2004 Ford F-150 Complaint Log

Rear-end. The rear drivers side tire fell off while driving on a side street. With no noise or wobble or evidence of a problem. 2 days earlier my family and I were going 70 on an express way. Upon shops inspection the bearing was no longer working but wheel kept rolling, it egged out the housing of the axle shaft and heated up that point of axle and snapped the shaft at that spot. The picture will show this point.

There is a recall on this vehicle

My Teenage daughter was in a car accident and the airbags did not deploy and her seatbelt did not lock , and smashed into her steering wheel.

Electrical malfunction with fuses , problems with brake light, engine light and air bag light . Some fuses blown out after brake light fuse popped wipers don't work at all air bog turns on and off every day not sure why

The vehicle rolled and killed the occupant because the roof caved in. The shoulder portion of the seat belt did not hold the occupant (only the lap portion) and the occupant was partially ejected out of the rear of the cab. The vehicle was inspected and purchased by State Farm insurance since the vehicle was totaled. The 2000's Ford F-150s have roofs that are too weak to support the weight of the vehicle, thereby putting the occupants in danger of injury or death. This is well documented. There were no warnings.

Frame on 2004 new body style ford f-150 rusted to the point no longer safe to drive according to 2 licensed repair shops. There is no recall on vin number [XXX] However I have been told there are other recalls on frame rust on this same model from 2004-2008. Please know I bought this truck brand new and only have operated on roadway no off roading. This is my primary vehicle. Please advice what can be done. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

The contact owns a 2004 Ford F-150. The contact stated that while driving at approximately 50 MPH, the engine began revving: however, the vehicle to accelerate properly. The transmission fault warning light was illuminated. The vehicle was taken to the residence. The vehicle was inspected by independent mechanic at the residence, and it was determined that the transmission needed to be replaced. The vehicle was not repaired. The manufacturer was notified of the failure. The failure mileage was 145,000.

I have a suspect that keeps adding air in brake lines of this vehicle. Police gave me permanent case number, but the guy is still breathing. Idk what to do, as he has done it on all our cars and on this F150 about 4 different times. The name of suspect is [XXX] , [XXX] . INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

The contact owns a 2004 Ford F-150. The contact stated that while driving at an undisclosed speed, the vehicle made an abnormal popping sound and then lost motive power. The contact was able to drive to the residence. The vehicle was taken to an independent mechanic, who determined that the spark plug had blown out of the cylinder and determined that the spark plug needed to be replaced. The manufacturer was made aware of the failure and advised the contact to file a complaint with the NHTSA Hotline. The failure mileage was approximately 364,000. The VIN was unavailable.

I get a warning message which indicates the the Crash Sensor is not working on my Ford truck - this component inflates the Air Bag in the event of a crash. The part number for the Crash Sensor is Motorcraft 6L3Z-14B004-AA. I attempted to purchase a replacement Crash Sensor from a local Ford dealer. I was told that Ford no longer makes this part. The parts manager suggested that I check with local aftermarket parts stores; Advance Auto Parts, AutoZone, Fisher and NAPA. Nobody makes an aftermarket Crash Sensor for my vehicle. I also searched Amazon without success. I am therefore driving a vehicle with Air Bags which will not deploy - possibly causing a fatality. It seems like the manufacturer, Ford, should be required to sell replacement Crash Sensors until they become available as an Aftermarket Product.

The contact owns a 2004 Ford F-150. The contact stated that while driving at undisclosed speeds, the vehicle shuddered and failed to accelerate while the accelerator pedal was depressed. The check engine warning light was illuminated. The contact pulled over to the shoulder of the roadway and was able to restart the vehicle. The contact scanned the vehicle with a scanner and retrieved an unknown camshaft phaser error code. The local dealer was not contacted. The vehicle was not repaired. The manufacturer was notified of the failure and referred the contact to the NHTSA Hotline for assistance. The failure mileage was approximately 100,000.

The contact owns a 2004 Ford F-150. The contact stated that while driving at an undisclosed speed, the air bag warning light illuminated. The vehicle was not diagnosed or repaired by an independent mechanic or dealer. The manufacturer was made aware of the failure and advised the contact to report the failure to the NHTSA Hotline. The contact was also informed that the repair could not be covered under NHTSA Campaign Number: 11V107000 (Air Bags) because the VIN was not included. The failure mileage was approximately 93,000.

The contact owns a 2004 Ford F-150. The contact stated that while the vehicle was parked in the driveway, the vehicle caught on fire inside the cab. The contact stated that she attempted to put the fire out with a water hose. The fire department was called and was able to put out the fire. No injuries were reported. No warning lights were illuminated. The vehicle was not taken to a local mechanic or dealer. The vehicle was not diagnosed nor repaired. The manufacturer was made aware of the failure. The failure mileage is unknown.

THERE ARE LARGE HOLES IN THE FRAME, AND THE SHACKLES ARE READY TO FALL OFF. SUSPENSION IS FALLING APART. BRAKES ARE NOT SAFE FOR STOPPING POWER FOR THE VEHICLE. MASTERTECH AT ZIEGLER TIRE.

N/a

The contact owns a 2004 Ford F-150. The contact stated that the rear driver's side door failed to open. The contact removed the door and replaced the plastic ends with new metal ends. The local dealer was not contacted. The vehicle was not diagnosed or repaired. The manufacturer was contacted and referred the contact to the NHTSA Hotline for assistance. The failure mileage was approximately 160,472.

Truck stalls in traffic. Also when hitting the brake. it stalls in reverse. it stalls while idling. Worst truck ever!! Severe safety issue

Air bag deployed suddenly while i was in the parked vehicle, it is available for inspection, has not been brought up to dealerships attention, no warning or light up on dash board to indicate problem

Got into accident I lent my vehicle to Daniel LeBlanc he has had my vehicle since October 2022 He gave permission to his girlfriend at the time she got into accident from black ice

Frame Failure, A licensed technician said my vehicle is dangerous to drive and cannot be fixed because of the advanced rusting of the frame. As I read the history of some Ford Trucks I find this is a continuing problem with no recalls and wonder why they can continue to manufacture faulty, dangerous products

The contact owns a 2004 Ford F-150. The contact stated that while driving at an undisclosed speed, the contact observed the spark plug being ejected from the fuel compartment. The check engine warning light was illuminated. The vehicle was taken to an independent mechanic, who was unable to diagnose the failure. The vehicle was repaired, but the failure reoccurred. The manufacturer was notified of the failure but referred the contact to the NHTSA Hotline for assistance. The failure mileage was 150,000.

The contact owns a 2004 Ford F-150. The contact stated while starting his parked vehicle, he found that the vehicle would not start. The contact self-diagnosed and bypassed the starter solenoid using a screwdriver and started the vehicle. The vehicle slipped out of the park and rolled backward. The contact was backed over by the vehicle and had received injuries to his ribs and stomach. He had lacerations and abrasions to his back and chest. The contact was able to get out from under the vehicle and attempted to stop the vehicle which was rolling. The contact jumped into the passenger side and attempted to brake but could not. The contact attempted to push the shift lever into "park" but the gear would not engage. The vehicle rolled and crashed into the rear end of a parked vehicle. The contact's vehicle had damage to the rear bumper and the rear end of the other vehicle had the bumper and trunk crumpled. The police were not called and the contact did not seek medical attention. The contact was able to start the vehicle and drove it to his residence. The contact then examined the undercarriage and determined that the transmission linkage cable had been resting on the doughnut of the exhaust system. The contact stated that the outer cable shell had melted and the metal cable was exposed. The contact diagnosed that the exposed cable had contributed to the vehicle slipping out of gear. The contact had not taken the vehicle to a dealer or an independent mechanic. The vehicle had not been repaired. The manufacturer had been informed of the failure. The failure mileage was approximately 260,000.

The truck has had a complete body frame failure. The entire frame is rusted through with large holes. I am unable to put it on a jack to change the tires. It has failed inspections and has not been inspected since 2019. I have a 1992 ford truck that has NO rust issue on the frame. This year is a complete design failure where they used substandard steel or other garbage. It is a safety hazard.

There hasn't been any accidents but the rails underneath of the truck bed are rotting completely off the truck and I feel that would be a safety problem if it collapses and I don't understand why they're so rusty when the rest of the truck is not it this could be a problem!

Hitch broke off due to ford common frame rot. Frame is rotted from leaf spring shackle and back

Door latch not working. Doors flies open. Frozen or stuck. Doesnt latch all the time very dangerous . Happens parked and while driving

Swollen lug nuts--- had to replace all at my expense

THROTTLE BODY CAUSES VEHICLE TO STOP DEAD WHEN SLOWING DOWN ON CITY STREET.

TL* THE CONTACT OWNS A 2004 FORD F-150. THE CONTACT STATED THAT WHILE THE VEHICLE WAS AT AN INDEPENDENT MECHANIC FOR ROUTINE MAINTENANCE, THE TECHNICIAN NOTICED THAT THE SUBFRAME WAS SEVERELY RUSTED THROUGH. THE VEHICLE WAS LATER TAKEN TO TONY BETTEN & SONS FORD, INC (3839 PLAINFIELD AVE NE, GRAND RAPIDS, MI 49525) WHERE THE CONTACT WAS INFORMED THAT THE DRIVER'S AND PASSENGER'S SIDE SUBFRAME WERE SEVERELY RUSTED, AND THAT THE SUBFRAME NEEDED TO BE REPLACED. THE SUBFRAME WAS NOT REPLACED NOR WAS THE VEHICLE REPAIRED. THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURE. THE FAILURE MILEAGE WAS APPROXIMATELY 167,000.

WHILE DRIVING ON THE FREEWAY I NOTICE A NOISE AND A LOSE OF POWER PULL OFF AND HAD TRUCK TOWED TO DEALER THEY CALLED ME TOLD ME NEEDED NEW MOTOR I WAS SHOCKED ONLY HAS 154000 MILES ON IT WHAT THE HELL DEALER TOLD ME $9000 TO REPLACE MOTOR WHAT TOLD THEM I WOULD BE THERE TO PICK UP TRUCK WITH TOW TRUCK WELL THEY CALLED ME BACK SAID $7000 STILL WAY TO MUCH BUT I NEED THE TRUCK CANT BUY A NEW ONE SO I HAD TO GET 2 LOANS TO REPLACE MY MOTOR THEN I FIND OUT THE MOTOR IN A 2004 F 150 HAS A MAJOR ISSUES BUT THE DEALER NEVER TOLD ME ANYTHING OF THE SORT SO NOW I HAVE A TRUCK WITH THE SAME MOTOR AS BEFORE THAT COST ME A LARGE AMOUNT OF MONEY I DIDN'T HAVE FORD SHOULD STEP UP AND TAKE CARE OF THE PROBLEM SO NOW I HAVE 2 LOANS TO PAY OFF HOPE TO HELL THIS MOTOR LAST AND THEY WONDER WHY PEOPLE GO POSTAL IF FORD DOSENT RESOLVE THIS I WILL NEVER BUY A FORD PRODUCT AGAIN !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!

F150 STALLS OUT RANDOMLY CAUSING A HAZARD FOR OTHER DRIVERS AND MYSELF. HAPPENS WHILE IN GEAR DRIVING, REVERSE, ETC.

THE TOP OF PASSENGER DASH HAS BECAME A STICKY SURFACE AND THE PAINT WILL RUB OFF. TRUCK ONLY HAS 60K MILES BECAUSE IT'S MY HUSBANDS PRIDE. VEHICLE STAYS IN A GARAGE WITH NO NATURAL LIGHT THAT COULD CAUSE PROBLEM.

THE FRAME IS ROTTED COMPLETELY. IT IS A SAFETY ISSUE THAT WHEN DISCOVERED AND SEARCHED SEEMS TO A HUGE ISSUE. I WAS ADVISED NOT TO DRIVE THE VEHICLE AS IT NOT SAFE TO DRIVE. I BOUGHT THIS TWO DAYS AGO.

TL* THE CONTACT OWNS A 2004 FORD F-150. THE CONTACT STATED WHILE ROUTINE MAINTENANCE WAS BEING PERFORMED ON THE VEHICLE, THE CONTACT DISCOVERED THAT THE SUBFRAME WAS EXTREMELY CORRODED. THE VEHICLE WAS NOT TAKEN TO BE DIAGNOSED NOR REPAIRED. NEITHER THE DEALER NOR THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 167,000.

Problem is already a recall item, took in to get fixed and the warning light continues to stay on.

DRIVERS DOOR SLUNG OPEN EVENTHOUGH IT APPEARED LATCHED WHEN I TURNED A CURVE. IT WAS 15 DEGREES OUTSIDE AT THE TIME OF INCIDENT. COULD CAUSE AN ACCIDENT .

FRONT SPRINGS TO LOW

PAINT CRACKED ,COILS MALFUNCTION,SPRINGS FRONT

IN MID NOVEMBER 2019, I WAS ENTERING MY VEHICLE AND NOTICED THE REAR CENTER GLASS WINDOW COMPLETELY SHATTERED THE MOMENT I OPEN THE TRUCK DOOR FOR NO REASON. NO INDICATION OF AN OBJECT STRIKING OR ANYTHING. THE VEHICLE WAS COMPLETELY STATIONARY IN MY DRIVEWAY. THE TEMPERATURE HAD DROPPED DOWN PAST 20 DEGREES THE DAY THIS HAPPENED. I REPLACED THE ENTIRE REAR WINDOW AND THEN,NOT EVEN A WEEK LATER, THE REAR RIGHT SIDE OF THE WINDOW IS COMPLETELY SHATTERING AND IS ABOUT TO BREAK....THE SAME PROBLEM AGAIN! NOW, I GO OUT TODAY, 12/12/19 TO MY PASSENGER SIDE DOOR WINDOW COMPLETELY SHATTERED FOR NO APPARENT REASON! IN ALL 3 INSTANCES, THE TEMPERATURE DROPPED BELOW 35 DEGREES. I HAVE NO IDEA WHAT'S GOING ON AND IT'S DRIVING ME INSANE TRYING TO FIGURE OUT WHY THE WINDOWS ARE RANDOMLY SHATTERING WHEN THE TEMPERATURE DROPS. NOW I AM ABOUT TO BE OUT I DON'T KNOW HOW MUCH MONEY TO TRY TO REPAIR MY FORD WINDOWS.

2004 F150 FX4. CONSUMER WRITES IN REGARDS TO DAMAGED FRAME. *LD *JS

THIS VEHICLE IS OTHERWISE IN GOOD CONDITION WITH VERY LITTLE BODY RUST LIMITED TO THE BACK CORNER OF THE PASSENGER CABIN. HOWEVER THE LEFT FRAME RAIL STARTING 14 INCHES AHEAD OF THE FRONT ATTACHMENT POINT OF THE LEAF SPRING. THE RUST HOLE EXTENDS THE WIDTH OF THE FRAME RAIL FOR A DISTANCE OF 17 INCHES. ONE FINGER SIZE HOLE WAS OBSERVED. THE FRAME BOTTOM STEEL WAS EASILY STRIPPED AWAY WITH TWO FINGERS AND A THUMB TO THE LENGTH AND WIDTH DESCRIBED. THE REMAINDER OF THE FRAME HAS EXTENSIVE SURFACE RUST BUT NO HOLE AND OTHERWISE FAIR CONDITION. THE LICENSED STATE VEHICLE INSPECTION SHOP FAILED THE VEHICLE DUE TO THE FRAME RUST AT THIS LOCATION. OTHERWISE, WITH SOME MINOR MECHANICAL ISSUES, THE TRUCK IS IN GOOD CONDITION AND COULD BE SAFELY USED FOR A NUMBER OF MORE YEARS. ONLINE THIS RUST PROBLEM AT THIS POINT HAS A LARGE NUMBER OF COMPLAINTS IN FORD F-150 TRUCKS IN 2004 AND 2005. OBVIOUSLY THERE WAS A MANUFACTURING ISSUE FRAME FORMING TO CAUSE THIS RUST THROUGH IN SO MANY TRUCKS AT THIS FRAME LOCATION AND NOT ELSEWHERE.

BOUGHT VEHICLE FROM INDIVIDUAL HE STATED MILEAGE ON ODOMETER 125K AND 2008 WENT TO GET INSURANCE AND IT'S A 2004 AND MILEAGE WAS 240K PLUS

TL* THE CONTACT OWNED A 2004 FORD F-150. WHILE THE CONTACT'S FIANCE WAS DRIVING 35 MPH, A DEER RAN INTO THE ROAD AND CAUSED THE DRIVER TO SWERVE AND CRASH INTO A TREE. THE AIR BAGS DID NOT DEPLOY. THERE WERE NO WARNING INDICATORS ILLUMINATED. THE DRIVER SUSTAINED A BROKEN LEFT WRIST AND STRUCK HIS HEAD ON THE WINDSHIELD. THE DRIVER RECEIVED MEDICAL ATTENTION. A POLICE REPORT WAS FILED. THE VEHICLE WAS TOWED TO AN IMPOUND LOT AND DEEMED DESTROYED. THE CONTACT CALLED CONWAY FORD (LOCATED AT 2393 CHURCH ST, CONWAY, SC 29526, (843) 365-5596) AND INFORMED THEM OF THE FAILURE. THE VEHICLE WAS NOT DIAGNOSED. THE MANUFACTURER WAS NOT NOTIFIED. THE FAILURE MILEAGE WERE UNKNOWN. *LN*JB * PM CONSUMER STATED OWNER OF THE VEHICLE WAS HER DAD'S WHICH WAS PURCHASED IN 2000. *JB

TRANSMISSION OVERDRIVE FAILED AT 130K MILES CAUSING TRANSMISSION TO BE REPLACED.

I TOOK MY TRUCK IN TO GET THE STEERING SHAFT REPLACED AND WHEN THE LIFTED UP ON THE HOIST THEY NOTICED THAT THE FRAME IN THE FRONT HAD A SPLIT IN IT UP IN THE FRONT PART OF THE FRAME ON THE DRIVER SIDE OF THE VEHICLE AND THAT THE FRAME WAS VERY RUSTY. I THEN TOOK IT TO ANOTHER PERSON TO HAVE IT LOOKED OVER TO SEE IF THERE WAS ANY WAY TO WELD THE FRAME TO FIX THE SPLIT. UPON HIS INSPECTION, HE FOUND THAT THE ENTIRE FRAME IN THE REAR AND THE MAJORITY OF THE REST OF THE FRAME WASN'T STABLE ENOUGH TO HANDLE A WELD SINCE THE FRAME IS RUSTED SO BAD THE WELD WOULDN'T HOLD. I THEN CALLED AND TALKED TO FORD DIRECTLY AND THEY TOLD ME THAT I HAD TO BRING IT INTO AN AUTHORIZED SERVICE CENTER TO HAVE IT INSPECTED. WHICH I DID AND THEY ALSO DEEMED THE FRAME BEYOND REPAIR. I THEN CALLED FORD BACK AND THEY TOLD ME THAT THERE WAS NOTHING THAT THEY COULD DO FOR ME SINCE THE VEHICLE WAS PAST 7 YEARS. SO, NOW I HAVE AN UN-USEABLE UN-SELLABLE VEHICLE. UPON SOME RESEARCH, I FOUND THAT THAT GENERATION OF FORD VEHICLES HAS HAD SEVERAL HUNDRED THOUSAND VEHICLE RECALLS FOR THE SAME ISSUES FRAME DETERIORATION AND OR FAULTY FRAME OR CHASSIS IN MULTIPLE MODELS. UPON FURTHER RESEARCH, I HAVE FOUND THAT THIS SEEMS TO BE A COMMON PROBLEM FOR THAT GENERATION FORD F150'S AS WELL HOWEVER THERE IS NO RECALL FOR THAT VEHICLE. MY TRUCK ONLY HAS 128,000 ORIGINAL MILES ON IT AND THE MOTOR ITS SELF PROBABLY WOULD LAST ANOTHER 150,000 MILES OR MORE. IF I HAD NOT TAKEN THE VEHICLE IN FOR SERVICE FOR ANY ISSUES THEN I WOULDN'T HAVE KNOWN THAT THERE WAS A FRAME ISSUE AND IF I WOULD HAVE BEEN IN AN ACCIDENT MY FRAME WOULD HAVE BUCKLED NO DOUBT ABOUT IT SINCE THAT IS EXACTLY WHAT EVERYONE HAS TOLD ME. I HAVE A FAMILY OF 5 AND IM SURE THAT IF WE WERE IN A SERIOUS RECK IT WOULD NOT HAVE BEEN GOOD. THIS IS UNACCEPTABLE FOR SUCH A MAJOR MANUFACTURER TO TURN THEIR CHEEK AND ON TOP OF IT MY FAMILY AND THEIR LIVES.

TL* THE CONTACT OWNS A 2004 FORD F-150. WHILE THE VEHICLE WAS UNDERGOING ROUTINE MAINTENANCE, THE INDEPENDENT MECHANIC DISCOVERED THAT THE FRAME AND CHASSIS OF THE VEHICLE WERE RUSTED AND CORRODED. FLAGSHIP FORD (850 FERN DR, BALDWIN, WI) AND THE MANUFACTURER WERE NOTIFIED OF THE FAILURE. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE FAILURE MILEAGE WAS 138,000.

TL* THE CONTACT OWNS A 2004 FORD F-150. WHILE DRIVING APPROXIMATELY 40 MPH, THE CHECK ENGINE INDICATOR ILLUMINATED. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC WHERE IT WAS DIAGNOSED THAT THE EGR VALVE AND THE FUEL INJECTOR NEEDED TO BE REPLACED. THE DEALER AND MANUFACTURER WERE NOT CONTACTED. THE CONTACT STATED THAT THE TRANSMISSION AND CHECK ENGINE INDICATORS ILLUMINATED AND WERE REPLACED IN 2018. THE VEHICLE WAS NOT REPAIRED. THE FAILURE MILEAGE WAS APPROXIMATELY 15,000.

THE DOOR LATCH OF THE REAR "SUICIDE" DOOR WILL NOT OPEN. THE LATCH ONLY MOVES BACK AND FORTH, BUT THE LATCH'S CABLE WILL NOT ENGAGE. I CHECKED AND LEARNED OTHER F-150S HAS THE SAME PROBLEM. IS THIS A "RECALL" ISSUE?

The underbody frame is 95% rusted out, this vehicle is available for inspection upon request. I could have been fatally injured, not knowing the under frame was gone, until vehicle was taken in for new tires. The vehicle was inspected by Firestone tire and Gene Butman Ford. There were no warning messages and the problem was first noticed in 2019 and was told the vehicle was unsafe to drive, a hazard and should not be driven.

FRAME IS ROTTING HUGE HOLES IN FRAME. VEHICLE HAS LESS THAN 110K MILES