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: hydraulic
95 reports, newest first. Show all
Service brakes, Hydraulic, May 23, 2016
TL* THE CONTACT OWNS A 2004 FORD F-150. WHILE DRIVING APPROXIMATELY 55 MPH AND ATTEMPTING TO SLOW DOWN, THE BRAKES FAILED TO ENGAGE. THE CONTACT DISCOVERED THAT THE BRAKE VACUUM HOSE SEPARATED DUE TO A DEFECTIVE CLAMP. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER STATED THAT THE VIN WAS NOT INCLUDED IN NHTSA CAMPAIGN NUMBER: 08V208000 (SERVICE BRAKES, HYDRAULIC). THE FAILURE MILEAGE WAS 226,000. ....UPDATED 07/05/16 *BF *CN
Service brakes, Hydraulic, Structure, Mar 6, 2015
2004 FORD F-150. CONSUMER WRITES IN REGARDS TO VEHICLE FRAME RUST PROBLEMS. *SMD CONSUMER SENT ADDITIONAL CORRESPONDENCE. *SMD THE VEHICLE HAD TO BE TOWED TO THE REPAIR SHOP, BECAUSE THE BRAKES WENT OUT. THE REAR BRAKE LINES, HOSES, CALIPERS, MASTER CYLINDER AND PADS WERE REPLACED. UPDATED 03/09/15. *JB
Service brakes, Hydraulic, Feb 19, 2012
TRUCK VIBRATING. SLOWED DOWN, APPLIED BRAKES SEVERAL TIMES, VIBRATING STOPPED. AFTER GETTING HOME, STATED CHECKING THINGS. FOUND EMERGENCY BRAKE CABLE OFF. THIS HAS HAPPENED SEVERAL TIMES. POOR DESIGN. I HAVEN'T FOUND OF ANY RECALL ON THIS. THIS IS UNSAFE AND SHOULD BE RECALLED BY FORD. IF SOMEONE WHO DOESN'T HAVE ANY MECHANICAL ABILITY COULD GET "BURNED" BY UNNECESSARY COST BY FORD OR REPAIR SHOPS. *TR
Suspension, Service brakes, Hydraulic, Power train, Jan 23, 2012
I'M DRIVING MY TRUCK WHEN ALL OF A SUDDEN IT WILL START VIBRATING HORRIBLY, LIKE DRIVING OVER A WASHBOARD TYPE OF ROAD. THE ONLY WAY TO GET IT TO STOP IS TO PULL OVER TO THE SIDE OF THE HIGHWAY, PUT IT IN PARK, WAIT, AND THEN TRY TO RESUME DRIVING. BUT THIS DOES NOT ALWAYS WORK. YOU SOMETIMES HAVE TO STOP AND CHANGE TO PARK, OR REVERSE, A COUPLE OF TIMES, BEFORE DRIVING AGAIN SO THAT THE VIBRATION GOES AWAY. I HAVE COMPLAINED ABOUT THIS BEFORE, AND I SEE HUNDREDS OF COMPLAINTS FOR THE SAME ISSUE ON "FORD OWNER WEBSITES", AND EVERYBODY IS PISSED. NOBODY CAN GET AN ANSWER FROM FORD SERVICE AS TO WHAT IS WRONG. MANY PEOPLE HAVE REPLACED MANY DIFFERENT THINGS (I.E. TRANSMISSION, CLUTCH PADS, BEARINGS, U-JOINTS, EMERGENCY BRAKE CABLE OR PADS), ALL TO NO AVAIL. THEY HAVE WASTED THEIR TIME AND MONEY, AND FORD REFUSES TO LIVE UP TO THIS AWFUL AND VERY DANGEROUS PROBLEM. APPARENTLY, FORD KNOWS THIS IS A BIG PROBLEM WITH 2004 F-150 TRUCKS, ESPECIALLY, BUT WILL NOT ACKNOWLEDGE IT. SOMEONE WROTE ON THE WEB THAT FORD KNOWS THEY HAD A RETOOLING PROBLEM WITH THESE TRUCKS, AND LET THE TRUCKS GO OUT FOR SALE ANYWAY. I AM NOW HAVING THIS PROBLEM MORE OFTEN, AND I AM AFRAID TO DRIVE IT. I DO NOT HAVE ANY MONEY TO FIX MY TRUCK, SINCE OUR ECONOMY IS SO BAD AND HAVE BEEN UNEMPLOYED FOR YEARS. MAKE FORD TAKE OWNERSHIP OF THIS RECALL PROBLEM! *TR
Service brakes, Hydraulic, Nov 6, 2011
THE REAR BRAKE LINES FAILED. THE RUBBER LINE FROM THE CALIPER TO THE STEEL LINE ON THE REAR AXLE SEPARATED, FIRST ON THE DRIVERS SIDE AND ABOUT THREE WEEKS LATER ON THE PASSENGER SIDE. ON THE FIRST OCCASION I WAS JUST LEAVING MY GARAGE AND ON THE SECOND OCCASION I WAS PULLING INTO A PARKING SPOT. THE STEEL FITTING THAT HOLDS THE RUBBER LINE TO THE STEEL LINE WAS SO BADLY CORRODED THAT IT LITERALLY DISINTEGRATED, ALLOWING THE RUBBER LINE TO SEPARATE FROM THE STEEL LINE WHEN THE BRAKES WERE APPLIED. *TR
Service brakes, Hydraulic, Power train, Sep 13, 2011
THE 2004 F150 AND I ASSUME EXPEDITIONS HAD UNDERSIZED FRONT BRAKE ROTORS AND CALIPERS AND WERE OUTLINED IN A SERVICE TECH BULLETIN FOR THE PURPOSE OF DIAGNOSING THE FRONT END SHAKING/SHIMMING DURING BRAKING. *TR THIS IS MY OPINION SHOULD HAVE FALLEN UNDER A MANDATORY RECALL DUE TO THE SERIOUS NATURE OF POOR ENGINEERING. NO RECALL AND OUT OF POCKET $$$. THE SAME HOLDS TRUE FOR THE REAR DIFFERENTIAL WHICH IN MY CASE HAS BEEN REPLACED (3) TIMES AND AGAIN FORD PUBLISHED A TECH BULLETIN OUTLINING THE FACT THAT THE '04 REAR DIFFERENTIAL HOUSING WAS SUBJECT TO FAULTY MACHINING CAUSING RAPID WEAR ON RING/PINION AND BEARINGS. I BELIEVE THESE TWO DEFECTS SHOULD HAVE BEEN ADDRESSED DUE TO THE FACT THAT FAILURE OF EITHER COMPONENT COULD RESULT IN A SERIOUS ACCIDENTS. I TRULY BELIEVE FORD TRIED TO COVER UP/WHITE WASH THESE DEFECTS. I STILL HAVE THIS '04 AND STILL HAVE ISSUES WITH THE BRAKES AND REAR DIFFERENTIAL NOT TO MENTION A HOST OF OTHER ISSUES THAT HAVE PLAGUED THIS PARTICULAR YEAR MODEL. I LOOK FORWARD TO HEARING FROM SOMEONE AND WOULD LIKE TO KNOW THE EXTENT OF FORDS INVOLVEMENT AND ANY ACCIDENTS INVOLVING '04F150'S. BEST REGADRS
Service brakes, Hydraulic, May 18, 2011
TL*THE CONTACT OWNS A 2004 FORD F250. THE CONTACT STATED WHILE THE LOCAL MECHANIC WAS INSPECTING THE VEHICLE HE ADVISED HIM THAT THE REAR EMERGENCY BRAKE HUB CORRODED WHICH CAUSED THE BRAKE AND BOLTS TO RUST AND BRAKE INTO PIECES. THE MANUFACTURER CONFIRMED THAT THE FAILURE WAS NOT RECALLED. THE VIN INFORMATION WAS NOT AVAILABLE. THE VEHICLE WAS NOT REPAIRED. THE FAILURE AND CURRENT MILES WERE 89,030.
Service brakes, Hydraulic, Exterior lighting, Dec 16, 2010
2004 FORD F150 W/ ADJUSTABLE PEDALS - AFTER A FEW YEARS USE, THE BRAKE LIGHTS DO NOT WORK PROPERLY. THE LIGHTS WILL COME ON, BUT ONLY UNDER EXTREME DECELERATION, HOPEFULLY. THE LIGHTS WILL RESET IF THE BRAKE SWITCH IS UNPLUGGED AND PLUGGED BACK IN WITH VEHICLE RUNNING, BUT THEN WILL CONTINUE TO ACT UNRELIABLY AFTER A FEW DAYS OF USE. THE BRAKES CONTINUE TO WORK ALONG WITH THE SWITCH TO REPOSITION THE AUTOMATIC SHIFTER FROM OUT OF PARK, BUT THE BRAKE LIGHTS ARE COMPLETELY UNRELIABLE. I VISIT AN OFFICIAL FORD F150 FORUM WITH MANY OTHER MEMBERS THAT SEVERAL OTHERS ARE STARTING TO NOTICE THAT THEIR TRUCKS ARE DOING THE SAME THING. REPLACING THE "BRAKE SWITCH" RECOMMENDED BY FORD DID NOT CORRECT THIS PROBLEM. THIS PROBLEM HAS BEEN REPORTED ON THE FORUM BY MEMBERS WITH 2005 AND 2006 MODELS AS WELL. *TR
Service brakes, Hydraulic, May 25, 2010
TL* THE CONTACT OWNS A 2004 FORD F-150. WHILE DRIVING AT APPROXIMATELY 30 MPH, THE WHEELS BEGAN TO LOCK. THE CONTACT FURTHER INSPECTED THE VEHICLE AND FOUND THAT THE LINING ON THE BRAKE PADS WERE SEPARATING AND CAUSING THE BRAKE FAILURE. THE VEHICLE WAS NOT TAKEN TO AN AUTHORIZED DEALER TO BE EXAMINED. THE FAILURE AND CURRENT MILEAGES WERE 52,000. UPDATED 10/26/10. *LJ THE CONSUMER STATED THE EMERGENCY BRAKE PADS SEPARATED FROM THE CALIPERS WHICH CAUSED THE PADS TO BIND UP IN THE CALIPERS CAUSING THE REAR WHEELS TO LOCK UP. UPDATED 10/26/10
Service brakes, Hydraulic, May 4, 2010
2004 F-150. CONSUMER STATES FAULTY SPONGY BRAKES *TGW THE CONSUMER STATED HE HAD TO GET ANOTHER BRAND OF BRAKE LININGS TO MAKE HIS VEHICLE SAFE. *JB
Service brakes, Hydraulic, Parking brake, Feb 18, 2010
I WAS DRIVING DOWN THE INTERSTATE AT 60 MPH IN A 65MPH ZONE WHEN OUT OF NOWHERE WITH NO PRIOR WARNING OR INDICATION OF MALFUNCTION IT HAPPENED. NO CRASH BUT EMERGENCY STOP DID HAVE TO HAPPEN AND COULD HAVE CAUSED A CRASH. THE EMERGENCY BRAKE ACTUATOR FROZE UP ON THE REAR RIGHT SIDE OF MY F150 2004 SUPERCREW WITH ONLY 46,000 MILES ON THE ODO. THIS FREEZE UP CAUSED THE REAR BRAKE TO ENGAGE INVOLUNTARILY AND DESTROYED THE ACTUATOR, THE BRAKE PADS, AND THE ROTOR. *TR
Service brakes, Hydraulic, May 11, 2009
BRAKE PADS AND ROTORS WEAR OUT EVERY 40,000 MILES. DEALER SAYS IT IS DUE TO SOFT METAL FORD USED. THEY RECOMMEND REPLACING. IS THIS A RECALL ITEM? IF NOT, WHY NOT? *TR
Service brakes, Hydraulic, Wheels, Apr 21, 2009
SEVERE VIBRATION WHILE BRAKING FROM ABOVE 40M/HR. DEALER HAD TO REPLACE BOTH FRONT ROTORS AND MACHINED BOTH REAR ROTORS FOR WARPING. ROTOR WORE OFF BEFORE THE ORIGINAL BRAEK PADS. DEALER SAYS ITS TYPICAL BUT I SUSPECT POOR QUALITY AS I AM A CAREFUL DRIVER. *TR
Service brakes, Hydraulic, Mar 12, 2009
TL*THE CONTACT OWNS A 2004 FORD F-150. WHILE DRIVING APPROXIMATELY 70 MPH ON NORMAL ROAD CONDITIONS, THE VEHICLE VIBRATED EXCESSIVELY WHEN THE BRAKE PEDAL WAS DEPRESSED. THE FAILURE OCCURRED WITHOUT WARNING. THE VEHICLE WAS TAKEN TO AN AUTHORIZED DEALER FOR INSPECTION AND THEY REPLACED BOTH FRONT ROTORS UNDER THE WARRANTY. ON THREE SEPARATE OCCASIONS, THE VEHICLE WAS TAKEN BACK TO AN AUTHORIZED DEALER FOR THE IDENTICAL FAILURES. THE FRONT BRAKE PADS AND ROTORS WERE REPLACED AT THE CONTACT'S EXPENSE. THE MANUFACTURER HAS BEEN NOTIFIED OF THE MALFUNCTIONS. THE FAILURE MILEAGE WAS 30 AND CURRENT MILEAGE WAS 32,000.
Service brakes, Hydraulic, Parking brake, Feb 3, 2009
PARKING BRAKE ACTIVATES WHILE DRIVING AT HIGHWAY SPEED. IT CAUSES VEHICLE TO SHUDDER. LOCAL DEALERSHIP, SAYS THIS HAS BEEN A CONSISTENT PROBLEM. *TR
Service brakes, Hydraulic, Parking brake, Jan 12, 2009
71K MILES ON THE ODOMETER HAS LEAKING REAR AXLE SEALS ON BOTH SIDES AND THE OIL IS RUNNING DOWN ON THE PARKING/EMERGENCY AS WELL AS THE MAIN BRAKES. THIS CONFUSES THE ABS SYSTEM AND RENDERS THE REAR BRAKES USELESS IN NORMAL AS WELL AS EMERGENCY SITUATIONS. I BLOGGED ON THE FORUM F150ONLINE AND SEVERAL OTHER OWNERS ARE EXPERIENCING THE SAME PROBLEM WITH SOME HAVING AS FEW AS 11K MILES ON THEIR VEHICLE. LOOK AT THE POST, 'REAR AXLE SEALS LEAKING ON A 2004 4X4'. I DID PURCHASE THIS VEHICLE FROM THE ORIGINAL OWNER KNOWING IT NEEDED A COMPLETE BRAKE JOB ON BOTH AXLES. I PERFORMED THE BRAKE JOB JUST PRIOR TO MAKING A 2K TRIP TO VISIT MY FATHER DURING THE HOLIDAYS NOTICING THE PROBLEM AND COULD DO NOTHING ABOUT THE LEAKING PROBLEM UNTIL MY RETURN. THE BRAKES WORKED VERY WELL DURING THE WHOLE TRIP. I NOTICED THE LEAKING BY OIL DRIPPING ON MY WHEEL AFTER MY RETURN. THE LEAKING IS WORSE ON THE RIGHT SIDE (PASSENGER). I AM A WELL TRAINED MECHANIC AND PERFORM BRAKE SERVICE TO MINE AND MY FAMILY'S VEHICLES USING THE BEST PARTS I CAN BUY IN THIS AREA. IF I DO IT, IT STAYS FIXED. I HAVE THE OLD PARTS REMOVED FROM THE BRAKE JOB AND WOULD BE WILLING PART WITH THEM FOR AN INVESTIGATION ON YOUR PART. *TR
Service brakes, Hydraulic, Wheels, Dec 10, 2008
ON MY 2004 F-150 SUPER CREW W/75000 MILES I HAVE HAD TO REPLACE FRONT ROTOR 3 TIMES BECAUSE ROTORS ARE TURNING BLUE AND WEARING DOWN PREMATURELY CAUSING BAD BRAKING, BECAUSE BEARINGS ARE FAILING AND CAUSING WOBBLE AND OVERHEATING ROTORS TAKING TEMPER OUT OF ROTORS, I HAVE BEEN TO DEALERS AND THEY SAY CAN'T FIND PROBLEM AND MUST BE EXCESSIVE BRAKING, (NOT) THIS MODEL ROTOR HAS BUILT IN BEARING AND COST OVER 200.00 EACH. NOW WHEEL IS DOING IT AGAIN AND LOOKING AT 4TH SET OF ROTORS BECAUSE WHEEL IS WOBBLING( BEARING FAILING AGAIN) SOME THING HAS TO BE DONE BECAUSE OTHER PEOPLE ARE HAVING SAME PROBLEM WITH FRONT BRAKES ON THIS MODEL VEHICLE, DID INTERNET SEARCH, PLEASE LET ME KNOW. *TR
Service brakes, Hydraulic, May 27, 2008
TL*THE CONTACT OWNS A 2004 FORD F-150. WHEN MAKING RIGHT TURNS AT ANY SPEED, THE CONTACT HEARS AN UNUSUAL SOUND COMING FROM THE VEHICLE. WHEN HE MAKES LEFT TURNS, HE HEARS NOTHING. THE FAILURE WORSENED TO THE POINT THAT THE UNUSUAL SOUND OCCURRED WHEN HE WOULD ACCELERATE FROM A STOP. THE DEALER INFORMED HIM THAT THE BRAKES FAILED AND THE VEHICLE NEEDED A COMPLETE BRAKE JOB. THE FAILURE MILEAGE WAS 7,000 AND CURRENT MILEAGE WAS 8,200. UPDATED 7/3/08 *CN UPDATED 07/03/08 *JB
Service brakes, Hydraulic, Apr 3, 2008
I OWN A 2004 F-150. WHEN THE BRAKE PEDAL IS DEPRESSED IT TRAVELS NEARLY TO THE FLOOR ON THE FIRST "PUMP." THE PROBLEM IS REMEDIED BY PUMPING THE BRAKE ONCE OR TWICE TO REGAIN A SOLID PEDAL FEEL. THIS PROBLEM HAS BEEN ADDRESSED TO MY DEALER AND TO NUMEROUS BRAKE SHOPS TO NO AVAIL. I HAVE REPLACED ALL THE MAJOR COMPONENTS OF MY BRAKE SYSTEM AND THE PROBLEM PERSISTS TO THIS DAY. *TR
Service brakes, Hydraulic, Mar 3, 2008
THE FRONT BRAKES HAVE SHUDDERED WHEN APPLIED SINCE PURCHASING THE TRUCK NEW. AS A RESULT OF THIS SHUDDER, THE ROTORS HAVE WARPED AND WORN SO THIN THEY NOW HAVE TO BE REPLACED. IF WE HAD NOT JUST BOUGHT NEW TIRES, WE WOULD NEVER HAD KNOWN THAT THE BRAKES WERE READY TO FAIL. FORD HAS KNOWN ABOUT THE SHUDDER PROBLEM SINCE 2004 AND IN FACT, MADE A DESIGN CHANGE TO THE FRONT BRAKES BEGINNING ON NOVEMBER 29, 2004. HOWEVER, THEY REFUSE TO COVER THE WORK UNDER WARRANTY OR SEND OUT A RECALL FOR THIS DEFECT. *TR
Service brakes, Hydraulic, Parking brake, Jan 19, 2008
MAY 07 REAR BRAKE PADS REPLACED. JANUARY 08 A VIOLENT SHAKING OCCURS AT 50MPH NEARLY CAUSING A LOSS OF CONTROL OF VEHICLE ON HIGHWAY. TOOK VEHICLE TO SHOP AND FOUND THAT A BROKEN CLIP ON THE PARKING BRAKE ALLOWED THE PARKING BRAKE SHOES (ON THE INSIDE OF THE ROTORS) TO BIND NEARLY LOCKING THE WHEELS. NEEDED TO REPLACE PARKING BRAKE, BOTH ROTORS AND BRAKE PADS DUE TO DAMAGE. SHOP DID NOT KEEP THE PARTS. CONCERN IS THE A BROKEN PARKING BRAKE CLIP CAN RESULT IN A LOSS OF VEHICLE. COST WAS OVER $800. FORD CLAIMED THAT BRAKE ABUSE WAS AT FAULT. *TR
Service brakes, Hydraulic, Jan 16, 2008, fire
I DROVE THE TRUCK HOME FROM THE AUTOMATIC CAR WASH (WITH UNDERFLUSH) AND I PARKED IT IN MY GARAGE. I LEFT FOR A 10 DAY VACATION AN HOUR AFTER I PARKED IT. WHEN I CAME HOME 10 DAYS LATER I FOUND THE TRUCK HOOD AND CAB COVERED IN BLACK SOOT. THE ENTIRE GARAGE ALSO HAD A THIN FILM OF BLACK SOOT. AS IT TURNS OUT, THE ANTILOCK BRAKE CONTROL MODULE CAUGHT ON FIRE SOME TIME AFTER I PARKED THE TRUCK. IT CAUSED $4000 DAMAGE BETWEEN THE BRAKE CONTROL MODULE AND OTHER RELATED COMPONENTS. I HAVE A FULL EXTENDED WARRANTY WHICH COVERED THE REPAIRS (INITIALLY THE DEALERSHIP TOLD ME THE WARRANTY WOULD NOT COVER THE REPAIR, BUT I CHALLENGED THAT DECISION, AND THE ESP PEOPLE AGREED WITH ME). *TR
Service brakes, Hydraulic, Dec 15, 2007
TSB 050621. THIS IS WHERE YOUR BRAKES SHUDDER VERY HARSHLY WHEN BRAKING AT HIGHER RATES OF SPEED. THIS IS A PROBLEM ON EVERY FORD F150 BUILT BEFORE MID NOVEMBER 2004. UNFORTUNATELY FORD HAS MADE THIS ONLY A TECHNICAL SERVICE BULLETIN BUT THE REPAIR IS VERY EXPENSIVE AND NOT COVERED IF THE TRUCK IS OUT OF WARRANTY. IT IS TOO DANGEROUS OF A PROBLEM TO NOT GET REPAIRED. *TR
Service brakes, Hydraulic, Dec 5, 2007
TL*THE CONTACT OWNS A 2004 FORD F-150. WHILE DRIVING BETWEEN 30-50 MPH, THE FRONT BRAKES WOULD GRIND AND THE BRAKE PEDAL WOULD PULSATE WHEN THE BRAKES WERE APPLIED. THE DEALER STATED THAT THE PISTONS IN THE CALIPERS WERE MISALIGNED AND FAILED TO RELEASE THE BRAKE ROTOR. THE DEALER REPLACED THE ROTORS AND CALIPERS. THE CURRENT AND FAILURE MILEAGES WERE 27,288.
Service brakes, Hydraulic, Dec 5, 2007
I NOTICED MY BRAKES PULSATING WHEN APPLIED. THE DEALERS SERVICE TECH TOLD ME THE FRONT BRAKES WERE NOT RELEASING FULLY AND HAD WARPED THE ROTORS BEYOND REPAIR. THE CALIPER PISTONS HAD "COCKED" IN THEIR HOUSINGS, DESTROYING THE FRONT CALIPERS. THE REPAIR COST OVER $1,400. THE RISK IS THAT THE BRAKES WOULD BIND, FAIL TO DISENGAGE WHEN APPLIED, AND CAUSE A CRASH. *TR