2004 Ford F-150
Problems, recalls and owner-reported issues
Visibility is the leading concern among 2,036 owner complaints filed for this model year. This is the highest complaint count among 26 F-150 model years with reports.
Of the 2004 reports, 75 involved a crash and 40 involved a fire. 74 people were injured and 6 people died.
What owners report most often
Recalls and investigations
Fuel system, gasoline, storage, tank assembly, mountingJul 29, 2011
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.
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.
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 NUMBER IS 11S21
Campaign 11V385000 on NHTSA.gov
Air bags, frontal, driver side, inflator moduleFeb 23, 2011
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.
THE DRIVER SIDE FRONTAL AIR BAG COULD INADVERTENTLY DEPLOY INCREASING THE RISK OF INJURY OR LOSS OF VEHICLE CONTROL IF OCCURRING WHILE IN MOTION.
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.
Campaign 11V107000 on NHTSA.gov
Exterior lighting, headlightsMay 11, 2009
DOPE, INC. IS RECALLING 42,540 COMBINATION CORNER AND BUMPER LAMP ASSEMBLIES OF VARIOUS PART NUMBERS SOLD FOR USE AS AFTERMARKET EQUIPMENT FOR VARIOUS PASSENGER VEHICLES. THESE HEADLAMPS FAIL TO CONFORM TO THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 108, "LAMPS, REFLECTIVE DEVICES, AND ASSOCIATED EQUIPMENT." THESE LAMPS DO NOT CONTAIN THE REQUIRED AMBER SIDE REFLECTORS.
DECREASED LIGHTING VISIBILITY MAY RESULT IN A VEHICLE CRASH.
DOPE, INC. WILL NOTIFY OWNERS AND OFFER A FULL REFUND FOR THE NONCOMPLIANT COMBINATION LAMPS. THE SAFETY RECALL BEGAN ON JULY 28, 2009. OWNERS MAY CONTACT DOPE, INC. AT 1-626-272-1798.
Campaign 09E025000 on NHTSA.gov
Exterior lightingApr 7, 2009
SABERSPORT IS RECALLING 16,270 COMBINATION CORNER AND BUMPER LAMP ASSEMBLIES OF VARIOUS PART NUMBERS SOLD FOR USE AS AFTERMARKET EQUIPMENT FOR VARIOUS PASSENGER VEHICLES. THESE HEADLAMPS FAIL TO CONFORM TO THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 108, "LAMPS, REFLECTIVE DEVICES, AND ASSOCIATED EQUIPMENT." THESE LAMPS DO NOT CONTAIN THE REQUIRED AMBER SIDE REFLECTORS.
DECREASED LIGHTING VISIBILITY MAY RESULT IN A VEHICLE CRASH.
SABERSPORT WILL NOTIFY OWNERS AND OFFER A FULL REFUND FOR THE NONCOMPLIANT COMBINATION LAMPS. THE SAFETY RECALL BEGAN ON MAY 11, 2009. OWNERS MAY CONTACT SABERSPORT AT 1-909-598-7589.
Campaign 09E012000 on NHTSA.gov
Exterior lighting, headlightsOct 25, 2007
CERTAIN SPYDER HEADLAMP REPLACEMENT ASSEMBLIES SOLD FOR USE ON 2004 THROUGH 2007 FORD F150 PICKUP TRUCKS. DURING PRODUCTION, THE HEADLAMPS WERE INTERNALLY MISALIGNED AND THEY FAIL THE PHOTOMETRY REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 108, LAMPS, REFLECTIVE DEVICES, AND ASSOCIATED EQUIPMENT.
THE PURPOSE OF THIS STANDARD IS TO REDUCE TRAFFIC CRASHES AND DEATHS AND INJURIES BY PROVIDING ADEQUATE ILLUMINATION OF THE ROADWAY.
SPYDER WILL NOTIFY OWNERS AND OFFER A FULL REIMBURSEMENT FOR ANY NONCOMPLIANT HEADLAMPS. THE RECALL IS EXPECTED TO BEGIN DURING NOVEMBER 2007. OWNERS CAN CONTACT SPYDER AT 866-558-4264.
Campaign 07E089000 on NHTSA.gov
Exterior lighting, headlightsSep 25, 2007
CERTAIN HEADLAMP ASSEMBLIES IMPORTED AND SOLD AS AFTERMARKET EQUIPMENT BY SONAR AUTO PARTS FOR USE ON 2004-2007 FORD F150 PICKUP TRUCKS. DURING PRODUCTION, THE HEADLAMPS WERE INTERNALLY MISALIGNED AND THEY FAIL THE PHOTOMETRY REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 108, LAMPS, REFLECTIVE DEVICES, AND ASSOCIATED EQUIPMENT.
THE PURPOSE OF THIS STANDARD IS TO REDUCE TRAFFIC CRASHES AND DEATHS AND INJURIES BY PROVIDING ADEQUATE ILLUMINATION OF THE ROADWAY.
SONAR WILL NOTIFY OWNERS AND OFFER A FULL REIMBURSEMENT FOR ANY NONCOMPLIANT HEADLAMPS. THE RECALL BEGAN ON DECEMBER 14, 2007. OWNERS CAN CONTACT SONAR AT 866-558-4264.
Campaign 07E080000 on NHTSA.gov
Exterior lighting, headlightsSep 14, 2007
CERTAIN EAGLE EYES HEADLAMP ASSEMBLIES, P/NOS. FR390-B001L AND FR390-B001R, SOLD FOR USE AS REPLACEMENT EQUIPMENT FOR THE ABOVE LISTED PASSENGER VEHICLES. THE THICKNESS IS UNSTABLE INHIBITING THE PERFORMANCE OF THE UPPER AND LOWER BEAMS WHICH FAILS TO CONFORM TO THE PHOTOMETRIC REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 108, LAMPS, REFLECTIVE DEVICES, AND ASSOCIATED EQUIPMENT.
DECREASED LIGHTING VISIBILITY MAY RESULT IN A VEHICLE CRASH.
EAGLE EYES WILL NOTIFY OWNERS AND OFFER REIMBURSEMENT FOR ANY NONCOMPLIANT HEADLIGHTS. THE RECALL BEGAN ON NOVEMBER 6, 2007. OWNERS MAY CONTACT EAGLE EYES AT 1-800-568-1098.
Campaign 07E075000 on NHTSA.gov
Equipment, electricalAug 28, 2007
CERTAIN CEQUENT 90 DEGREE 7-WAY RIGHT ANGLE ADAPTORS SOLD BY DISTRIBUTORS IN TOW PACKAGES FOR AFTERMARKET SALES TO TOW 5TH WHEEL RV TRAVEL TRAILERS. DUE TO INCORRECT WIRING OF THE HARNESS, THE TRAILER LIGHTS MAY NOT OPERATE PROPERLY.
IF THE TRAILER LIGHTS ARE NOT WORKING PROPERLY, A VEHICLE CRASH CAN OCCUR.
ALL OF THE DEFECTIVE TOW PACKAGES ARE STILL AT THE DISTRIBUTOR LEVEL AND HAVE NOT BEEN SOLD TO ANY CONSUMERS.
Campaign 07E066000 on NHTSA.gov
Vehicle speed controlAug 3, 2007
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.
THIS COULD RESULT IN AN UNDERHOOD FIRE.
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.
Campaign 07V336000 on NHTSA.gov
Exterior lightingJul 17, 2006
CERTAIN TRADESONIC COMBINATION LAMPS SOLD AS REPLACEMENT LAMPS FOR USE ON THE ABOVE LISTED PASSENGER VEHICLES. COMBINATION LAMPS NOT EQUIPPED WITH AMBER SIDE REFLECTORS FAIL TO CONFORM WITH THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 108, LAMPS, REFLECTIVE DEVICES, AND ASSOCIATED EQUIPMENT.
LACK OF AMBER SIDE REFLECTORS IN THE LAMPS WILL DECREASE LIGHTING VISIBILITY TO OTHER DRIVERS AND MAY POSSIBLY RESULT IN A VEHICLE CRASH.
TRADESONIC WILL NOTIFY OWNERS AND REPLACE THE LAMPS FREE OF CHARGE. THE RECALL IS EXPECTED TO BEGIN DURING JULY 2006. OWNERS MAY CONTACT TRADESONIC AT 626-934-8884.
Campaign 06E064000 on NHTSA.gov
Exterior lightingJun 29, 2006
CERTAIN AAI MOTORSPORTS COMBINATION LAMPS SOLD AS REPLACEMENT LAMPS FOR USE ON THE ABOVE LIST PASSENGER VEHICLES. COMBINATION LAMPS NOT EQUIPPED WITH AMBER SIDE REFLECTORS FAIL TO CONFORM WITH THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 108, "LAMPS, REFLECTIVE DEVICES, AND ASSOCIATED EQUIPMENT."
LACK OF AMBER SIDE REFLECTORS IN THE LAMPS WILL DECREASE LIGHTING VISIBILITY TO OTHER DRIVERS AND MAY POSSIBLY RESULT IN A VEHICLE CRASH
AAI MOTORSPORTS WILL NOTIFY OWNERS AND REPLACE THE LAMPS FREE OF CHARGE. THE RECALL BEGAN ON AUGUST 1, 2006. OWNERS MAY CONTACT AAI MOTORSPORTS AT 909-923-9188.
Campaign 06E060000 on NHTSA.gov
Fuel system, gasolineJun 13, 2006
CERTAIN AFTERMARKET FUEL FILTERS SOLD UNDER THE PUROLATOR BRAND NAME, P/N F65277, SHIPPED FROM JANUARY 16 THROUGH JUNE 2, 2006, FOR USE ON THE ABOVE LISTED PASSENGER VEHICLES. DUE TO INCORRECT DESIGN, THE QUICK CONNECTORS MAY NOT FULLY SEAT WITH THE TUBE INTERFACE, EVEN THOUGH THE PERSON MAKING THE CONNECTION MAY BELIEVE THAT THE QUICK CONNECTOR IS FULLY ATTACHED.
FAILURE OF THIS CONNECTION COULD LEAD TO FUEL SPILLAGE AND, IN THE PRESENCE OF AN IGNITION SOURCE, A FIRE COULD OCCUR.
UFI WILL NOTIFY OWNERS AND REPLACE THE FILTERS FREE OF CHARGE. THE RECALL BEGAN ON AUGUST 4, 2006. OWNERS MAY CONTACT UFI FILTERS USA AT 800-230-5876.
Campaign 06E056000 on NHTSA.gov
Exterior lighting, headlightsJun 12, 2006
CERTAIN EAGLE EYES HEADLAMPS, P/NOS. FR208-B101R, FR208-B101L, FR208-B001R, AND FR208-B001L, SOLD FOR USE AS REPLACEMENT EQUIPMENT FOR THE PASSENGER VEHICLES LISTED ABOVE. THESE HEADLAMPS FAIL TO CONFORM TO THE PHOTOMETRIC REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 108, LAMPS, REFLECTIVE DEVICES, AND ASSOCIATED EQUIPMENT.
DECREASED LIGHTING VISIBILITY MAY RESULT IN A VEHICLE CRASH.
SABRY LEE WILL NOTIFY OWNERS AND OFFER FULL CREDIT FOR ANY NONCOMPLIANT HEADLAMP. THE RECALL IS EXPECTED TO BEGIN ON JUNE 14, 2006. OWNERS MAY CONTACT SABRY LEE ACCOUNT EXECUTIVE AT 1-866-467-2279.
Campaign 06E052000 on NHTSA.gov
Exterior lighting, headlightsMar 13, 2006
CERTAIN ANZO COMBINATION HEADLAMP ASSEMBLIES SOLD AS REPLACEMENT LAMPS FOR USE ON CERTAIN PASSENGER VEHICLES. SOME COMBINATION LAMPS ARE NOT EQUIPPED WITH AMBER SIDE REFLECTORS WHICH FAIL TO CONFORM TO FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 108, "LAMPS, REFLECTIVE DEVICES, AND ASSOCIATED EQUIPMENT."
WITHOUT THE AMBER REFLECTORS, THE VEHICLE WILL BE POORLY ILLUMINATED, POSSIBLY RESULTING IN A VEHICLE CRASH.
ANZO WILL NOTIFY OWNERS AND REPLACE THE HEADLAMPS FREE OF CHARGE. THE RECALL BEGAN MAY 9, 2006. OWNERS MAY CONTACT ANZO USA AT 909-468-3688.
Campaign 06E023000 on NHTSA.gov
Fuel system, gasoline, storage, tank assembly, mountingSep 13, 2004
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 LEAKAGE, IN THE PRESENCE OF AN IGNITION SOURCE, COULD RESULT IN A FIRE.
DEALERS WILL REPLACE THE FUEL TANK. THE RECALL BEGAN SEPTEMBER 17, 2004. OWNERS SHOULD CONTACT FORD AT 1-800-392-3673.
Campaign 04V443000 on NHTSA.gov
Fuel system, gasoline, storage, tank assemblyApr 26, 2004
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.
IF LEFT UNCORRECTED, A FUEL LEAK COULD EVENTUALLY DEVELOP.
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.
Campaign 04V200000 on NHTSA.gov
Representative owner complaints: engine and engine cooling
169 reports, newest first. Show all
Engine and engine cooling, Nov 23, 2009
HAD TUNE UP ON VEHICLE AT 100,140 MILES, PER MANUFACTURE REQUIREMENTS. INCURRED ADDITIONAL COSTS DUE TO TWO SPARK PLUGS EXPLOITING IN BLOCK. MECHANIC SAID THIS IS A REGULAR PROBLEM, SEE TECHNICAL BULLETIN. FORD HAS A SPECIAL WAY OR TOOL FOR FIXING THIS PROBLEM . Q: I AM REQUESTING RESEARCH BE DONE TO SEE IF RECALL SHOULD BE IN PLACE FOR THIS ISSUE IN THE FORD F150. Q: HOW MANY FORD OWNERS HAVE HAD SAME REPAIR? Q: WHAT ARE REQUIREMENTS BY THIS AGENCY FOR ISSUING RECALLS? *TR
Engine and engine cooling, Oct 21, 2009
I HAVE A FORD 2004 F150 5.4 L TRITON ENGINE (3 VALVE) AND IT HAS 51,777 MILES ON IT AS OF TODAY. I CALLED DAVE SINCLAIR FORD TO CHECK ON HAVING THE SPARK PLUGS CHANGED. THEY INFORMED ME THAT THIS JOB IS HAS BEEN A MAJOR PROBLEM BECAUSE THE SPARK PLUGS DESIGNED AND MADE FOR THE 2004 MODEL BREAK OFF BECAUSE OF POOR DESIGN. THIS BREAKING OF THE SPARK PLUGS HAS BEEN ADDING ON 1000 TO 2000 EXTRA DOLLARS BECAUSE THEY HAVE TO TAKE SPECIAL MEASURES AND USE SPECIAL TOOLS TO FIX THIS ISSUE. FORD MOTOR CO. HAS HAD THE SPARK PLUG REDESIGNED AS OF 2006 AND HAS ALSO ISSUED A TSB SPECIAL INSTRUCTION FOR REMOVING THE DEFECTIVE PLUGS. THE TSB 06-15-2 CAN BE FOUND ON WWW.ETOOLCART.COM/06152.PDF . FORD HAS ACKNOWLEDGED THAT THEIR IS A PROBLEM HOWEVER, THEY WILL NOT OFFER TO COVER ALL OF THE EXTRA CHARGERS THAT ARE ADDED ON DUE TO THIS DEFECTIVE SPARK PLUG ISSUE. A RECALL SHOULD HAVE BEEN ISSUED AS SOON AS THEY CHANGED OUT THE SPARK PLUG DESIGN, ADDED THE TSB BULLETIN, OR WHEN THEY STARTED HAVING SPECIAL TOOLS MADE FOR THE JOB. FORD NEEDS TO TAKE CARE OF ITS CONSUMERS AND OFFER A RECALL FOR ALL OF THE 5.4 L TRITON ENGINES THAT ARE HAVING THIS PROBLEM. I HAVE CONTACTED MIKE DETWILER, SERVICE MANAGER, AT DAVE SINCLAIR FORD. I HAVE CONTACTED FORD MOTOR CORP. AND MADE TWO COMPLAINTS AND THEY WERE SENT TO ENGINEERING. EVERYBODY ACKNOWLEDGES THAT THIS IS A MAJOR PROBLEM, HOWEVER; FORD WILL NOT COVER THIS ISSUE AND I CANNOT EVEN USE MY EXTENDED WARRANTY THAT I PURCHASED EXTRA TO HELP COVER UNJUSTLY EXPENSES. *TR
Engine and engine cooling, Sep 6, 2009
2004 FORD F150 WITH 4.6 ENGINE. 140,616 MILES. #2 SPARK PLUG BLEW OUT OF HEAD. HAD TO HAVE HELI-COIL INSERT INSTALLED. *TR
Engine and engine cooling, Aug 7, 2009
FORD DEALERSHIP BROKE ALL 8 OF MY SPARK PLUGS, INITIALLY MY REPAIR COST WAS $609 BEFORE THEY BROKE MY PLUGS AND AFTER THEY ARE CHARGING ME $3200 TO FIX SOMETHING THAT WAS NOT CAUSED BY ME. *TR
Engine and engine cooling, Aug 5, 2009
2004 F150 5.4 TRITON 88,000 MILES. FOMOCO RECOMMENDS SPARK PLUG CHANGE AT 100,00 DEALER CHANGED 8 PLUGS BROKE 6.I WAS CHARGED A PLUG EXTRACTION FEE OF $85 PER PLUG IN ADDITION TO THE $320 INITIAL QUOTE.INTERNET RESEARCH AND WORD OF MOUTH SHOWS MANY,MANY INSTANCES WITH THE SAME PROBLEM.FOMOCO QUOTED"WE ARE NOT ASSISTING CUSTOMERS AT THIS TIME".DEFINITE ENGINEERING FLAW THEY DENY.FOMOCO EVEN INVENTED THEIR OWN EXTRACTION TOOL TO AID IN REMOVAL OF PLUGS. *TR
Engine and engine cooling, Jul 1, 2009, fire
2004 F150 4.6LTR ENGINE. SPARK PLUG BLOW OUT #3 CYLINDER 64865 MILES. ORIGINAL FACTORY PARTS. SPOKE DIRECTLY TO FORD MOTORS THEY ACT AS IF THIS IS MY FAULT. THE PARTS HAVE NEVER BEEN CHANGED. FORD TOLD ME IT IS NOT COVERED UNDER WARRENTY BECAUSE THIS IS A MAINTANENCE PART. THE DEALER TOLD ME THAT THIS HAS BEEN A BIG PROBLEM FOR FORD. BUT THEY WONT HONOR TO FIX THE PROBLEM EVEN THOUGH IT IS A MECHANICAL FAILURE DUE TO BAD DESIGN. IT COST 600.00 TO FIX AND I BELEIVE THIS SHOULD BE COVERED BY FORD DUE TO THE NUMBER OF INSTENCES. THERE WERE TWO TRUCKS FIXED THE SAME DAY FOR THE SAME PROBLEM AND AGAIN THE SERVICE DEPARTMENT SAID THIS HAS BEEN A BIG ISSUE. I WOULD LIKE THIS TO BE RESOLVED. THE CONSUMER SHOULD NOT HAVE TO WORRIE ABOUT A SPARK PLUG BLOWING OUT WHILE DRIVING. THIS IS A SAFTEY ISSUE BECAUSE FUEL KEEPS FLOWING INTO THE CYLINDER AND WHEN IGNIGHTS FLAMES FLY OUT THROUGH THE SPARK PLUG HOLE. QUIT ACTING LIKE TH IS IS NOT A PROBLEM AND RECALL THESE POOR DESINGED PARTS BEFORE SOMEONE DOES GET HURT. *TR
Engine and engine cooling, Jun 29, 2009
THERE IS ALREADY A TSB FOR THE PROBLEM BUT FORD SHOULD REALLY RECALL THE CAM PHASERS ON THE 2004 AND NEWER F150'S. MOST PEOPLE IN THIS ECONOMY CANNOT AFFORD TO THROW 2 GRAND INTO THERE CAR TO HAVE A FACTORY DEFECT FIXED AND FORD WON'T STEP UP TO THE PLATE. I HAVE OWNED NUMEROUS FORD'S IN THE PAST AND WILL NEVER BUY ONE AGAIN BECAUSE OF THEIR LACK OF BEING A GOOD COMPANY. I'M SURE BECAUSE THE PROBLEM IS ON THERE NUMBER ONE ENGINE THEY DON'T HAVE THE MONEY TO COVER IT AND DON'T CARE THAT THEY'LL LOOSE HALF THOSE CUSTOMERS. *TR
Engine and engine cooling, Jun 16, 2009
OWN 2004 F150 WHILE TAKING OFF FROM STOP IN TRAFFIC HERD LOAD POP AND POWER LOSS.BLEW OUT NUMBER #3 SPARK PLUG. TOOK TO DEALERSHIP FOR REPAIR THEY TOLD ME THEY SEE THIS ALOT INSTALLED INSERT FOR REPAIR 534.00 TOLD ME NOT TO USE TRUCK FOR TOWING ANYTHING ANYMORE. CALLED FORD ABOUT PROBLEM WAS TOLD THAT THIS WAS A SERVICE PROBLEM. FOUND OVER 1000 COMPLAINTS ON LINE FOR SAME THING SOMEONE IS GOING TO GET KILLED IF THIS IS NOT RESOLVED A LOSS OF POWER LIKE THIS OR FIRE FROM FUEL BLOWING OUT OF THE CYLINDER AND NHTSA CALLING THIS NOT A SAFETY PROBLEM. SOMEONE NEEDS TO WAKE UP! *TR
Engine and engine cooling, Jun 15, 2009
ON A SUNDAY, I WAS ON A SIDE STREET WHEN THE ENGINE WENT DEAD. I NOTICED THE WRENCH LIGHT WAS ON. I CALLED THE WRECKER SERVICE AS IT WAS STILL IN WARRANTY. THE WRECKER DRIVER ARRIVED AND ASKED IF I HAD TRIED TO RESTART IT, WHICH I DIDN'T. I STARTED IT AND DROVE HOME. I TOOK IT TO THE DEALER ON 06/04/08. THEY COULD NOT DUPLICATE THE ERROR NOR FIND ANYTHING IN THE COMPUTER MODULE. ON 03/29/09, THE SAME THING HAPPENED. IF I HAD BEEN ON A HIGHWAY OR FREEWAY, I MIGHT HAVE HAD A SERIOUS ACCIDENT. I WAITED A FEW MINUTES, THEN THE TRUCK STARTED UP AGAIN. I TOOK IT BACK TO THE DEALER ON 04/01/09. THEY KEPT IT OVERNIGHT DOING VARIOUS TESTS. THE COMPUTER SHOWED NOTHING. THEY FINALLY SUGGESTED TO REPLACE THE THROTTLE BODY AND REPROGRAM THE PCM. I AGREED EVEN THOUGH IT WAS OUT OF WARRANTY AND COST ME $484 TO REPAIR. I WAS LEERY OF DRIVING ON A HIGHWAY AND FREEWAY AS IF IT HAPPENS THERE, I'M SURE IF I CAN'T PULL OVER I WILL SURELY CAUSE AN ACCIDENT. SUBSEQUENT CHECKS ON THE INTERNET FOUND THE IS A COMMON OCCURRENCE. THE ENGINE IS SUPPOSED TO GO INTO "LIMP MODE" TO ALLOW ONE TO SLOWLY, BUT SAFELY DRIVE TO A SAFE SPOT. MY TRUCK, AND MANY OTHERS, DO NOT GO INTO "LIMP MODE"; THEY JUST GO DEAD. I STRONGLY SUGGEST THIS BE INVESTIGATED BEFORE A SERIOUS ACCIDENT OCCURS DUE TO THIS DEFAULT. *TR
Engine and engine cooling, Jun 3, 2009
FORD 2004 SUPERCREW PICKUP WITH 5.4L ENGINE. FACTORY SPARK PLUGS BREAK OFF WHEN TRYING TO DO NORMAL FACTORY SERVICE AND FORD WANTS CUSTOMER TO PAY LABOR CHARGES FOR THE REMOVAL OF THE BROKEN SPARK PLUGS. I WAS QUOTED $800. SPARK PLUGS SHOULD NOT BREAK OFF FROM THE FACTORY. *TR
Engine and engine cooling, Jun 3, 2009, fire
2004 FORD F150 CAUGHT ON FIRE WHILE DRIVING. BURNED TO A TOTAL LOSS.
Engine and engine cooling, Apr 9, 2009
FORD F150 SPARK PLUGS BREAKING. *TR
Engine and engine cooling, Apr 2, 2009
TL*THE CONTACT OWNS A 2004 FORD F-150. WHEN THE CONTACT INSPECTED THE VEHICLE, HE NOTICED THAT A SPARK PLUG WAS LOOSE AND CREATED A HOLE ON TOP OF THE CYLINDER. THE SPARK PLUG WAS DEFECTIVE AND CAUSED ALL THE OTHER SPARK PLUGS TO COME OUT OF PLACE. THE MANUFACTURER STATED THAT THEY WOULD NOT ASSIST WITH THE REPAIR. THE VEHICLE WILL NOT BE REPAIRED. THE CURRENT AND FAILURE MILEAGES WERE 90,000.
Engine and engine cooling, Mar 30, 2009
DRIVING MY TRUCK ON MY LUNCH BREAK I NOTICED A POP SOUND WHICH FOLLOWED WITH A BAD IDLE, A CHECK ENGINE LIGHT, AND A LOUD MIS-FIRE SOUND... I PULLED INTO MY JOBS PARKING LOT AND NOTICE THAT MY 2004 FORD F150 SHOT SPARK PLUG NUMBER 2 OUT OF THE CYLINDER HEAD AND SHATTERED THE COIL BOOT INTO MANY PIECES THIS WAS WITH ONLY 76,000 MILES. BEING IN THE AUTO PARTS BUSINESS I KNOW THAT THEY ARE KNOWN FOR THIS AND DEAL WITH MANY PEOPLE DAILY HAVING THIS ISSUE YET FORD HAS STILL NOT MADE A RECALL TO HELP US WITH THIS PROBLEM... I HAD TO REPLACE ONE SPARK PLUG, AND ONE COIL BOOT.. SO FAR MY COIL HAS MANAGED TO HOLD UP HOWEVER FROM WHAT I HAVE NOTICED IT IS JUST A MATTER OF TIME BEFORE THIS HAPPENS AGAIN AND I WOULD LIKE TO HAVE SOME SORT OF INFO ON WHY OR HOW THIS HAPPENS AND WHAT FORD PLANS TO DO ABOUT THIS ISSUE. *TR
Engine and engine cooling, Electrical system, Mar 28, 2009
THE VEHICLE WRENCH LIGHT CAME ON AND THE ENGINE QUIT. HAD I BEEN ON A FREEWAY, A SERIOUS ACCIDENT MIGHT HAVE OCCURRED. I CALLED THE WARRANTY SERVICE FOR A WRECKER AS IT WAS STILL IN WARRANTY. ABOUT 40 MINUTES LATER, THE WRECKER ARRIVED AND THE DRIVER ASKED ME IF I HAD TRIED TO RESTART THE ENGINE. I HADN'T, TRIED, AND IT STARTED. I RESEARCHED THE INTERNET AND FOUND SOME INFORMATION INCLUDING A SUGGESTION TO DISCONNECT THE BATTERY TO RESET THE COMPUTER. UNFORTUNATELY, I DID THAT AND WHEN I TOOK IT TO THE DEALER THE FOLLOWING TUESDAY THEY COULDN'T TELL WHAT CAUSED THE PROBLEM. IT HAPPENED AGAIN ON MARCH 25, 2009. AGAIN, I WAS GLAD I WAS ON A SIDE STREET. I WILL TAKE THE TRUCK TO THE DEALER TUESDAY EVEN THOUGH THE WARRANTY HAS EXPIRED AS THIS COULD BE A VERY SERIOUS PROBLEM ON A HIGHWAY. *TR
Engine and engine cooling, Mar 26, 2009
ON MY 2004 FORD F150 WITH A 5.4L 3 VALVE ENGINE, THE SPARK PLUGS ALL BROKE OFF WHEN A TUNE-UP WAS ATTEMPTED. THIS IS DUE TO A KNOW DEFECT IN THE HEAD DESIGN ON THE 04/05 MODELS. THE DEALER CHARGED ME $904 DOLLARS TO CHANGE THEM. FORD IS NOT REIMBURSING CUSTOMERS FOR THIS OUTRAGEOUS CHARGE EVEN THOUGH THEY KNOW IT IS A DESIGN FLAW, AND ARE DOING NOTHING TO FIX THE PROBLEM. MY UNDERSTANDING IS THAT ALL OF THESE ENGINES WILL HAVE THIS PROBLEM. *TR
Engine and engine cooling, Mar 20, 2009
I HAVE A FORD F150 AND ONE OF THE SPARK PLUGS JUST JUMPED OUT. THIS IS THE ORIGINAL PLUG FROM THE FACTORY. THE SERVICE MAN AT THE FORD DEALER SAID HE HAD NEVER SEEN THAT HAPPEN BEFORE. CHECKING THE NET THERE ARE MANY COMPLAINTS ABOUT THE PROBLEM. THEY WANTED TO REPLACE THE HEAD FOR 4K. I CALLED AROUND AND FOUND OUT ABOUT PUTTING A SLEEVE IN FOR FOUR HUNDRED. *TR
Engine and engine cooling, Vehicle speed control, Mar 16, 2009, fire
TL*THE CONTACT OWNS A 2004 FORD F-150. APPROXIMATELY THIRTY MINUTES AFTER PARKING THE VEHICLE IN THE GARAGE, THE CONTACT HEARD A NOISE AND FOUND THE VEHICLE ON FIRE. THE FIRE DEPARTMENT ARRIVED, BUT COULD NOT DETERMINE THE ORIGIN OF THE FIRE. A REPORT WAS FILED. THE FLAMES WERE LOCATED IN THE REAR CAB OF THE VEHICLE. THE INSURANCE COMPANY DECLARED THE VEHICLE TO BE DESTROYED. THERE WERE NO INJURIES. THE FAILURE MILEAGE WAS 46,000. UPDATED 4/23/09 *CN UPDATED 04/27/09.*JB
Engine and engine cooling, Mar 16, 2009
TL*THE CONTACT OWNS A 2004 FORD F150. THE CONTACT STATED THAT THE SPARKS PLUGS SPLIT INTO THREE PIECES WHEN REMOVING THEM FROM THE ENGINE BLOCK. HE TOOK HIS VEHICLE TO A REPAIR SHOP AND THE SPARK PLUGS SPLIT INTO PIECES WHEN THE MECHANIC ATTEMPTED TO INSTALL NEW SPARK PLUGS. FORD'S TSB NUMBER 08-7-6 WAS REFERENCED. THE CONTACT WILL CALL THE FORD MANUFACTURER REGARDING THIS ISSUE. THE FAILURE MILEAGE WAS 85,000. 4/01/09 *NJ UPDATED 04/07/09. *JB
Engine and engine cooling, Mar 15, 2009
TRUCK TAKEN INTO BE SERVICED. MECHANIC BROKE SPARK PLUG OFF INTO THE HEAD. POSSIBLY LEADING TO COMPLETE REMOVAL OF ENGINE AND HEAD. *TR
Engine and engine cooling, Mar 13, 2009
TL*THE CONTACT OWNS A 2004 FORD F150. THE CONTACT TOOK THE VEHICLE IN FOR A ROUTINE TUNE-UP IN 2007. A FEW MONTHS LATER, HE HAD TO REPLACE THE MOTOR. ON MARCH 9, 2008, THE VEHICLE STALLED AND THE CHECK ENGINE INDICATOR ILLUMINATED. HE TOOK THE VEHICLE TO A REPAIR SHOP AND THE DIAGNOSTIC INDICATED THAT THE TIMING CHAIN SLIPPED AND CAUSED THE METAL CLIPS TO FAIL. THE MANUFACTURER STATED THAT BECAUSE A FORD DEALER DID NOT REPLACE THE MOTOR, THEY WOULD NOT ASSIST WITH THE REPAIRS. THE VEHICLE WAS REPAIRED AT THE COST OF $1,893 AT AN INDEPENDENT REPAIR SHOP. THE FAILURE MILEAGE WAS 94,000 AND CURRENT MILEAGE WAS 95,000. UPDATED 0424/09. *LJ UPDATED 04/27/09.*JB
Engine and engine cooling, Mar 10, 2009
I BOUGHT A FORD F450 NEW AND FROM DAY ONE I HAVE PROBLEMS WITH THE 6.0 DIESEL ENGINE. THE LATEST WAS A BLOWN INTERCOLLER AND TO ENGINE CYLINDERS. *TR
Engine and engine cooling, Mar 2, 2009
WENT TO CHANGE THE SPARK PLUGS. TEN DAYS AND $1000 LATER I HAVE THE TRUCK BACK. IF I HAD TO DO IT ALL OVER AGAIN, I WOULD SELL THE TRUCK WELL BEFORE THE 100,000 MILE MARK. IDIOTIC DESIGN LEADS TO SPARK PLUGS BREAKING. DO NOT CHANGE PLUGS WITHOUT DISCUSSING WITH DEALER FIRST. THEY HAVE A SPECIAL TOOL FOR EXTRACTING THE BROKEN PART. IT SAYS A LOT ABOUT THE SITUATION THAT FORD HAD TO COME OUT WITH A TOOL TO FIX THEIR POOR ENGINEERING. FORD NEEDS TO RECALL THESE VEHICLES WITH THIS DEFECT AND MAKE GOOD ON IT. I WILL NEVER BUY FORD AGAIN. IF YOU HAVE THIS PROBLEM, SPEAK UP AND LETS GET THEM TO FIX IT. *TR
Engine and engine cooling, Fuel system, Gasoline, Feb 24, 2009
TL*THE CONTACT OWNS A 2004 FORD F150. WHEN THE CONTACT DEPRESSED THE BRAKE PEDAL, THE VEHICLE WOULD STALL. THE FAILURE ALSO OCCURRED WHEN TURNING THE VEHICLE AT LESS THAN 5 MPH. THE RPMS WOULD DROP TO ZERO BEFORE THE VEHICLE STALLED AND JERKED AS IF IT WERE ATTEMPTING TO PROCEED FORWARD. THE DEALER COULD NOT DUPLICATE THE FAILURES. THE CONTACT DISCOVERED THAT BY PLACING A HIGHER GRADE OF FUEL INTO THE VEHICLE, THE FAILURES WOULD TEMPORARILY CEASE FOR A FEW MONTHS. THE FAILURE MILEAGE WAS 17,000 AND CURRENT MILEAGE WAS 103,000.
Engine and engine cooling, Feb 7, 2009, fire
WENT TO HAVE SPARK PLUGS CHANGED AT 100,000 MILES IN ACCORDANCE WITH MANUFACTURER'S FACTORY MAINTENANCE SCHEDULE. SPARK PLUGS ARE STUCK DUE TO FACTORY NOT SEATING PLUGS CORRECTLY AND NOT USING ANTI-SEIZE COMPOUND DURING FACTORY INSTALLATION. IT REQUIRES A $10,000 MACHINE TO NEGATIVELY POLARIZE THE ENGINE SO THAT THE PLUG THREADS CAN BE DECARBONIZED AND HOPEFULLY REMOVED. THIS IS AN UNACCEPTABLE FACTORY DEFECT AND FORD NEEDS TO ADDRESS THE ISSUE IMMEDIATELY AND RE-IMBURSED THE UNREASONABLE COSTS AND BURDEN PLACED ON THE CONSUMER. NO WHERE IN THE LITERATURE PROVIDED BY FORD WAS THIS ISSUE DISCUSSED HAD IT BEEN OPENLY DISCUSSED OR PRESENTED IN THE LITERATURE I WOULD NOT HAVE PURCHASED THE VEHICLE. THIS IS FRAUD. *TR