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, Jan 4, 2009
CHANGING OUT SPARK PLUG AT 65000 BECAUSE AN EMPLOYEE OF A FORD GARAGE ADVISED ME TO DO SO BECAUSE OF THEM GETTING STUCK AT 100,000 MILES. I STARTED TO CHANGE THEM ONLY TO FIND THE SHAFT BELOW THE THREADS OF THE SPARK PLUGS STUCK ANYWAY. I HAULED THE TRUCK TO BOYD COUNTY FORD WHERE THE SERVICE MAN STATED THAT THIS WAS PRETTY COMMON AND THAT IT WOULD TAKE ABOUT 500 DOLLARS TO FIX. WELL 1000.00 DOLLARS LATER THEY REMOVED THE STUCK SPARK PLUGS AND REPLACED THEM WITH SOME NEW ONES. *TR
Engine and engine cooling, Nov 18, 2008
TL*THE CONTACT OWNS A 2004 FORD F-150. WHILE DRIVING APPROXIMATELY 60-65 MPH, THE CONTACT HEARD SEVERAL LOUD POPS. THE VEHICLE BEGAN JERKING AND IDLING ROUGHLY. HE SHIFTED INTO NEUTRAL AND ALLOWED THE VEHICLE TO COAST TO STOP AT AN INTERSECTION. THE VEHICLE WAS DRIVEN BACK TO HIS RESIDENCE AND THEN TOWED TO A LOCAL REPAIR SHOP. THE MECHANIC STATED THAT THE NUMBER 1, 3, AND 5 SPARK PLUGS DETONATED AND DESTROYED THE HELI-COIL FOR THE NUMBER 5 CYLINDER. THE VEHICLE WAS REPAIRED. THE DEALER AND MANUFACTURER HAVE NOT BEEN NOTIFIED. THE CURRENT MILEAGE WAS 63,424 AND FAILURE MILEAGE WAS 63,400. UPDATED 02-18-09 UPDATED 02/18/09. *JB
Engine and engine cooling, Nov 10, 2008
AT ~ 30,000 MILES, THE ENGINE (A 5.4 TRITON V8) BEGAN SOUNDING LIKE A DIESEL ENGINE. TOOK THE TRUCK TO THE DEALER. THE DEALER "..RECALIBRATED THE CAM SENSOR..." AND STATED THE SOUND(S) WERE NORMAL FOR THIS ENGINE. I CALLED FORD MOTOR COMPANY AND THEY CUSTOMER SERVICE REP TOLD ME SAME THING. THE NOISE IS GETTING LOUDER INDICATING THE PROBLEM IS WORSENING. IS THERE ANYTHING THAT CAN BE DONE TO CORRECT THIS ISSUE BEFORE THE ENGINE SUFFERS A CATASTROPHIC FAILURE? *TR
Engine and engine cooling, Nov 3, 2008
2004 F150 5.4 TRITON SOUNDS LIKE A DIESEL ENGINE TOOK TO DEALER FOR DIAGNOSIS AT APROX. 30,000 MILES. DEALER STATED THAT THIS IS NORMAL. ENGINE FAILED AT 98,000 MILES DUE TO VALVE TIMING ISSUES, RELATED TO CAM PHASERS. THUS CAM SHAFT QUIT ROTATING ALLOWING PISTONS TO COLLIDE WITH VALES CAUSING ENGINE FAILURE. DEALER NOW WANTS 7624.00 TO REPLACE ENGINE. THE FORD DEALERSHIP STATES THAT THEY HAVE NOT SEEN THIS TYPE OF ENGINE FAILURE. BUT AFTER REVIEWING THE COMPLAINTS ON THIS SITE ALONG WITH MANY OTHER WEB SITES RELATED TO THIS ISSUE IT SEEMS THAT FOMOCO KNOWS THAT THIS IS A SERIOUS ISSUE AND THEY ARE UNWILLING TO ADDRESS THE ISSUE. WHAT CAN BE DONE TO HAVE FOMOCO ADDRESS AND COMPENSATE FOR THESE ISSUES. *TR
Engine and engine cooling, Oct 29, 2008
FORD MOTOR COMPANY HAS DESIGNED A DEFECTIVE HEAD DESIGN THAT CAUSES SPARK PLUGS TO GET STUCK IN THE HEAD WHEN SERVICE IS ATTEMPTED. THE 100K MILE INTERVAL IS TOO LONG, EVEN SUB 50K MILES IS UNACCEPTABLE. THE CARBON BUILDUP AROUND THE LONG 2 PIECE SPARK PLUG CAUSES THE LOWER, CRIMPED ON PART TO STAY IN THE HEAD WHILE THE TOP 2/3 AND ELECTRODE COME OUT WHEN CHANGING THE PLUG. THIS DESIGN HAS BEEN PUT IN USE FOR 4 YEARS ON ALL 5.4L 3VALVE MOTORS. FORD HAS A TSB THAT ACKNOWLEDGES THE PROBLEM, BUT THEIR REMEDY STILL DOES NOT HELP. ONCE THE PLUGS, BROKEN AND UNBROKEN, ARE REMOVED, PUTTING NICKEL ANTI-SEIZE ON THE THREADS STILL DOES NOT REMEDY THE ISSUE BECAUSE THE THREADS ON THE PLUG ARE NOT WHAT IS STICKING. THE LOWER PART OF THE SPARK PLUG IS WHAT CAUSES THE TROUBLE. FORD HAS EVEN DESIGNED A TOOL TO REMOVE THE OFTEN BROKEN PLUGS. THIS JUST RIDICULOUS AND A SOLUTION NEEDS TO BE MADE BEFORE A VERY LARGE CLASS ACTION SUIT IS DRAWN UPON FOMOCO. *TR
Engine and engine cooling, Oct 29, 2008
DRIVING MY TRUCK I HEARD A POP, I THOUGHT I BLEW OUT A TIRE BUT DIDN'T. I DROVE IT OFF THE HIGHWAY TO A PARKING LOT AND IT WAS DRIVING VERY ROUGH. TOOK IT TO THE SHOP AND THEY SAID IT BLEW OUT A SPARK PLUG (ORIGINAL SPARK PLUGS). CALLED THE DEALER AND THEY QUOTED ME A 2500.00 DOLLAR REPAIR! DID RESEARCH AND FOUND THAT THIS HAS HAPPENED NUMEROUS TIMES ALREADY AND I ASK IF THERE WAS A RECALL AND THEY SAID NO. BUT OFFERED ME A NEW TRUCK REDUCED 7 THOUSAND...CAN YOU PLEASE CHECK INTO THIS ISSUE. *TR
Engine and engine cooling, Oct 7, 2008
I BOUGHT THE FORD TRUCK F 150 5.4 MOTOR 2004 NEW. I WENT INTO THE FORD HOUSE TO GET PLUGS AND WIRES CHANGED. ABOUT TWO HOURS LATER THEY COME OUT HOLDING A SPARKPLUG, SAYING THEY NEED TO KEEP MY TRUCK FOR A COUPLE DAYS BECAUSE THESE SIZE OF MOTORS BLOW OUT SPARK PLUGS AND PART OF YOUR PLUG HAS FALLEN INTO THE MOTOR. THEY SAID THIS HAPPEN ALL THE TIME, BUT IT HAS NOT BEEN RECALLED YET. I SENT FORD A LETTER ALSO, I JUST DON T KNOW WHERE TO GO FROM HERE. THANKS FOR YOUR HELP! *TR
Engine and engine cooling, Sep 24, 2008
2004 FORD F150 5,4 CAMSHAFT FAILURE BEEN WAITING 2 MONTHS ON PART FORD SAYS UNAVAILABLE COULD TAKE ANOTHER 2 MONTHS FORD SAYS OVER 800 CAMSHAFTS ON BACK ORDER THERE ARE NO AFTERMARKET PARTS EVEN AVAILABLE THERE ARE 3 TRUCKS IN THE SAME FORD DEALERSHIP WITH SAME PROBLEM. *TR
Engine and engine cooling, Sep 15, 2008
TL*THE CONTACT OWNS A 2004 FORD F-150. WHILE DRIVING AT AN UNKNOWN SPEED, THE VEHICLE SPORADICALLY STALLED AND THE ENGINE WARNING LIGHT ILLUMINATED ON THE INSTRUMENT CONTROL PANEL. SPEED WAS NOT A FACTOR. THE DEALER REPLACED THE FUEL THROTTLE SENSOR AND CLEANED THE THROTTLE BODY. SEVERAL DAYS LATER, THE FAILURE RECURRED. THE DEALER STATED THAT SHE WOULD HAVE TO PAY FOR TEN HOURS OF DIAGNOSTIC FEES BEFORE THEY COULD DETERMINE THE CAUSE OF THE FAILURE. THE TECHNICIAN STATED THAT THE VEHICLE HAD A HISTORY OF STALLING PRIOR TO THE CONTACT MAKING THE PURCHASE. THE VEHICLE HAS NOT BEEN REPAIRED. THE CONTACT CALLED THE MANUFACTURER AND WAS REFERRED BACK TO THE DEALER. THE FAILURE MILEAGE WAS 40,601 AND CURRENT MILEAGE WAS 57,700.
Engine and engine cooling, Aug 17, 2008
MY 2004 FORD F150 WITH 106,000 MILES STARTED TO HAVE AN ENGINE KNOCK WHICH WE THOUGHT WAS JUST A STUCK LIFTER. WE TOOK IT IN TO THE LOCAL FORD DEALERSHIP AND WAS TOLD THAT THE TIMING GUIDE BROKE AND WRAPPED UP IN THE ENGINE CAUSING IT TO BE DEPRIVED OF OIL AND NOW WE WILL HAVE TO REPLACE THE ENGINE. *TR
Engine and engine cooling, Jul 30, 2008
TRUCK(83000 MILES) WAS PARKED IN DRIVEWAY. WENT AND STARTED AND THE TRUCK BEGAN TO SPUTTER AND SHAKE AND THE CHECK ENGINE LIGHT CAME ON. TRUCK WOULD NOT ACCELERATE AND I TOOK TO DEALER. BEGAN TO SHAKE EVEN MORE AND LOSE POWER. PROBLEM WAS TIMING CHAIN TENSIONER FAILURE WHICH CAUSED FAILURE TO ENGINE. ENGINES NEEDS REPLACED. DEALER EXPLAINED THAT THIS CAN HAPPEN AT ANY TIME AND USUALLY CAUSES MAJOR ENGINE DAMAGE AND FAILURE. *TR
Engine and engine cooling, Jun 15, 2008
CONSTANT ENGINE NOISE THAT SOUNDS LIKE LIFTERS, VERY LOUD....HAVE HAD NUMEROUS PEOPLE LOOK AT THE PROBLEM, NO ONE CAN SEEM TO LOCATE THE ISSUE, OR REPAIR IT IN ANY WAY OR DIAGNOSE THE PROBLEM. *TR
Engine and engine cooling, May 15, 2008
WE TOOK OUR VEHICLE IN FOR SERVICE IMMEDIATELY AFTER WE EXPERIENCE THE ENGINE MISSING. THE SERVICE CENTER DIAGNOSED THE PROBLEM WOULD BE CORRECTED BY REPLACING THE IGNITION COIL, PLUGS AND WIRE BOOTS. THIS SEEMINGLY SIMPLE SERVICE JOB HAS LITERALLY TURNED INTO A NIGHTMARE. AFTER ALMOST 4 WEEKS OUR VEHICLE IS STILL IN THE SHOP. IN THE PROCESS OF CHANGING THE PLUGS, 2 PLUGS BROKE. THE DEALERSHIP NEEDED A "SPECIAL" TOOL TO REMOVE THE BROKEN PLUGS AND HAD TO ORDER IT. WHEN THEY GOT THE TOOL, THE STILL COULDN'T REMOVE THE PLUGS AND SAID THEY WOULD DRILL THEM OUT. AND THEN - THE BIGGEST BLUNDER OF ALL HAPPENED - WHILE THEY WERE DRILLING SOME PIECES OF PORCELAIN FELL INTO THE ENGINE AND SCARRED THE CYLINDER(S)WHICH COULD POTENTIALLY CAUSE THE ENTIRE ENGINE TO FAIL. NOW WE'RE BEING TOLD BECAUSE OF THIS WE NEED TO REPLACE THE ENGINE!! EACH TIME THEY CALLED IT WAS ABOUT SOMETHING ELSE GOING WRONG AND MORE MONEY!! WE'RE LOYAL FORD CUSTOMERS! THESE ADTL REPAIRS SHOULD NOT BE AT OUR COST! *TR
Engine and engine cooling, Apr 27, 2008
I WANT TO PREFACE THIS BY SAYING THAT BEFORE THIS PROBLEM OCCURRED I HAD MY F-150 IAT A FORD DEALERSHIP IN RALEIGH NC TWO SAYS BEFORE BECAUSE THE VEHICLE WOULD RANDOMLY SHUT OFF WHEN I WAS DRIVING IT ABOUT 600 MILES BEFORE THE EXTENDED WARRANTY WAS UP. THEY SAID THEY COULD NOT FIND ANYTHING WRONG WITH IT SO I WAS FORCED TO TAKE THE VEHICLE BACK I WAS DRIVING HOME FROM MY PARENTS HOUSE IN OHIO ON CHRISTMAS DAY. AS I WAS HEADING THROUGH VIRGINIA TO NORTH CAROLINA I HEARD A NOISE COMING FROM UNDER THE HOOD. I STOPPED TO SEE WHAT IT WAS AND EVENTUALLY FOUND OUT THAT THE SPARK PLUG HAD BLOWN AWAY FROM THE HEAD. APPARENTLY THIS IS A COMMON PROBLEM WITH THIS MAKE AND MODEL VEHICLE ALONG WITH MANY OTHERS. AFTER HORRIBLE CUSTOMER SERVICE I WAS FORCED TO PAY ALMOST 3500 DOLLARS IN ORDER TO GET MY TRUCK BACK. FORD SAID THAT THEY COULD NOT DO ANYTHING ABOUT IT. 1D *TR
Engine and engine cooling, Apr 21, 2008
ENGINE MAKES A TAPPING NOISE AT HEAD COVERS. *TR
Engine and engine cooling, Apr 14, 2008
ENGINE STALLS WHEN TURNING CORNERS. UNLESS I HAVE IT TOWED TO A REPAIR SHOP THIS VEHICLE IS NOT SAFE TO BE DRIVEN. *TR
Engine and engine cooling, Feb 28, 2008
2 SPARK PLUGS FOWLED UP, SEIZING IN BLOCK AND BREAKING INSIDE. *TR
Engine and engine cooling, Feb 26, 2008
TL*THE CONTACT OWNS A 2004 FORD F-150. WHILE DRIVING APPROXIMATELY 50 MPH, THE CONTACT NOTICED THAT THE ENGINE WARNING LIGHT ILLUMINATED ON THE INSTRUMENT CONTROL PANEL. THE POWER BEGAN DECREASING SIMULTANEOUSLY AND PREVENTED THE VEHICLE FROM TRAVELING ABOVE 35 MPH. THE DEALER REPLACED THE COIL PACK AND SPARK PLUGS IN THE NUMBER FIVE CYLINDER. THE CONTACT HEARD A KNOCKING NOISE WHEN HE STARTED THE VEHICLE AND THE FAILURE RECURRED. THE DEALER STATED THAT THE SPARK PLUGS BLEW OUT OF THE ALUMINUM HEAD. THEY ALSO STATED THAT THERE WERE ONLY FIVE THREADS HOLDING THE PLUGS TO THE ALUMINUM HEAD, AND, EVEN IF THEY MADE THE REPAIR, THE VEHICLE COULD STILL FAIL. THE MANUFACTURER WOULD NOT ASSUME ANY LIABILITY. THE FAILURE AND CURRENT MILEAGES WERE 44,000. UPDATED 03/25/08. *LJ
Engine and engine cooling, Power train, Tires, Feb 14, 2008
OUT OF THE BLUE THE TRUCK JUST STARTS SHAKING, NEVER KNOW WHEN OR WHERE. I HAVE TO PULL OFF ROAD AND SHUT IT OFF ,WAIT A BIT, THEN START AND LEAVE AND SEEMS TO BE OK TILL NEXT TIME. IT HAS 37,800 MILES . LAST TIME ON I-94 AT 65MPH IT SCARED ME TO DEATH IT STARTED SHAKING SO BAD . I ALSO HAD A 2005 F150 THAT DID THIS. ITS NOT THE TIRES, OR ENGINE BUT I THINK THE DRIVETRAIN . VERY BAD SAFETY ISSUE AS I AM FINDING I AM NOT ALONE WITH THIS PROBLEM. SOMEONE NEEDS TO MAKE FORD ADMIT WHAT THIS IS AND FIX THESE TRUCKS. *TR
Engine and engine cooling, Jan 28, 2008
MOTOR WOULD BEGIN TO SURGE AND THEN THE CHECK ENGINE LIGHT WOULD COME ON. TOOK TO DEALER AND THEY CHANGED SPARK PLUGS AFTER ONLY 5,706 MILES. WE HAVE SINCE CHANGED THE SPARK PLUGS 7 MORE TIMES WITH IN 80,000 MILES. SOME THING OCCURS EACH TIME. *TR
Engine and engine cooling, Jan 17, 2008
MY VEHICLE HAS LOW POWER, STUTTERS, AND CUTS OFF. A SERVICE BULLETIN WAS SAID TO HAS COME OUT ABOUT POSSIBLE DEFECTIVE PUSHROD OR ROCKER ARMS AM NOT SURE BUT I AM SURE THAT THE PROBLEM COME FROM THE POINT OF ORIGINAL ASSEMBLY AND I SHOULD NOT HAVE TO PAY FOR AN ISSUE THAT STARTS FROM MANUFACTURING. *TR
Engine and engine cooling, Jan 16, 2008
ENGINE HAS HAD A TICKING NOISE IN ENGINE SINCE DAY I BOUGHT THE TRUCK. TALKED TO DEALERSHIP AND THEY SAID NORMAL NOISE FROM 04 F-150 TRITION THEY HAVE SINCE CLOSED. WENT TO ANOTHER DEALERSHIP WAS TOLD SAME THING. BROKE DOWN WENT TO HOMETOWN MECHANIC REPLACED CAM GEARS AFTER ANOTHER DEALERSHIP ASKED IF IT SOUNDED LIKE A DIESEL. ALSO PULLED VALVE COVER OFF TO FIND VALVE SPRING AND ROCKER ARM ON CAM. TOTAL DISCOUNTED COST FROM FRIEND WAS $2400 NOT COUNTING MACHINING HEADS. *TR
Engine and engine cooling, Dec 17, 2007
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. *KB THE DEALER FOUND ERROR CODES FOR CYLINDERS 2 AND 4 WHICH WERE SOAKED WITH OIL. *JB
Engine and engine cooling, Nov 22, 2007
FORD RECOMMENDS CHANGING THE SPARK PLUGS ON MY 2004 F150 5.4 3-VALVE AT 100,000 MILES. MILEAGE WAS GETTING CLOSE SO I TRIED TO CHANGE THEM. UNFORTUNATELY FORD DID NOT TELL OWNERS THAT THERE IS A HUGE PROBLEM WITH THE SPARK PLUGS BREAKING-OFF IN THE CYLINDER CAUSING A MASSIVE REPAIR BILL. ENGINE HAD MUST BE REMOVED TO TAKE OUT BROKEN PLUG. FORD DID PRODUCE A TSB, BUT DID NOT INFORM OWNERS THAT THIS ROUTINE SERVICE SHOULD BE DONE BY DEALER. UPON CHECKING INTERNET, THERE ARE SCORES OF REPORTS OF THE PLUGS BREAKING WHEN BOTH OWNERS AND DEALERS ATTEMPT THE ROUTINE MAINTENANCE. *TR
Engine and engine cooling, Nov 3, 2007
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 WITH FIRES. I WONDER WHY THIS SITUATION HAS GONE ON SO LONG AND STILL NOT FIXED. *TR