2004 Ford F-150 Suspension Problems

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

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

FRONT SPRINGS TO LOW

MY 2004 FORD F-150 HAS 61,000 MILES AND NO RUST ON THE OUTSIDE OF THE VEHICLE. I'VE KEPT THE TRUCK WELL MAINTAINED AND IT LOOKS ALMOST NEW. THE FRAME HOWEVER RIGHT WHERE THE REAR LEAF SPRING ATTACHES TO THE FRAME IS RUSTED RIGHT THROUGH. IT IS INCREDIBLE THAT THIS HAS NOT BEEN RECALLED AS OF YET. HOPEFULLY IT WILL BE RECALLED. WHILE DRIVING A PART OF THE EXHAUST HEAT SHIELD FELL ONTO THE DRIVESHAFT. WHEN I WENT TO INSPECT THE UNDERSIDE I FOUND A HOLE IN THE FRAME AND I WAS ABLE TO PUT MY FINGER RIGHT THROUGH IT. *DT CONSUMER STATED ONE IMPORTANT FACT THAT I FORGOT TO ADD TO MY COMPLAINT IS THE SECTION OF THE FRAME THAT RUSTED THROUGH HAS THE EXACT SAME ISSUE IN THE SAME SPOT ON BOTH THE PASSENGER FRAME RAIL AS WELL AS THE DRIVER'S SIDE FRAME RAIL. THE 2004 FORD ESCAPE WAS RECALLED FOR SIMILAR ISSUES THAT YEAR BUT IN THE FRONT OF THE VEHICLE. MY TRUCK HAS ONLY 61,000 MILES ON IT AND FROM FORUMS AND POSTS I'VE READ IT SEEMS TO BE A MAJOR ISSUE FOR THAT YEAR VEHICLE.*JB

TOOK TRUCK GET NEW TIRES, MECH SAID, NEEDED NEW COIL SPRINGS, SPRINGS BUSTED. (MECH STATED SEEN MANY FORD F150 SAME PROBLEM, ).

WHEN BRAKING SPRINGS MADE NOISE AND IT TAKES SEVERAL BRAKES TO STOP.

112000 MILES 90% DRIVEN IN SUMMER MONTHS. GARAGED EXTENSIVE RUST AND FRAME DAMAGE FROM CORROSION .BODY AND INTERIOR FLAWLESS ALL SERVICE RECOMMENDATIONS BY FORD FOLLOWED

FRAME RUSTING OUT PREMATURELY CAUSING A SAFETY HAZARD.

LOWER CONTROL ARM MOUNT IS BROKEN ,MOUNT IS WELDED TO THE FRAME,I JUST NOTICED IT ON 2-20-2016 WHILE REPLACING MY FRONT SHOCKS.

TL* THE CONTACT OWNS A 2004 FORD F-150. THE CONTACT STATED THAT WHILE DRIVING AT AN UNKNOWN SPEED, THE VEHICLE BEGAN TO VEER TO THE DRIVER SIDE. THE FAILURE RECURRED SEVERAL TIMES. THE VEHICLE WAS TAKEN AN INDEPENDENT MECHANIC WHERE IT WAS DIAGNOSED THAT THE COIL SPRING NEEDED TO BE REPLACED. IT WAS UNKNOWN IF THE VEHICLE WAS REPAIRED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 82,000.

I OWN A 2004 FORD HERITAGE 4X4 AND THE FRAME IS LITERALLY RUSTING AWAY ON OR ABOUT THE 10TH OF MARCH THE BRACKET THAT HOLDS THE REAR DRIVER SIDE LEAF SPRING ROTTED AWAY AND PUNCHED THROUGH THE BOTTOM OF MY BED. I WAS ONLY GOING 30 WHEN IT HAPPENED SO EVERYONE WAS SAFE. I ALSO HAD TO REPLACE THE TRAILER HITCH LAST YEAR BECAUSE THE FRAME WAS SO ROTTED AWAY. I STOPPED AT A STOP SIGN AND WHEN I WENT TO GO I SAW MY TRAILER JUST GO UP AND SLAM BACK DOWN ON THE GROUND. LUCKILY I WAS NOT GOING 65 MPH OTHERWISE I WOULD HAVE HAD A ACCIDENT. THE BACK OF THE FRAME NOW IS PAPER THIN. FORD SHOULD DO A RECALL ON THESE FRAMES. I HAVE OWNED MANY FORD AND NEVER HAD RUST THIS BAD. *TR

BOUGHT A 2004 FORD F-150 FROM A NEIGHBOR RECENTLY. FRONT END WAS DROOPING. WENT TO PUT A "LEVELING KIT" ON IT AND FOUND BOTH FRONT COIL SPRINGS BROKE IN THE SAME PLACE. THIS CAN'T BE A COINCIDENCE. CAN'T REALLY AFFORD NEW SPRINGS RIGHT NOW BUT LOOKS LIKE A MANUFACTURE DEFECT. THANKS. *TR

A NEW YORK STATE INSPECTION REVEALED TWO BROKEN SPRINGS ON FRONT END OF 2004 FORD F150. THE COST TO REPLACE IS NOT CHEAP AND AFTER RESEARCHING ONLINE, SEEMS TO BE A COMMON PROBLEM WITH THIS VEHICLE. FORD MOTOR COMPANY SHOULD RECALL THESE VEHICLES BASED ON SAFETY ISSUE. I HOPE OTHERS WILL DOCUMENT THIS PROBLEM TO HELP RESOLVE THIS ISSUE. *TR

I TOOK MY TRUCK TO A GARAGE TO HAVE THE OIL CHANGED. WHILE UP ON THE RACK THE RUST WAS NOTICED BY MY MECHANIC WHO SAID IT WOULD NOT PASS INSPECTION BETTER HAVE IT FIXED. I CONTACTED A PROFESSIONAL WHO CAME TO MY HOUSE AND LOOKED AT IT WITH THE BED OFF. UPON HIS INSPECTION HE FOUND IT WAS UNREPAIRABLE THERE WAS NOT ENOUGH ORIGINAL METAL LEFT TO WELD TO. I HAVE CONTACTED FORD CUSTOMER RELATIONSHIP CENTER ONLY TO BE TOLD THERE IS NO WARRANTY, NO RECALL, SORRY FOR YOUR LUCK AND GOT HUNG UP ON. WHILE RESEARCHING ONLINE I HAVE DISCOVERED THAT FORD HAS A RECALL ON 2004 ESCAPES FOR THIS VERY SAME REASON "THE FRAMES ARE RUSTING OUT" IT WOULD MAKE SENSE TO ME THAT THERE MUST HAVE BEEN A BAD BATCH OF METAL USED IN THE BUILDING OF THESE FRAMES. I WOULD LIKE TO KNOW IF ANY MORE 2004 VEHICLES FROM FORD HAVE REPORTED SIMILAR PROBLEMS AND WHAT CAN WE DO ABOUT THIS? *TR

I TOOK MY TRUCK IN FOR STATE INSPECTION AND WAS TOLD THAT BOTH FRONT COIL SPRINGS WERE BROKEN. THEY EXPLAINED THAT THE COATING APPLIED TO THE SPRINGS ACTUALLY CAUSED RUST AND MADE THEM FAIL. I CONSIDER THIS TO BE A MANUFACTURING AND SAFETY DEFECT BUT WAS INFORMED BY THE DEALER AND FORD THAT THEY WOULD NOT CONSIDER ANY HELP TOWARD THE $400 BILL TO REPLACE THEM. I DON'T FEEL THAT A CONSUMER SHOULD HAVE TO PAY FOR A STRUCTURAL DESIGN FLAW THAT COULD HAVE CAUSED AN ACCIDENT. INTERNET RESEARCH SHOWS THIS TO BE A COMMON PROBLEM. *TR

-REPAIR SHOP-2004 FORD F150 CREW CAB, FRAME COMPLETELY ROTTED THROUGH, FRAME REPLACEMENT REQUIRED. CUSTOMER WILL NOT HAVE REPAIRED. *TR

TL* THE CONTACT OWNS A 2004 FORD F-150. THE CONTACT NOTICED RUST ON THE REAR AXLE HOUSING. THE DEALER DIAGNOSED THAT THE AXLE WAS NEARLY RUSTED ALL THE WAY THROUGH AND THAT THE VEHICLE WAS UNSAFE TO DRIVE. THE VIN WAS EXCLUDED FROM NHTSA CAMPAIGN NUMBER: 15V608000 (SUSPENSION). THE MANUFACTURER WAS NOTIFIED. THE VEHICLE WAS NOT REPAIRED. THE FAILURE MILEAGE WAS APPROXIMATELY 76,000.

FRONT COIL SPRINGS BOTH BROKE IN SAME PLACE. *TR

TL* THE CONTACT OWNS A 2004 FORD F150. THE CONTACT STATED THAT BOTH FRONT SUSPENSION SPRINGS WERE BROKEN. THE VEHICLE WAS NOT TAKEN TO A DEALER OR INDEPENDENT MECHANIC. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE FAILURE AND THE CURRENT MILEAGE WAS 93,000.