There are 42 owner-reported fuel system complaints for the 2004 Ford F-150in NHTSA's database. These are unverified consumer reports and may not reflect confirmed defects.
2004 FORD F150 STARTED UP FINE, DROVE IT FOR 10 MINUTES, SLOWED DOWN AND IT STALLED IN THE MIDDLE OF AN INTERSECTION. WOULD NOT START BACK UP, CALLED A TOW TRUCK TO GET THE TRUCK HOME. NEXT DAY, STARTED UP AND DID THE SAME THING, STALLED OUT. THE FUEL PUMP DRIVER MODULE IS CAUSING THIS, ALONG WITH A LOT OF OTHER FORD F150'S. THIS IS A SAFETY ISSUE! I HAD MY CHILD IN THE TRUCK WHEN IT STALLED IN THE MIDDLE OF AN INTERSECTION. THE FPDM GETS CORRODED DUE TO THE BAD POSITIONING OF THE PART.
FUEL TANK LEAKS PROFUSELY AFTER BEING FILLED PAST HALF WAY ABOUT 11 GALLONS
TL* THE CONTACT OWNS A 2004 FORD F-150. WHILE THE VEHICLE WAS PARKED, A STRONG ODOR OF FUEL WAS NOTICED AROUND THE VEHICLE. THE CONTACT NOTICED FUEL LEAKING ONTO THE GROUND. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE VIN WAS NOT INCLUDED IN NHTSA CAMPAIGN NUMBER: 04V443000 (FUEL SYSTEM, GASOLINE). THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE WAS 90,000.
TL* THE CONTACT OWNS A 2004 FORD F-150. WHILE DRIVING AT 30 MPH AFTER REFUELING THE VEHICLE, THE FUEL TANK DETACHED AND FELL ONTO THE GROUND. THE VEHICLE WAS TAKEN TO A DEALER, WHO INFORMED THAT THE FUEL STRAPS AND THE FUEL TANK RUBBER HOSE SEPARATED DUE TO CORROSION CAUSING THE FUEL TANK TO DETACH. AS A RESULT, THE FUEL TANK STRAPS WERE REPLACED BUT THE FUEL TANK RUBBER HOSE WAS NOT REPLACED. THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURE. THE VIN WAS NOT AVAILABLE. THE FAILURE MILEAGE WAS 180,000.
I WENT TO GO START MY F150 AND APRON STARTING IT STARTED TO MAKE A VERY LOAD BANGING NOISE WHICH I THOUGHT WAS A BLOWN ENGINE THE TRUCK HAD VERY LITTLE POWER AND WOULD NOT MOVE . I HAD TRUCK TOWED HOME AND UPON INVESTIGATION I FOUND THAT ONE OF THE SPARK PLUGS BLEW OUT OF THE HEAD. AFTER LOOKING INTO TO THIS MORE THIS IS A VERY COMMON THING WITH THE TRITON V8 MOTOR. THE HEADS ARE MADE OUT OF ALUMINUM AND EACH PLUG IS ONLY HOLD ON BY 4 THREADS FROM THE CONSTANT PISTON PUTTING PRESSURE ON THE PLUGS THEY BLOW RIGHT OUT OF THE HOLE THE ONLY WAY TO REPAIR IS TO RETAP THE HOLE AND INSTALL NEW PLUG. THE IS A FLAW FROM FORD AND THESE ENGINES SHOULD BE RECALLED AND PROPERLY FIXED BY FORD. WHEN THE PLUG BLOWS OUT RAW GAS IS GOING AND NOT BEING BURNED THIS CAN CAUSE AND SURE IT HAS CAUSED A FIRE ON SOME OF THE ENGINES . THIS IS A VERY SERIOUS PROBLEM AND COULD LEAD TO DEATH IF A PERSON IS LOOKING IN THE ENGINE COMPARTMENT WHEN ONE OF THESE PLUGS LET GO IT COULD KILL THEM PLEASE HAVE FORD OWN THE MISTAKE AND RECALL THE TRITON V8 2 CYLINDER AND 3 CYLINDER ENGINES. *TR
SMELT FUEL EMITTING FROM THE GAS TANK AREA BUT COULD NOT FIND THE SOURCE OF THE SMELL; TURNED ON THE IGNITION KEY WITHOUT STARTING THE TRUCK. I SAW FUEL RUNNING DOWN THE SIDE OF THE FUEL TANK. I TURNED OFF THE KEY AND PROCEEDED TO REMOVED THE FUEL TANK GAS STRAPS TO LOWER THE TANK; WITH ALL HOSES STILL CONNECTED I TURNED THE KEY BACK ON; FUEL WAS SPEWING FROM THE FUEL PUMP. I COMPLETELY REMOVED THE FUEL TANK AND ALL HOSES AND FOUND A LINEAR CRACK ON THE PRESSURE SIDE OF THE FUEL PUMP HOSE CONNECTION. THIS VEHICLE HAS NEVER BEEN IN AN ACCIDENT AND IS THE ORIGINAL FUEL PUMP TO THIS VEHICLE. *JS
FUEL SYSTEM PROBLEM.
WHILE DRIVING NORMALLY AT 55 MPH I DROVE THROUGH A SMALL PUDDLE OF WATER AND NEXT THING I KNOW THE TRUCK STALLS AND LOST ALL POWER. I MANAGED TO PULL OF ROAD WITHOUT GETTING HIT FROM BEHIND. I TRIED TO RESTART THE TRUCK WITH NO LUCK. SEEMED LIKE IT WASN'T GETTING FUEL. WAITED IN POURING RAIN AND SLEET FOR MECHANIC AND 120 FOR THE NEW FUEL PUMP DRIVER MODULE AND ARM AND LEG FOR LABOR ON SOMETHING THAT SHOULD BE RECALLED. ITS NOT SAFE FOR THE TRUCK TO STOP LIKE THAT JUST FOR GOING THROUGH A PUDDLE. I LIVE IN MICHIGAN AND WE HAVE CRAZY WEATHER HERE. REPLACE THIS PART NOW FORD AND TAKE CARE OF YOUR CUSTOMERS! *TR
FUEL PUMP DRIVER MODULE, BACK SIDE OF MODULE CORRODED AWAY EXPOSING CIRCUIT BOARD CAUSING THE FUEL PUMP TO STOP RUNNING AND LEAVING ME STRANDED DURING A SNOW STORM,SEEMS TO BE A COMMON PROBLEM ON 2004-2008 FORD PICKUPS. I CONSIDER THIS A POOR DESIGN AND SHOULD BE A RECALL, LOT OF GARAGES INSTALLING NEW FUEL PUMPS AT 300.00 A CRACK WHEN ITS A EASY TO REPLACE 80.00 DOLLAR PART. *TR
TL* THE CONTACT OWNS A FORD F-150. THE CONTACT WAS DRIVING 60 MPH WHEN THE CHECK ENGINE WARNING LIGHT ILLUMINATED. THE VEHICLE WAS TAKEN TO THE DEALER FOR INSPECTION WHERE THE CONTACT WAS INFORMED THAT THE FUEL PUMP CONTROL MODULE DISINTEGRATED AND NEEDED TO BE REPLACED. THE VEHICLE WAS REPAIRED BY THE CONTACT. THE MANUFACTURER WAS NOTIFIED OF THE INCIDENT. THE APPROXIMATE FAILURE MILEAGE WAS 148,000.
TL* THE CONTACT OWNS A 2004 FORD F-150. THE CONTACT STATED THAT UPON INSPECTION, THE BOTTOM OF THE FUEL TANK WAS FOUND TO BE CORRODED. THE CONTACT ALSO MENTIONED THAT THE FUEL TANK STRAPS WERE ALSO CORRODED. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC BUT WAS NOT REPAIRED. THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURE. THE FAILURE MILEAGE WAS 85,000. THE CURRENT MILEAGE WAS 100,000.
TL* THE CONTACT OWNS A 2004 FORD F-150. THE CONTACT STATED THAT HE CONTACTED THE MANUFACTURER TO INQUIRE ABOUT AN UNRELATED ISSUE WHEN HE WAS ADVISED OF A RECALL FOR HIS YEAR, MAKE AND MODEL UNDER NHTSA CAMPAIGN ID NUMBER: 11V385000 (FUEL SYSTEM, GASOLINE:STORAGE:TANK ASSEMBLY:MOUNTING). THE MANUFACTURER ALSO ADVISED THE CONTACT THAT HIS VIN WAS NOT INCLUDED IN THE RECALL. THE CONTACT STATED THAT ALL OF THE VEHICLES OF THE SAME YEAR, MAKE AND MODEL SHOULD HAVE AT LEAST BEEN PROVIDED A FREE SAFETY INSPECTION OF THE FUEL TANK TO ENSURE THERE WAS NO FAILURE PRESENT. THE FAILURE AND CURRENT MILEAGE WAS 71,000.
TL* THE CONTACT OWNS A 2004 FORD F150. THE CONTACT STATED THAT THE VEHICLE MADE A NOISE WHEN DRIVING VARIOUS SPEEDS. THE CONTACT INSPECTED THE VEHICLE AND FOUND THAT THE FUEL TANK BRACKET FAILED AND CAUSED THE FUEL TANK TO SEPARATE FROM THE VEHICLE. AS A RESULT, THE FUEL TANK WAS BEING DRAGGED WHEN DRIVING. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURE. THE APPROXIMATE FAILURE AND CURRENT MILEAGE WAS 100,000. UPDATED 11/13/12 *CN
TL* THE CONTACT OWNS A 2004 FORD F-150 EXTENDED CAB. THE CONTACT STATED AFTER CLEANING THE VEHICLE, IT FAILED TO START. A PRIVATE MECHANIC CONFIRMED THAT WATER ENTERED AN EXPOSED MODULE FOR THE FUEL PUMP AND NEEDED TO BE REPLACED. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE VEHICLE WAS REPAIRED. THE FAILURE AND CURRENT MILEAGE WAS 153,000.
TL* THE CONTACT OWNS A 2004 FORD F150. THE CONTACT STATED THAT WHILE DRIVING 25 MPH, THE VEHICLE STALLED WITHOUT WARNING. THE VEHICLE WAS TOWED TO THE DEALER WHERE IT WAS DIAGNOSED WITH A FAULTY FUEL PUMP DRIVER MODULE. THE DEALER PERFORMED THE REPAIRS. THE MANUFACTURER WAS AWARE OF THE FAILURE. THE CURRENT AND FAILURE MILEAGES WERE 61,552. UPDATED 11/03/11 *BF UPDATED 12/16/11
AS I TURNED RIGHT INTO A SIDE STREET ENGINE STALLED. I HAD VERY LITTLE CONTROL OF VEHICLE BUT MANAGED TO STEER IT ONTO LEFT SIDE OF STREET. LUCKY NO CARS COMING. ALSO HAPPENED ON 4 AUG. CHECKED INTERNET AND POSSIBLE CORRODED FUEL PUMP DRIVER MODULE. MANY COMPLAINTS. COULD CAUSE A MAJOR ACCIDENT. *TR
TL* THE CONTACT OWNS 2004 FORD F-150. THE CONTACT STATED THAT THE VEHICLE WOULD NOT START. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC WHERE THE CONTACT WAS INFORMED THAT THE FUEL PUMP AND FUEL MODULE FAILED. BOTH THE FUEL PUMP AND MODULE WERE REPLACED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE AND ADVISED THE CONTACT TO NOTIFY NHTSA. THE FAILURE AND CURRENT MILEAGES WERE 58,715. UPDATED 09/21/2011 *LN *TR
2004 FORD F150. I HAVE ALREADY FILED A COMPLAINT. THE CONSUMER STATED WHEN HE ARRIVED AT THE DEALER, TO HAVE THE RECALL PERFORMED, THE DEALER INFORMED HIM, THERE WERE NO PARTS AVAILABLE. UPDATED IVOQ 06/30/11 *TR
TL-THE CONTACT OWNS A 2004 FORD F-150. THE CONTACT STATED THE VEHICLE WOULD NOT START. THE VEHICLE WAS TOWED TO AN INDEPENDENT REPAIR SHOP WHERE THE CONTACT WAS INFORMED THE FUEL PUMP DRIVER MODULE FAILED DUE TO CORROSION. THE MANUFACTURER WAS NOTIFIED AND THE CONTACT WAS INFORMED THE PARTS NECESSARY TO REMEDY THE FAILURE WERE UNAVAILABLE. THE CONTACT ALSO STATED THE SAME FAILURE OCCURRED APPROXIMATELY 30,000 MILES PRIOR. THE VEHICLE WAS NOT REPAIRED. THE FAILURE AND CURRENT MILEAGES WERE 150,000. SM.
I WENT TO START THE VEHICLE, HAND SLIPPED OFF OF THE KEY, THE VEHICLE WOULD CRANK BUT NOT TURN OVER. TRIED TO RESTART THE VEHICLE NUMEROUS TIMES. UNPLUGGED THE BATTERY, LEFT IT SIT FOR 10-15 MINS (THOUGHT IT WAS THE ANTI THEFT). LATER IN THE DAY A FRIEND LOOKED AT IT, TROUBLESHOT IT AS FUEL PUMP- USED OWNER MANUAL TO LOOK AT FUSES, EVERYTHING LOOKED FINE. CONCLUDED HAD TO BE WITH THE FUEL PUMP OR SENSOR. HAD TO HAVE THE VEHICLE TOWED TO A GARAGE, PULLED THE FUEL PUMP SENSOR OFF, THERE WAS A GIANT WHOLE IN THE OUTER LAYER AND PLASTIC WAS CRACKED. MOISTURE FRIED THE CIRCUIT BOARD. THE PART IS CURRENTLY AT VRTC. I AM GLAD MY VEHICLE WAS AT HOME AND NOT SOMEWHERE IN A PARKING LOT OR FAR FROM HOME. NO REAL SIGNS OF THIS HAPPENING PRIOR TO NOT STARTING.
Showing 1–20 of 42 complaints
Complaints are unverified consumer reports submitted to NHTSA. A high complaint count may reflect vehicle popularity, not defect severity. Data sourced from NHTSA public records.
Data synced from NHTSA on Apr 25, 2026