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: structure
104 reports, newest first. Show all
Electrical system, Structure, Visibility/wiper, Jul 5, 2012
ON 25 MARCH 2011, I ENCOUNTERED A LOUD POP IN THE DOOR ON THE DRIVER-SIDE OF MY 2004 FORD F-150 REGULAR CAB TRUCK, AND THE WINDOW DISAPPEARED INTO THE DOOR FRAME. I REMOVED THE DOOR PANEL AND DISCOVERED THAT THE CABLE MECHANISM WITHIN THE WINDOW REGULATOR HAD FAILED. WITHOUT FURTHER DELAY I TURNED THE TRUCK INTO MY FORD DEALER TO HAVE THE WINDOW REGULATOR REPAIRED, AND RECEIVED A REPAIR BILL OF $301.86 (THE REGULATOR ALONE COST $159.36); THE FORD ADVISOR STATED THAT THEY HAD THE PART IN STOCK SINCE THE WINDOW REGULATOR FAILURE WAS A COMMON OCCURRENCE. I DID NOT INSPECT THE REGULATOR TO DETERMINE WHY THE CABLE MECHANISM HAD FAILED. AFTER THIS INCIDENT I VISITED WWW.NHTSA.GOV TO DETERMINE THE EXTENT OF THE PROBLEM, AND LEARNED THAT MORE THAN 240 OTHER 2004 FORD TRUCK OWNERS HAD EXPERIENCED THE EXACT SAME PROBLEM IN ONE DOOR OR THE OTHER IN THEIR TRUCKS. AS MIGHT BE EXPECTED WHEN INFERIOR PARTS ARE INSTALLED IN A VEHICLE, SUCH AS THE WINDOW REGULATORS IN THE 2004 FORD TRUCKS, THE PASSENGER-SIDE WINDOW REGULATOR ALSO FAILED. IN THE SECOND INSTANCE I DETERMINED THAT A SMALL, CHEAP PIECE OF MOLDED PLASTIC ON THE WINDOW REGULATOR HAD FAILED BECAUSE OF THE IMMENSE PRESSURE APPLIED TO IT WHEN THE WINDOW WAS BEING RAISED. DETAILS OF THAT FAILURE ARE LISTED ELSEWHERE ON THIS WEBSITE. *TR
Electrical system, Structure, Visibility/wiper, Jul 5, 2012
IN LATE-JUNE 2012 A LOUD CLUNK/THUD/POP/SMALL EXPLOSION OCCURRED IN THE PASSENGER-SIDE DOOR OF MY 2004 FORD F-150 REGULAR CAB TRUCK, WHILE THE VEHICLE WAS STOPPED AND IDLING, AND THE WINDOW DROPPED INTO THE DOOR FRAME. WHEN I RETURNED HOME I REMOVED THE DOOR PANEL AND DISCOVERED THAT A SMALL PIECE OF MOLDED PLASTIC, 1 1/8" X 1 7/8" (PROBABLE COST TO FORD ABOUT 39 CENTS) ON THE WINDOW REGULATOR HAD DISINTEGRATED/FAILED, ALLOWING THE REGULATOR CABLE TO RELEASE THE WINDOW. I HAVE FOUND A REPLACEMENT WINDOW REGULATOR ON THE INTERNET FOR $70 (FORD CHARGES $175 FOR THE PART) AND WILL REPAIR THE DEFECTIVE ITEM MYSELF. I NOTIFIED FORD OF THE FAILURE OF A LESS-THAN-QUALITY PLASTIC PIECE ON THE REGULATOR AND ASKED FOR REIMBURSEMENT. FORD RESPONDED: "THERE ARE NO FACTORY WARRANTIES OR PROGRAMS IN EFFECT ON YOUR VEHICLE THAT WOULD PROVIDE FINANCIAL ASSISTANCE FOR YOUR CURRENT VEHICLE CONCERN." HOWEVER, THEY DID ADD: "RECOMMEND THAT YOU KEEP YOUR REPAIR RECEIPTS IN CASE FORD INITIATES A RECALL OR CUSTOMER SATISFACTION PROGRAM IN THE FUTURE BASED ON CUSTOMER FEEDBACK OR FURTHER ENGINEERING REVIEW OF SIMILAR COMPLAINTS." I SEE FROM THE LARGE NUMBER OF COMPLAINTS ON THIS WEBSITE BY FORD TRUCK OWNERS THAT I AM BUT ONE OF HUNDREDS WHO HAVE BEEN AFFECTED, AND OBVIOUSLY, THERE WILL BE HUNDREDS MORE; THE ODDS ARE VERY HIGH THAT THE MAJORITY OF THE PLASTIC PIECES ON FORD TRUCK WINDOW REGULATORS WILL FAIL SOONER OR LATER, AND I SERIOUSLY DOUBT THAT THE 2004 FORD F-150 TRUCK IS THE ONLY MODEL YEAR THAT CONTAINS PLASTIC PARTS IN THE WINDOW REGULATORS. $70 TO REPLACE A FAILED PIECE OF PLASTIC THAT INITIALLY PROBABLY COST FORD ABOUT 39 CENTS TO PRODUCE IS A SAD COMMENTARY ON QUALITY. *TR
Structure, Jun 20, 2012
IS ANYBODY DOING ANYTHING ABOUT THE FORD WINDOW REGULATOR PROBLEM. OVER THE YEARS ALL OF MY SONS WINDOWS HAVE ALL FALLEN DOWN. AT TIMES LEAVING THE KIDS WITH EXPOSURE TO WHOEVER PASSES BY...THIS IS NOT SAFE. TWO WINDOWS FAILED ON THE SAME DAY. TRIED TO CALL FORD AND GOT NO REASONABLE RESPONSE... *JS
Electrical system, Structure, Mar 1, 2012
I HAVE OWNED THIS TRUCK SINCE 2004, NO SERIOUS ISSUES. THIS PAST FRIDAY I NOTICED POWER WAS STILL GOING TO MY TRUCK WHEN IT WAS TURNED OFF. THE POWER ACCESSORY RELAY WAS CLICKING VIGOROUSLY THEN STOPPED, NO POWER INSIDE MY VEHICLE. I STARTED THE TRUCK AND EVERYTHING WORKED EXCEPT FOR THE RADIO. I WENT FOR A DRIVE THAN AND THEN THE REVERSE LIGHTS CAME ON THE DOOR BUZZER WAS GOING OFF, AS I WENT TO STOP I HEARD A GRINDING NOISE OCCUR THAN STOPPED. WAS ABLE TO GET IT HOME. I HAVE 30 YEARS OF MECHANIC EXPERIENCE AND TRIED TO FIND A POSSIBLE SHORT. WHEN I REMOVED THE PASSENGER SIDE ROCKER PANEL I FOUND THE HARNESS COVERED IN RUSTY WATER. NOW DOING RESEARCH ON THE INTERNET, I HAVE SEEN HUNDREDS OF PEOPLE COMPLAINING ABOUT THIS ISSUE, THAT FORD WONT COVER. IT TURNS OUT MANY PEOPLE HAD TO HAVE WIRING HARNESS REPLACED COSTING THOUSANDS. WHILE CONDUCTING MY RESEARCH I HAVE FOUND OUT WATER IS LEAKING THROUGH THE WINDSHIELD THE REAR WINDOW AND WIRING HARNESS THAT TRAVELS THROUGH THE FIREWALL. PLEASE HELP, FORD WILL NOT ADMIT TO THEIR MISTAKE. *TR
Structure, Jan 30, 2012
I AM THE OWNER OF A 2004 F-150. THIS IS MY FIFTH FORD PRODUCT ON A ROW, TWO OF THEM PURCHASED NEW. RECENTLY THE PASSENGER SIDE REAR WINDOW REGULATOR FAILED, CAUSING THE WINDOW TO SLIDE DOWN INTO THE DOOR. IN DECEMBER. I PURCHASED A REPLACEMENT REGULATOR/MOTOR ASSEMBLY AND JUST FINISHED THE INSTALLATION. WHEN I EXAMINED THE OLD UNIT I FOUND THE OPERATING CABLE INCORRECTLY SPOOLED ONTO THE PRIMARY PULLEY. WHEN THE CABLE OVERLAPPED ITSELF THE END PULLED OUT OF THE LIFTING BLOCK. WHEN I WAS SEARCHING FOR INFORMATION ABOUT THE REPLACEMENT PROCEDURE, I CAME ACROSS NUMEROUS WEBSITES DETAILING COMPLAINTS ABOUT THE FAILURE OF F150 WINDOW REGULATORS. THIS LEADS ME TO BELIEVE THAT THE PROBLEM IS DUE TO A FAULTY DESIGN AND SHOULD BE ADDRESSED BY FORD WITH A REDESIGNED PART AND A RECALL TO REPLACE EXISTING UNITS. I WILL BE CONTACTING MY CONGRESSMAN, ABOUT THIS EXPENSIVE AND ANNOYING DEFECT.WEBSITES DETAILING THE ISSUE ARE LISTED BELOW: HTTP://WWW.JEREBEASLEYREPORT.COM/2011/08/PROBLEMS-WITH-FORD-F-150-WINDOW-REGULATORS/ HTTP://WWW.CARCOMPLAINTS.COM/FORD/F-150/2005/WINDOWS_WINDSHIELD/POWER_WINDOW_REGULATOR_FAILURE.SHTML INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6) *TT
Electrical system, Visibility, Structure, Oct 24, 2011
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 IN ME WHICH RESULTED IN PULLING ON THE STEERING WHEEL TO ONE SIDE. THANKFULLY, THERE WERE NO VEHICLES TO THAT SIDE AND I WAS ABLE TO CORRECT MY STEERING TO GET BACK INTO MY LANE. AS IF ONE EXPERIENCE WAS NOT SUFFICIENT, IT HAPPENED AGAIN 9/1/11. THIS TIME ON THE PASSENGER SIDE DOOR. THE SAME EXACT EXPERIENCE REPEATED EXCEPT THAT THIS TIME I WAS DRIVING AT 75MPH ON I-25. I EXPECTED TO FIND A RECALL TO THIS DIS-FUNCTIONAL MECHANISM. WHAT ARE THE CHANCES OF THIS HAPPENING ALMOST BACK TO BACK WITHIN A 6 WEEK PERIOD? *TR
Visibility, Structure, Jul 4, 2011
WINDOW REGULATOR ON 2004 F 150 LARIAT DRIVERS DOOR BROKE ALLOWING THE WINDOW TO DROP SCARING ME SO BAD THAT I WENT OFF THE ROAD JUST MISSING CRASHING INTO SEVERAL TREES. IT SOUNDED LIKE SOMEONE HAD SHOT OUT MY WINDOW, WHILE I WAS DRIVING IN A THUNDER STORM. THE ROADS WERE WET, BUT THERE WAS KNOW WARNING WHEN THE WINDOWBROKE, THEN I WAS GETTING HIT IN THE FACE WITH RAIN IT FELT LIKE GLASS HITTING ME IN THE FACE. THIS SHOULD BE A RECALL BY FORD, I HAVE RESEARCH THIS PROBLEM AND HAVE FOUND IT TO BE MASSIVE IN NUMBERS WITH A BIG EXPENSE TO FORD CUSTOMERS. THIS MANY CASES SEEMS MORE THAN JUST A FLUKE INCIDENT. THIS SHOULD BE LOOKED INTO, I'M SO LUCKY TO BE HERE NOW I JUST MISSED THOSE TREES AND MY WIFE IS NOW SCARED THAT IT MAY HAPPEN TO ONE OF MY OTHER REMAINING WINDOWS AND DOES NOT WANT TO RIDE WITH ME ANYMORE.. *TR
Suspension, Structure, May 31, 2011
2004 FORD F150 SUPERCREW STARTS SHAKING HORRIBLY AT HIGHWAY SPEEDS WHEN PULLING A TRAVEL TRAILER. IT DOESN'T MATTER IF YOU SLOW DOWN, SPEED UP, OR TAKE OUT OF GEAR THE ONLY WAY TO MAKE IT QUIT IS TO COME TO A COMPLETE STOP. THIS HAS HAPPENED 3 TIMES TO ME SO FAR AND IT FEELS AS IF ALL THE WHEELS ARE ABOUT TO FALL OFF. I CALLED MY DEALER AND THEY SAID THAT THEY HAVEN'T HEARD OF THIS PROBLEM, BUT IF YOU DO A SEARCH ON IT THERE IS A LOT OF PEOPLE CONCERNED OF THIS DANGEROUS ISSUE. LUCKILY I HAVEN'T BEEN ON AN INTERSTATE WITH MY TRAVEL TRAILER BECAUSE I WOULD BELIEVE THAT THIS COULD CAUSE ME TO POSSIBLY LOSE CONTROL AT THOSE KIND OF SPEEDS. *TR
Structure, May 24, 2011
TL* THE CONTACT OWNS A 2004 FORD F-150. THE CONTACT STATED THAT THE VEHICLE FRAME WAS NOT PROPERLY ALIGNED WITH THE BODY OF THE VEHICLE. THE CONTACT DISCOVERED THE FAILURE WHEN HE NOTICED THAT THE REAR TIRES WERE PROTRUDING OUTWARD ABNORMALLY. THE VEHICLE WAS TAKEN TO THE DEALER WHO DID NOT DIAGNOSE THE FAILURE. THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURE AND THE VEHICLE WAS NOT REPAIRED. THE FAILURE MILEAGE WAS 83,000 AND CURRENT MILEAGE 99,000.
Visibility, Structure, May 22, 2011
DOOR POWER WINDOW REGULATOR FAILS (BROKEN PLASTIC PIECE) AND DOOR WINDOW GLASS FALLS INTO THE DOOR. THIS USUALLY OCCURS WHILE DRIVING - SEE THOUSANDS OF INTERNET REPORTS. THIS IS A DANGEROUS DEFECT IN THE REGULATOR THAT FORD KNOWS ABOUT AND REFUSES TO RECALL. REPAIR PART AND LABOR COST APPROX $400 PER WINDOW. I HAVE HAD 2 WINDOW REGULATORS FAIL SO FAR! FORD SHOULD BE RESPONSIBLE FOR THIS. *TR
Visibility, Structure, Sep 12, 2010
3RD POWER WINDOW REGULATOR FAILURE IN 1.5 YRS ON 2004 FORD F-150 SUPERCREW TRUCK. WHEN REGULATOR FAILS, IT SOUNDS AS THOUGH SOMEONE STRUCK OR SHOT THE WINDOW CAUSING ME TO JUMP AND TAKE MY EYES OFF THE ROAD TO SEE WHAT HAD HAPPENED AND IF ANY PASSENGERS WERE INJURED ALMOST CAUSING ME TO COLLIDE WITH AN ON-COMING VEHICLE. I HAVE HAD TWO OF THE REGULATORS REPLACED BY A LOCAL PAINT AND BODY SHOP WHERE I WAS TOLD THAT IT IS A KNOWN PROBLEM WITH THE REGULATORS. MY COST TO DATE HAS BEEN IN EXCESS OF $350 AND I NOW HAVE TWO SUCTION CUPS HOLDING ONE WINDOW UP UNTIL I CAN AFFORD TO HAVE IT REPAIRED. *TR
Visibility, Structure, Sep 9, 2010
2004 FORD F150 WINDOW REGULATOR FAILURES...MULTIPLE TIMES..SEVERAL MONTHS APART. THE WINDOW COMES CRASHING DOWN AND IS TOTALLY OPEN. I HAVE DOGS THAT RIDE WITH ME. THIS HAS GOT TO BE FIXED BY FORD. *TR
Visibility, Structure, Sep 7, 2010
WHILE DRIVING AT HIGHWAY SPEED THE REAR PASSENGER WINDOW DROPED, AT THAT TIME MY GRANDSON (3) TAUGHT IT WOULD BE OK TO THROW HIS SOCKER BALL OUT. THE BALL BOUNCED OF A CAR BEHIND ME BUT NO DAMAGE BUT SCARED THE DRIVER ALMOST CAUSING AN ACCIDENT. THIS IS A BIG PROBLEM, WINDOWS SHOULD NOT DROP LIKE THAT GOOD THING WEATHER WAS GOOD, I CAN ONLY IMAGINE IF IT HAD BEEN RAINING THE OTHER CAR WOULD HAVE NOT BEEN ABLE TO STOP CAUSING A MAJOR ACCIDENT AND I WOULD BE GETTING SEUD. THIS ISSUE NEEDS FIXING BY FORD BECAUSE IS NOT AN ISOLETED PROBLEM THOUSANDS ARE HAVING THE SAME PROBLEM. WINDOW NOT FIXED YET STILL RESEARCHING FOR PARTS. *TR
Visibility, Structure, Aug 27, 2010
FRONT PASSENGER SIDE WINDOW SUDDENLY DROPPED FOR NO REASON. *TR
Structure, Jun 3, 2010
I PURCHASED A USED 2004 FORD XL F 150 4 X 4 WHCIH WAS MANUFACTURED IN THE U.S. BUT SOLD IN CANADA SER # [XXX]. THE TRUCK HAS A CONSTANT VIBRATION AT 50 MPH AND I HAVE SPENT $2,500 TRYING TO FIX IT WITH OUT SUCCESS. WHAT REALLY SCARED ME WAS THAT ON ONE OCCASSION THE VIBRATION INSTANTLY BECAME SO SEVERE, THAT I ALMOST LOST CONTROL OF THE TRUCK AND HAD TO PULL OFF THE ROAD.. ARE THERE OTHER COMPLAINTS WITH THIS SAME PROBLEM? ARE YOU AWARE OF WHAT CAUSES THIS PROBLEM? MY INVESTIGATION LEADS ME TO BE CONVINCED THAT IT IA AN INHERENT FORD MANUFACTURING DEFECT. ANYTHING THAT YOU HAVE THAT WOULD SUPPORT MY BELIEF WOULD BE OF GREAT ASSISTANCE, OR ANY INFO AT ALL WOULD HELP. I HAVE SUED FORD AND THE TRIAL IS JUNE 12 A FEW WEEKS FROM NOW SO IF YOU HAVE ANYTHING PLEASE FORWARD IT ASAP [XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6). *TR
Structure, Tires, Jun 2, 2010
I WAS HAVING A RATTLING NOISE UNDER MY TRUCK FOR THE PAST SEVERAL MONTHS. MY NEIGHBOR WHO USED TO WORK FOR FORD THINKS ITS THE CABLES FOR THE SPARE TIRE UNDER MY TRUCK. HE BELIEVES THE SPARE TIRE CABLES ARE LOOSE AND NEED TO BE TIGHTENED. I LOOKED IN THE OWNERS MANUAL TO FIGURE OUT HOW TO GET THE SPARE TIRE OUT. I HAVE TO USE MY IGNITION KEY TO OPEN THE LOCK TO GET TO THE TIRE. MY KEY ONLY FITS HALF WAY IN AND WONT OPEN THE LOCK. I USED WD40 TO MAYBE GET IT LOOSE. TRIED AGAIN AND NOTHING. I RESEARCHED ONLINE AND MANY PEOPLE HAVE THE SAME PROBLEM. I CALLED THE DEALER AND THEY WONT FIX IT FOR FREE SINCE ITS NOT UNDER WARRANTY. WHAT HAPPENS IF I GET A FLAT TIRE? I WONT BE ABLE TO GET TO MY SPARE. THIS ALSO HAPPENED ON MY OTHER FORD TRUCK. *TR
Structure, Mar 21, 2010
THERE ARE FACTORY MADE SQUARE HOLES UNDER THE SIDES OF THE TRUCK. WHEN IT RAINS, THE WHEELS SPLASH WATER INTO THESE HOLES. THE WATER COMES UP INTO THE FLOOR OF THE TRUCK. INSIDE THE TRUCK THERE IS A PLASTIC PANEL ALONG THE EDGES OF THE DOOR THAT POPS OUT. IT IS THE SQUARE HOLES THAT IT POPS OUT OF THAT THE WATER COMES IN THROUGH. I CAN STICK MY FINGER FROM THE UNDER OUTSIDE IF THE TRUCK AND SEE THEM THRU THE HOLES THAT HOLD THE PLASTIC PANELING ON THE INSIDE. THE WATER COLLECTS ALONG WHERE ALL THE ELECTRICAL WIRES ARE RUNNING AND SOAKS UP INTO THE CARPET. *TR
Structure, Nov 24, 2009
2004 FORD F-150 SUPERCREW WINDOW REGULATOR FAILURE. DRIVING SAFETY HAZARD, DISTRACTIONS DURING DRIVING AT HIGHWAY SPEEDS. COULD LEAD TO POSSIBLE SEVERE INJURY OR DEATHS. SECOND TIME IN 10,000 MILES. POOR DESIGN AND FLIMSY PARTS USED BY FORD. EXPENSIVE REPAIR. *TR
Visibility, Structure, Sep 14, 2009
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 CRASHED DOWN INTO THE DOOR SCARING ME AND ALMOST CAUSING AN ACCIDENT. AFTER DOING SOME RESEARCH I REALIZED THAT THIS IS PROBLEM MANY OTHER FORD OWNERS ARE HAVING AND NOT JUST A FLUKE. SOMETHING NEEDS TO BE DONE ABOUT THIS BEFORE IT CAUSES AN ACCIDENT RESULTING IN SOMEONE'S DEATH. *TR
Visibility, Structure, Latches/locks/linkages, Aug 3, 2009
SECOND WINDOW DRIVE FAILURE IN 6 WEEKS. VERY LOUD BANG FROM DOOR (SOUNDS LIKE TRUCK IS HIT BY LARGE ROCK/HARD OBJECT) WHICH IS VERY STARTLING, THEN WINDOW GLASS SLIDES DOWN INTO DOOR. ON THE FREEWAY THIS IS EXTREMELY DISTRACTING AND DANGEROUS. THE FIRST WINDOW FAILURE (ONE MONTH AGO) COST ME $430.00 AT FORD DEALER TO REPAIR. I WAS NEVER INFORMED THAT THIS WAS A FREQUENT PROBLEM. AFTER SECOND FAILURE IN 4 WEEKS, I WENT ON THE WEB AND DISCOVERED THAT THIS IS HAPPENING TO THOUSANDS OF 2004-2005 F-150'S, AND FORD REFUSES TO ADDRESS IT! I'M WAITING TO TALK TO DEALERS SERVICE MANAGER ABOUT SECOND FAILURE TO TRY AND GET FORD TO PAY FOR THE REPAIRS, AS WELL AS INSPECT THE OTHER WINDOWS AND REPAIR THEM AS NECESSARY. IT'S ONLY A MATTER OF TIME BEFORE THEY FAIL AS WELL. - THIS IS A WELL-KNOWN DESIGN DEFECT!!! FORD HAS ALREADY CHANGED THE DESIGN/PART # FOR THE FAULTY PART (REGULATOR/CABLE ASSY) THREE TIMES- AND IT STILL FAILS WITHOUT WARNING! THESE TRUCKS SHOULD BE RECALLED AND FIXED AT FORD'S EXPENSE!!!! *TR
Structure, Jun 19, 2009
THE PAINT ON MY 2004 FORD F150 IS BUBBLING AND RUSTING ON THE REAR QUARTER PANEL AND FORD REFUSES TO FIX IT DESPITE THE FACT THAT ITS A KNOWN ISSUE. *TR
Structure, Mar 30, 2009
I WAS DRIVING DOWN I-35 IN THE RAIN WHEN A LOUD BANG STARTLED ME. I NOTICED RIGHT AWAY THAT MY 2 YEAR OLD GIRL WAS CRYING AND HER WINDOW WAS DOWN WITH RAIN POURING IN. I HAD TO PULL OVER IN TRAFFIC ON THE INTERSTATE IN THE RAIN TO TRY AND FIX THE PROBLEM. THE BANG HAD SCARED HER AND SHE WAS GETTING WET. WE MOVED THE CARSEAT OVER TO THE OTHER SIDE AND I WAS ABLE TO PULL THE WINDOW UP. MY WIFE HAD TO HOLD IT UP WITH HER HAND ALL THE WAY HOME. FROM THE SOUND OF THAT BANG I AM SUPRISED THE WINDOW DIDN'T SHATTER. IF IT WOULD HAVE MY LITTLE GIRL COULD HAVE LOST AN EYE OR BEEN CUT BADLY. I WAS ABLE TO LOOK AT IT TODAY AND IT SEEMS THAT THE LITTLE CABLE THAT PULLS THE WINDOW UP HAS BROKEN LOOSE FROM THE PLASTIC PULLEY IT WINDS UP ON. I HAVE DONE A BIT OF RESEARCH TONIGHT AND THIS IS A VERY COMMON PROBLEM. FORD KNOWS ABOUT THE PROBLEM SINCE THEY TEND TO KEEP PLENTY OF THESE WINDOW REGULATORS IN STOCK. MANY OF THE PEOPLE ON THESE WEBSITES HAVE HAD MULTIPLE FAILURES. ONE HAD REPLACED ALL FOUR WINDOW REGULATORS ON HIS F-150. THE PROBLEMS STARTED WHEN THEY CHANGED FROM A SOLID METAL SCISSORS TYPE TO THIS MOUSE TRAP LOOKING THING WITH PLASTIC PULLEYS. THE ENGINEER THAT DESIGNED THIS THING SHOULD HAVE HIS P.E. LICENSE REVOKED. IT IS A TERRIBLE PIECE OF ENGINEERING. FORD SHOULD FIX THIS PROBLEM AND DO A RECALL ON THIS PROBLEM BEFORE ONE OF THESE WINDOWS SHATTERS AT HIGHWAY SPEED AND THROWS GLASS INTO THE FACE OF A SMALL CHILD. *TR
Structure, Jan 17, 2009
OWN A FORD F-150 YEAR 2004 AND A WINDOW IN ONE OF THE DOORS HAS FALLEN. THIS TIME IT WAS THE BACK PASSENGER WINDOW THAT SCARED MY WIFE WHILE DRIVING WHEN IT FELL TO THE BOTTOM OF THE INSIDE DOOR. I HAVE ALREADY HAD EVERY WINDOW REPLACED ONCE AND THE DRIVER WINDOW TWICE, AND THIS WILL BE TWICE FOR THIS DOOR, IN TOTAL IT HAS BEEN 6 TIMES WINDOWS HAVE FELL. THIS REQUIRES A RECALL. WHEN DRIVING THIS CAN BE A SAFETY HAZARD WHEN YOU THINK SOMEONE HAS SHOT YOUR WINDOW OR SOMETHING HAS CRASHED BEHIND YOU AND IT HAPPENS THAT YOUR WINDOW HAS FELL DOWN MAKING LIKE A CRASHING SOUND. IT CAN BE VERY FRIGHTENING WHILE DRIVING AND COULD CAUSE A SAFETY PROBLEM. AND BEING THE 6TH TIME, NEEDS REDESIGNED PROPERLY. *TR
Structure, Oct 13, 2008
A RUST AND PANEL PERFORATION ON THE RIGHT BOX OUTER OF 2004 FORD F-150'S. RUST DEVELOPS UNDER THE PAINT ON THE RIGHT BOX OUTER PANEL BEHIND THE RIGHT REAR WHEEL OPENING AND ABOUT AT THE CENTER FOR HEIGHT OF THE PANEL. THIS HAS HAPPENED ON SEVERAL TRUCKS OF FRIENDS AS WELL AS MY TRUCK. THE DEALERS ARE SAYING IT IS BECAUSE THERE IS A BRACE WELDED TO THE PANEL DURING PRODUCTION AND THE WELD ID THE ROOT OF THE RUST. FORD IS SAYING THAT THEY HAVE NO RESPONSIBILITY AND WON'T HELP TO COVER THE COST OF REPAIR. AS A RETIRED ENGINEER FROM ANOTHER MANUFACTURER AND ALSO HAVING WORKED FOR THE OTHER OF THE BIG THREE, I KNOW THAT WELDING DESTROYS THE RUST PREVENTABLE ON THE SHEET METAL. THE WELD PROCESS FLOWS GALVANIZE AWAY FROM THE WELD AREA AND THEN HELPS TO PRECIPITATE THE RUST TO FORM. THE TRUCKS HAVE ALL HAD NO PAINT DAMAGE OR ACCIDENTS IN THE AREA OF THE RUST FORMING. BUBBLES APPEAR UNDER WHAT LOOKS LIKE GOOD SOLID PAINT AND THEN BREAKS THROUGH AND SHOWS RUSTED METAL. WITH THE NUMBER OF TRUCKS HAVING THE SAME ISSUE IT LOOKS TO BE A SYSTEMIC ISSUE FROM THE MANUFACTURING PROCESS. THE OTHER TWO DOMESTIC MANUFACTURERS WILL NOT WELD ON WHAT IS KNOWN AS A CLASS A OUTER PANEL SURFACE. A CUSTOMER?S LINE OF SIGHT WALKING UP TO A VEHICLE IS CONSIDERED TO BE CLASS A SURFACE. THERE SHOULD NOT ANY BE WELDS ON IT AND LITTLE OR NO METAL FINISH. THAT, METAL FINISHING, ALSO WOULD REMOVE THE RUST PROTECTING GALVANIZE. ANOTHER CONCERN IS THAT SOME STATES HAVE ANNUAL INSPECTIONS THAT WOULD CAUSE THIS TO HAVE TO BE REPAIRED. THE OWNER WOULD BE STUCK WITH THIS COST THROUGH NO FAULT OF HIS OR HER OWN. *TR
Structure, Jul 20, 2008
NOTED THAT DRIVERS DOOR DID NOT LINE UP CORRECTLY AS BEFORE. BODY SHOP NOTED THAT DOOR HAD EVIDENCE OF A WELD FAILING IN AREA WHERE THE HINGES INSERT INTO THE DOOR. THAT WAS 2/27/06 AND TRUCK HAD APPROX. 62,000 MILES ON IT. THEN THIS SPRING (2008) I BEGAN TO NOTICE THAT THE DOOR BEGAN TO FIT EVEN WORSE THAN BEFORE AND PUT MY CAMERA BETWEEN DOOR AND DOOR POST TO TAKE PHOTOS AS MY HEAD WOULD NOT FIT IN THAT AREA TO GET A GOOD VIEW. PHOTOS SHOWED NUMEROUS CRACKS HAD DEVELOPED IN AREA OF HINGE INSERTIONS ON THE DOOR AND THE ENTIRE DOOR END HAD WARPED OUT OF SHAPE IN AREA OF HINGE ATTACHMENTS. NOW TRUCK HAS 113,000 MILES AND WHEN MY DEALER SPOKE TO CORPORATE FORD, THEY WERE TOLD THAT THE WARRANTY FOR BODY DEFECTS HAD EXPIRED AT 36,000 MILES. I SPOKE TO CUSTOMER ASSISTANCE AND WAS TOLD THEY WOULD DO NOTHING AS THERE WAS NO RECALL ISSUED. THAT WAS SOMETIME IN MAY 2008. MY CONTENTION IS THAT THIS IS A SAFETY ISSUE NOT A BODY DEFECT AND PUTS ME IN DANGER SHOULD THERE BE A CRASH. THIS DOOR WILL NOT PROTECT ME IN A SIDE IMPACT AS IT IS NOT PROPERLY ATTACHED TO THE VEHICLE. *TR