KnownCarProblems2004 Ford F-150 Problems and Recalls
Owners filed 2,029 complaints with NHTSA about the 2004 Ford F-150, most often about the visibility and wipers (43% of complaints, typically around 64,000 miles). It is 5th of 27 F-150 model years by number of complaints and has 5 recalls.
Most common 2004 Ford F-150 problems
Visibility and wipers
863 complaints · 43%Half of these problems showed up before 64,000 miles. Parts named most often: power window devices and controls, glass, side/rear, windshield wiper/washer, windshield.
While driving rear passenger window fell, got it fixed in california, el monte Ford, it was under warranty @ 56,312 miles. That was on july 20, 2007. Right side passenger window fell while driving today march 9, 2008 out of warranty @ 64,545 miles. I have noticed there are quite a lot of problems with this window…
I have you seen how many complaints there are for faulty power window motor/regulators? I was leaving my place of employment which we scan out and my window would not go back up. When I got home I removed the door panel and the cables were twisted, kinked and frayed. Right now my window is propped to keep weather…
Engine
257 complaints · 13%Half of these problems showed up before 88,500 miles. Parts named most often: engine, exhaust system, cooling system.
Without any warning the v-8 5.4 engine started missing, dealer in winslow az said they had a lot oftrouble with that engine shooting the spark plugs out. Two of the plugs were loose , one apparently more than the other. Replacing plugs did not help. Some reports of others tell of this going on since before 97. Some…
2004 Ford F-150 ejecting spark plugs. Consumer states the engine started missing. Dealer told him they were having problems with the engine shooting spark plugs out. The dealer found error codes for cylinders 2 and 4 which were soaked with oil.
Transmission
232 complaints · 11%Half of these problems showed up before 35,000 miles. Parts named most often: automatic transmission, driveline, axle assembly, transfer case (4-wheel drive).
A chatter/ vibration in the rear- clutches in the rear were replaced. Check engine light came on- replaced the fuel vapor management system. Brake light on roof leaking- light was replaced. Roof of truck rusting- nothing done.
1. No signs or events lead up to the drive-line on my Ford F-150 detaching from my vehicle. 2. No consequences or failures occured. 3. My vehicle is under warranty and nothing has been done for over 30 days. Description: on june 14, 2005 between 7:30-8:00 am, I was traveling to work on freeway 99 in fresno…
Brakes
139 complaints · 7%Half of these problems showed up before 24,000 miles. Parts named most often: foundation components, antilock/traction control/electronic limited slip, conventional, pedals and linkages.
Dt: the contact owns a 2004 Ford f150. The rear end failed seven times. The contact took the truck to service dealer on 9-28-05, and the service dealer acknowledged that there was a problem, but stated that the contact could drive the vehicle , and advised him to call customer care because there was going to be a…
Rear brakes applied without prompting truck vibrated wildly causing loss of control. Result right rear emergency brake cable detached from seat, rear brakes burnt down to 33 mm. Brake rotors out of true. Tires wearing irregularly.
Suspension
118 complaints · 6%Half of these problems showed up before 14,500 miles. Parts named most often: front, rear, multiple axle.
Front suspension vibrates violently enough that the windshield wipers come off the glass. Problem occurs at all speeds but is worse at about 40 MPH. It last any where from one quarter of a mile to four miles and then stops. It comes and goes with no warning and there is no build up to the violent shakin. It stops as…
2004 Ford f150 problems with upper ball joint assembly as well as tire wear. The upper joint was the cause of the tire wear on one tire. The consumer stated since he purchased the vehicle it exhibited a rattle noise, the side view mirror had to be replaced because it was vibrating so badly, the hood had to be…
Body and structure
104 complaints · 5%Half of these problems showed up before 72,500 miles. Parts named most often: body, frame and members.
I own a Ford f150 v8 5.4 tritan about a month ago my passengers side window fell down in the door while I was driving down the road. It scared me and caused me to swerve while driving. This is definitely an issue. About a week ago my drivers side e window did the same thing while driving on a two lane winding road. It…
I was traveling on a main boulevard when all of a sudden the drivers side window slid down with a loud sounding bang. The window did not break. However, what seems to be a spring loaded mechanism, must have broken causing the window to collapse down inside the door. The sound was so loud, it caused a nervous reaction…
Electrical
99 complaints · 5%Half of these problems showed up before 55,000 miles. Parts named most often: wiring, alternator/generator/regulator, ignition, software.
I have lost 4 window regulators over the space of 2 years. I have replaced the drivers front , pass front twice pass rear once. I currently have a broom handle holding up drivers rear. This has gotten very old and tiresome. I worked for Ford dealerships for 27 years and I am very disappointed with the apparent…
Tl contact owns a 2004 Ford f150. The contact states while he was in his home. He was informed that his vehicle had caught on fire. He noticed that the flames where coming from under the hood. The vehicle has not been diagnosed by the dealer. The contact did not notice any difference previously. The current and…
Air bags
85 complaints · 4%Half of these problems showed up before 68,500 miles. Parts named most often: frontal.
The contact owns a 2004 Ford f150. The contact stated that the air bag warning light illuminated continuously. The vehicle was not taken to the dealer for diagnostic testing or repairs. The manufacturer was not contacted. The failure mileage was 67.000.
The contact owns a 2004 Ford f150. The contact was driving 15 MPH when another vehicle crashed into the front of his vehicle and the air bags did not deploy. The vehicle was destroyed. The contact sustained extreme injuries and was transported to the hospital. The driver of the second vehicle was not injured. A police…
Complaints are owner reports to NHTSA, not verified defects. One complaint can name several components, so shares add up to more than 100%.
2004 Ford F-150 recalls
Fuel system: mounting
Risk: As a result of the corrosion, one or both straps may fail allowing the fuel lines to separate from the tank, or in some cases, causing the tank to contact the ground. Either scenario may result in a fuel leak presenting a fire hazard.
Fix: Ford will notify owners and instruct them to take their vehicles to a ford or lincoln dealer to have the fuel tank straps replaced with straps that have increased corrosion protection. Early in this campaign, if replacement straps are not available, dealers may install a cable support under the strap as an interim repair or a steel reinforcement over the existing strap as a permanent repair. Any repairs will be performed free of charge. The safety recall began on september 16, 2011. Owners may contact ford motor company customer relationship center at 1-866-436-7332. Ford's recall campaign num
Full defect summary
Ford is recalling certain 1997 through 2003 model year ford f-150, 2004 model year ford f-150 heritage, 1997 through 1999 model year f-250 less than 8,500 lbs. Gross vehicle weight rating (gvwr), and 2002 and 2003 lincoln blackwood vehicles manufactured from june 20, 1995, through august 4, 2004, originally sold, or currently registered in, connecticut, delaware, illinois, indiana, iowa, kentucky, maine, maryland, massachusetts, michigan, minnesota, missouri, new hampshire, new jersey, new york, ohio, pennsylvania, rhode island, vermont, west virginia, wisconsin, and the district of columbia. Prolonged exposure to road deicing chemicals may cause severe corrosion of the fuel tank straps which secure the tank to the vehicle.
Air bags: inflator module
Risk: The driver side frontal air bag could inadvertently deploy increasing the risk of injury or loss of vehicle control if occurring while in motion.
Fix: Ford will notify owners and instruct them to take their vehicles to a ford or lincoln/mercury dealer to have a new clockspring jumper wire installed that incorporates a protective mesh cover. Repairs will be performed free of charge. This safety recall began on some vehicles in march 2011. The recall campaign on the expanded population is expected to begin on or about may 9, 2011. Owners may contact the ford motor company customer relationship center at 1-866-436-7332.
Full defect summary
Ford is recalling certain model year 2004-2006 f-150 pick up trucks as well as certain model year 2006 lincoln mark lt vehicles. If the clockspring jumper wire comes in contact with the driver side frontal air bag lower horn plate, the wire insulation may become chafed, creating a potential for a short circuit. If this occurs the air bag warning lamp may illuminate indicating that service is required.
Speed control: vehicle speed control
Risk: This could result in an underhood fire.
Fix: Dealers will install a fused wiring harness. Owners of the passenger cars included in this campaign will be instructed to return their vehicles to their dealers to have the speed control deactivation switch disconnected as an interim repair. As soon as repair parts are available (expected october 2007), owners will be instructed to return to the dealers for installation of a fused wiring harness. The recall began on august 13, 2007, and mailing completed by september 19, 2007. Owners may contact ford at 1-888-222-2751.
Full defect summary
On certain pickup trucks, passenger vehicles, sport utility vehicles, and motor homes chassis, the speed control deactivation switch may, under certain conditions, leak internally and then overheat, smoke, or burn.
Fuel system: mounting
Risk: Fuel leakage, in the presence of an ignition source, could result in a fire.
Fix: Dealers will replace the fuel tank. The recall began september 17, 2004. Owners should contact ford at 1-800-392-3673.
Full defect summary
On certain trucks equipped with 4.2l, 4.6l and 5.4l gasoline engines, the fuel tank may have a depression at the seam between the top and bottom halves of the tank. If a depression is large enough, fuel may permeate the fuel tank wall resulting in a fuel odor, illumination, of the "service engine soon" indicator light, or a fuel leak.
Fuel system: tank assembly
Risk: If left uncorrected, a fuel leak could eventually develop.
Fix: Dealers will replace the fuel tank on these vehicles. Owner notification began on may 6, 2004. Owners should contact ford at 1-800-248-0186.
Full defect summary
Certain pickup trucks may have a fuel tank with localized depressions in the fuel tank wall at the seam between top and bottom halves of the tank. If a depression is large enough, fuel may permeate the fuel tank wall resulting in a fuel odor, or the "service engine soon" indicator light in the instrument cluster may illuminate.
Recall repairs are free at any franchised dealer. Enter your VIN at nhtsa.gov/recalls to see which recalls are still open on your car.
NHTSA defect investigations
Fuel tank strap failure due to corrosion
Summary
One or both of the steel straps holding up the fuel tank and attaching it to the truck frame can corrode and fail (break or separate).if one strap fails, the tank may tilt and drop and possibly contact the road surface.if both straps break, the entire tank may drop to the road.if either failure occurs while the vehicle is being driven, contact with the road can abrade the tank and create a hole from which gasoline can spill.when the tank drops, it remains attached to the vehicle only by the fuel filler hose and/or supply lines, or in rare instances, by the skid plate, if present.in some cases the weight of the tank sufficiently strained the hoses and fittings and caused separation and subseq
Inadvertent airbag deployment
Summary
Odi opened this investigation based on reports of inadvertent airbag deployment.data provided by ford indicated that the airbag clockspring jumper wire, which is situated inside the steering wheel assembly, was installed in a manner that would allow it to rub (abrade) against a sharp metal edge on the nearby horn plate.because the horn plate is electrically grounded the abrasion of an airbag wire on the sharp edge could cause a short circuit condition.as a result the airbag light may illuminate and/or the airbag may inadvertently deploy.inadvertent deployments are most likely to occur during the airbag system's self-diagnostic test that initiates when the ignition switch is turned on.ford mo
Cng regulator leak
Summary
The agency has closed this investigation based on its review of complaint reports, discussions with complainants and field and technical data provided by ford.the subject vehicles are 1/2 ton pickup trucks and are natural gas vehicles (ngv) that are fueled by gasoline or compressed natural gas.the agency has received reports alleging improper operation of the natural gas fuel pressure regulator allowing release of excess amounts of natural gas into the engine compartment.ford reports that the regulator contains an over pressure relief valve that will vent natural gas should the pressure exceed a set threshold.the complaint reports and data reviewed by the agency indicate that an improperly o
Spark plug ejection from cylinder head
Summary
On september 6, 2005, odi received a petition requesting that the agency investigate allegations of engine spark plug ejection in certain model year 1997 through 2004 ford vehicles with triton v-8 and v-10 engines.odi received a total of 474 non-duplicative complaints on the subject vehicles where the complainant, or the dealer repairing the vehicle, reported that a spark plug detached from the cylinder and/or ejected from the engine.as of december 8, 2005, odi is not aware of any allegations where the alleged defect resulted in a loss of vehicle control, a crash, an injury, or a fatality in any of the 10,319,810 subject vehicles.in addition, odi is aware of only two incidents where the vehi
Questions about the 2004 Ford F-150
- What are the most common problems with the 2004 Ford F-150?
- By NHTSA owner complaints: visibility and wipers (863 complaints, typically around 64,000 miles); engine (257 complaints, typically around 88,500 miles); transmission (232 complaints, typically around 35,000 miles).
- How many recalls does the 2004 Ford F-150 have?
- 5 recalls listed by NHTSA, the latest from July 29, 2011 (fuel system). Check your VIN at nhtsa.gov/recalls to see which ones are still open on your car.
- Is the 2004 a bad year for the Ford F-150?
- It is 5th of 27 F-150 model years by number of complaints, with 2,029 complaints. Complaint counts are not adjusted for how many cars were sold, so popular years collect more of them, and the newest years have had less time to.