February 2008

Other problems reported for the 2004 Ford F-250 SD

Exhaust system problems in other years

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Exhaust system problems across all Ford models