Engine problems of the 2004 Ford F-150

31 problems related to engine have been reported for the 2004 Ford F-150. The most recently reported issues are listed below. Please also check out the statistics and reliability analysis of the 2004 Ford F-150 based on all problems reported for the 2004 F-150.

car   Engine problem 1
Failure Date: 06/01/2011

S10 appropriate handling- letter from doj forwarding a letter from re his 2004 Ford F-150 the consumer stated the dealer botched the spark plugs replacement, and now the cost to replace all eight spark plugs is $2200 when he was originally quoted a price of $335. The dealer informed the consumer the spark plugs were difficult to replace and needed extra care and a special solvent. Updated 07/19/11.

car   Engine problem 2
Failure Date: 05/26/2011

The contact owns a 2004 Ford f150. The contact stated during routine maintenance with a local mechanic he was advised that the spark plugs broke off into the spark plug casing and the spark plugs were defective. The manufacturer was not contacted. The vehicle was not repaired. The VIN information was not available. The failure and the current miles were 94,000.

car   Engine problem 3
Failure Date: 02/10/2011

The contact owns a 2004 Ford F-150. The contact was driving 10 mph as the vehicle began jerking violently. The manufacturer was contacted who advised him to take the vehicle to the dealer for diagnosis. The vehicle was taken to the dealer who diagnosed the failure as the cam shaft which would need to be replaced. The vehicle was not repaired. The failure and current mileage was 120,000.

car   Engine problem 4
Failure Date: 11/13/2010

The #3 spark plug was ejected from the engine block. Upon inspection, the threads were stripped and damaged beyond belief. After tapping the whole, the plug was able to be replaced. A month later, the #7 plug did the same thing being ejected from the engine. Another round of fixing but this time the repair was not successful. The new plug did not stay in. Both of the old plugs are in pieces with most of the parts lost to the roadway below.

car   Engine problem 5
Failure Date: 07/18/2010

My gently used 2004 Ford F-150 with approximately 63k miles is having motor problems. There is severe ticking/knocking of the motor for no apparent reason. There is also a gross loss of power and the gas mileage has immensely decreased. All the required maintenance and service has been consistently done on this vehicle and it is mainly driven on the weekends due to the fact that I am a nyc commuter. I have taken the truck to Ford and they are unable to help me without thousands of dollars of repair. This truck is gently used and was conveyed to be in excellent condition & excellent working order by Ford at the time of purchase. There is no reason for this problem to occur. The vehicle has become unsafe to drive and Ford refuses to take responsibility for the problem. Updated ivoq 12/01/10.

car   Engine problem 6
Failure Date: 03/15/2010

2004 Ford f150 with issue during spark plug replacement. Consumer states that it is impossible to remove spark plugs without breaking them causing more money to be spent to get the dealer or mechanic to fix it. The consumer stated once that happens it involves removing the head and incurring charges of $2,000 to $2, 5000 in labor costs.

car   Engine problem 7
Failure Date: 02/20/2010

I own a 2004 Ford f150 5. 4 liter engine. I have never changed the spark plugs. I driving and a spark plug blew out of the engine. This could be a serious problem and expensive and not created by me,it has to be a defect. The gas vapors coming out of the plug hole could start a fire.

car   Engine problem 8
Failure Date: 02/06/2010

Ford spark plugs fail and are unable to be removed without damage, requiring special tool or significant cost.

car   Engine problem 9
Failure Date: 12/11/2009

The contact owns a 2004 Ford F-150. Upon vehicle inspection, a technician from the dealer stated that the spark plugs would fractured soon, if they were not repaired. Shortly after the advisement, the vehicle was taken to the dealer. The technician stated that the sparks plugs would have to be replaced at the owners expense because they have fractured. The vehicle was in the process of being repaired. The failure and current mileages were 48000.

car   Engine problem 10
Failure Date: 11/29/2009

Spark plug was ejected from the engine stripping the threads in the head, and causing the truck to die in the middle of the road. Dealership gave a bulletin reporting that there is a problem, and reports that it happens all the time. Ford refusing to help. According to the dealership repair will cost $2,100. I was picking up my 3 yr. Old daughter, and if this problem would have happened 10 minutes later I would have been crossing a busy intersection with my daughter in the truck. Once I get me truck fixed who is to say that one of the other cylinders won't do the same thing! I feel the truck is unsafe to have my daughter in it. What if this would have happened when pulling onto the interstate. The bulletin says that this has been an issue since 1997, when is someone going to make sure that they are held responsible. How do I even know that this is not a problem that is still ongoing?.

car   Engine problem 11
Failure Date: 08/04/2009

2004 f150 5. 4 triton 88,000 miles. Fomoco recommends spark plug change at 100,00 dealer changed 8 plugs broke 6. I was charged a plug extraction fee of $85 per plug in addition to the $320 initial quote. Internet research and word of mouth shows many,many instances with the same problem. Fomoco quoted"we are not assisting customers at this time". Definite engineering flaw they deny. Fomoco even invented their own extraction tool to aid in removal of plugs.

car   Engine problem 12
Failure Date: 06/30/2009

2004 f150 4. 6ltr engine. Spark plug blow out #3 cylinder 64865 miles. Original factory parts. Spoke directly to Ford motors they act as if this is my fault. The parts have never been changed. Ford told me it is not covered under warrenty because this is a maintanence part. The dealer told me that this has been a big problem for Ford. But they wont honor to fix the problem even though it is a mechanical failure due to bad design. It cost 600. 00 to fix and I beleive this should be covered by Ford due to the number of instences. There were two trucks fixed the same day for the same problem and again the service department said this has been a big issue. I would like this to be resolved. The consumer should not have to worrie about a spark plug blowing out while driving. This is a saftey issue because fuel keeps flowing into the cylinder and when ignights flames fly out through the spark plug hole. Quit acting like th is is not a problem and recall these poor desinged parts before someone does get hurt.

car   Engine problem 13
Failure Date: 06/29/2009

There is already a TSB for the problem but Ford should really recall the cam phasers on the 2004 and newer f150's. Most people in this economy cannot afford to throw 2 grand into there car to have a factory defect fixed and Ford won't step up to the plate. I have owned numerous Ford's in the past and will never buy one again because of their lack of being a good company. I'm sure because the problem is on there number one engine they don't have the money to cover it and don't care that they'll loose half those customers.

car   Engine problem 14
Failure Date: 06/03/2009

Ford 2004 supercrew pickup with 5. 4l engine. Factory spark plugs break off when trying to do normal factory service and Ford wants customer to pay labor charges for the removal of the broken spark plugs. I was quoted $800. Spark plugs should not break off from the factory.

car   Engine problem 15
Failure Date: 03/23/2009

On my 2004 Ford f150 with a 5. 4l 3 valve engine, the spark plugs all broke off when a tune-up was attempted. This is due to a know defect in the head design on the 04/05 models. The dealer charged me $904 dollars to change them. Ford is not reimbursing customers for this outrageous charge even though they know it is a design flaw, and are doing nothing to fix the problem. My understanding is that all of these engines will have this problem.

car   Engine problem 16
Failure Date: 03/13/2009

Truck taken into be serviced. Mechanic broke spark plug off into the head. Possibly leading to complete removal of engine and head.

car   Engine problem 17
Failure Date: 03/01/2009

Went to change the spark plugs. Ten days and $1000 later I have the truck back. If I had to do it all over again, I would sell the truck well before the 100,000 mile mark. Idiotic design leads to spark plugs breaking. Do not change plugs without discussing with dealer first. They have a special tool for extracting the broken part. It says a lot about the situation that Ford had to come out with a tool to fix their poor engineering. Ford needs to recall these vehicles with this defect and make good on it. I will never buy Ford again. If you have this problem, speak up and lets get them to fix it.

car   Engine problem 18
Failure Date: 02/07/2009

Went to have spark plugs changed at 100,000 miles in accordance with manufacturer's factory maintenance schedule. Spark plugs are stuck due to factory not seating plugs correctly and not using anti-seize compound during factory installation. It requires a $10,000 machine to negatively polarize the engine so that the plug threads can be decarbonized and hopefully removed. This is an unacceptable factory defect and Ford needs to address the issue immediately and re-imbursed the unreasonable costs and burden placed on the consumer. No where in the literature provided by Ford was this issue discussed had it been openly discussed or presented in the literature I would not have purchased the vehicle. This is fraud.

car   Engine problem 19
Failure Date: 11/15/2008

Changing out spark plug at 65000 because an employee of a Ford garage advised me to do so because of them getting stuck at 100,000 miles. I started to change them only to find the shaft below the threads of the spark plugs stuck anyway. I hauled the truck to boyd county Ford where the service man stated that this was pretty common and that it would take about 500 dollars to fix. Well 1000. 00 dollars later they removed the stuck spark plugs and replaced them with some new ones.

car   Engine problem 20
Failure Date: 10/27/2008

Driving my truck I heard a pop, I thought I blew out a tire but didn't. I drove it off the highway to a parking lot and it was driving very rough. Took it to the shop and they said it blew out a spark plug (original spark plugs). Called the dealer and they quoted me a 2500. 00 dollar repair! did research and found that this has happened numerous times already and I ask if there was a recall and they said no. But offered me a new truck reduced 7 thousand. . . Can you please check into this issue.

car   Engine problem 21
Failure Date: 10/26/2008

Ford motor company has designed a defective head design that causes spark plugs to get stuck in the head when service is attempted. The 100k mile interval is too long, even sub 50k miles is unacceptable. The carbon buildup around the long 2 piece spark plug causes the lower, crimped on part to stay in the head while the top 2/3 and electrode come out when changing the plug. This design has been put in use for 4 years on all 5. 4l 3valve motors. Ford has a TSB that acknowledges the problem, but their remedy still does not help. Once the plugs, broken and unbroken, are removed, putting nickel anti-seize on the threads still does not remedy the issue because the threads on the plug are not what is sticking. The lower part of the spark plug is what causes the trouble. Ford has even designed a tool to remove the often broken plugs. This just ridiculous and a solution needs to be made before a very large class action suit is drawn upon fomoco.

car   Engine problem 22
Failure Date: 07/31/2008

My 2004 Ford f150 with 106,000 miles started to have an engine knock which we thought was just a stuck lifter. We took it in to the local Ford dealership and was told that the timing guide broke and wrapped up in the engine causing it to be deprived of oil and now we will have to replace the engine.

car   Engine problem 23
Failure Date: 06/01/2008

On a Sunday, I was on a side street when the engine went dead. I noticed the wrench light was on. I called the wrecker service as it was still in warranty. The wrecker driver arrived and asked if I had tried to restart it, which I didn't. I started it and drove home. I took it to the dealer on 06/04/08. They could not duplicate the error nor find anything in the computer module. On 03/29/09, the same thing happened. If I had been on a highway or freeway, I might have had a serious accident. I waited a few minutes, then the truck started up again. I took it back to the dealer on 04/01/09. They kept it overnight doing various tests. The computer showed nothing. They finally suggested to replace the throttle body and reprogram the pcm. I agreed even though it was out of warranty and cost me $484 to repair. I was leery of driving on a highway and freeway as if it happens there, I'm sure if I can't pull over I will surely cause an accident. Subsequent checks on the internet found the is a common occurrence. The engine is supposed to go into "limp mode" to allow one to slowly, but safely drive to a safe spot. My truck, and many others, do not go into "limp mode"; they just go dead. I strongly suggest this be investigated before a serious accident occurs due to this default.

car   Engine problem 24
Failure Date: 07/31/2007

The contact owns a 2004 Ford f150. He noticed that the spark plugs were breaking off and going into the engine. As a result, the dealer stated that the engine should be replaced. The manufacturer stated that they have received numerous complaints regarding the failure. The failure and current mileages were 73,000. The VIN was unavailable.

car   Engine problem 25
Failure Date: 04/09/2007

The contact owns a 2004 Ford F-150. The contact stated that the engine head detached while changing the spark plugs on the vehicle. The dealer stated that the engine must be disassembled in order to remove the spark plugs. The contact will be responsible for the repair cost. The current and failure mileages were 53,000.

car   Engine problem 26
Failure Date: 10/02/2006

My vehicle is f150 supercrew lariat. The vehicle has 80kmil. It has been running very sluggishly and idles hard in a complete stop. The auto repair shop has diagnosed the problem with the truck engine as 2c oils burned and 2pzt2fe spark plugs split in half--white middle cover of plug plug still lodged into engine.

car   Engine problem 27
Failure Date: 09/28/2005

On 9/28/05 our 2004 f150 Ford pick up caught fire as the operator was driving at approximately 10 m. P. H on a dirt road. The fire appeared to start in a location in the engine compartment. The vehicle was totally destroyed by the fire.

car   Engine problem 28
Failure Date: 10/03/2004

The consumer's 2004 Ford f150 experienced sudden acceleration which resulted in an accident. The vehicle was taken to the dealer who ran a diagnostic test. The test indicated 4 trouble codes (camshaft position sensor, pcm processor fault, throttle actuator control system which forced shutdown and an internal control module software incompatibility).

car   Engine problem 29
Failure Date: 10/03/2004

The consumer 2004 Ford f150 experienced sudden acceleration which resulted in an accident. The vehicle was taken to the dealer who ran a diagnostic test. The test indicated 4 trouble codes (camshaft position sensor, pcm processor fault, throttle actuator control system which forced shutdown and an internal control module software incompatibility).

car   Engine problem 30
Failure Date: 08/02/2004

Without warning the car dies while driving. At a stop light it died, and consumer could not get it started. Pushed it to the side of the road, and after 15 minutes it started. They didn't know when it was going to happen, and it happens intermittently. Dealer replaced the starter, and did something on the computer. Manufacturer did not offer any help.

car   Engine problem 31
Failure Date: 03/03/2004

Vehicle 2004 f150 5. 4l triton problem: you cannot service the spark plugs without breaking them off in the head. Even when using Ford written TSB, spark plugs will break off leaving ground shield in cylinder head. Per Ford's owners manual spark plugs should be replaced at the 100,000 mile mark. I replaced mine at 35,000 and broken one off in the cylinder head. I used the Ford issued TSB to extract them and was still not successfully. This issue will only grow in magnitude as more people become aware and more vehicles start to approach the 100,000 mile mark. This issue is begin well documented at the Ford dealers and Ford has also acknowledged by writing a TSB for this failure mode. I ask that NHTSA get involved and force Ford to design a spark plug that is capable of begin extracted at any mileage interval without the threat of them breaking off. Thank you for your time.

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