Engine Clicking And Tapping Noises problems of the 2004 Ford F-150

I have 2004 F-150 with 92,000 miles on it , I bought it 3 years ago with 70,000 on it making a slight tapping noise . I talked with many people and and the dealer saying that this is the way the engine is designed and should be fine. Yesterday driving down a major highway in northern virginia traveling at 65 mph my truck started making a noise from the engine and shut off , I had good oil pressure ,water temp was fine I pulled it off the highway, never to start again. I had it towed to a locale Ford dealer in fairfax va. After reading from Ford forum web site and hearing the horror stories I feel I am in for a hugh repair bill. I also see there is a class action suit against the Ford motor company for not standing behind their vehicles when there seems to be a major flaw in the engines design. Aprox. Cost of a new engine is between 7 and 10,000 some consumers started to have problems as early as 12,000 miles, I baby my truck, the heaviest thing I have hauled in it is a 6 ft. Christmas tree for my living room. I babied my truck to what means just to have a high repair bill like so many others??? I hope you can help . Please/thank -you in advance.

The contact owns a 2004 Ford F-150. The contact stated while starting the vehicle, there was a loud popping noise coming from the engine without warning. There was also smoke coming from the engine. The vehicle was taken to a dealer who stated that the engine coils needed to be replaced. The manufacturer was notified of the failure. The vehicle was repaired. The approximate failure and current mileage was 149,000.

Got into vehicle, started, and immediately loud popping sounds came from under the engine, and worse when put into reverse. Luckily had 2 hobby mechanics, that I work with, come take a look. They immediately determined that one of my spark plugs had backed-out. They took the cover off and determined it was the 1st spark plug, and luckily the threads were in good shape. Put spark plug back in, and vehicle started fine after that. I travel 45 miles one way to/from work. If this happens again, could leave me stranded. 2nd luck, no repair cost. I can only imagine what the dealer would have charged. In addition, 2 weeks later, I had the 3rd (2 previous were in front right & rear driver window) out of 4 door windows fall into the door. This time it was the driver's front door - regulator assembly. Loud bang before they fell. Scared me - thought someone had thrown a large rock at my vehicle. This is the 3rd to fail within 8 months (last 2 on the same day in July 2012). Total repair cost on windows was $900. 00. There is still no recall on the spark plug problem, and the regulator assembly problems, although hundreds, if not thousands, have had the same problem. I contacted Ford for complaint & reimbursement, and received no response. It's very obvious, it's time to do something about this!.

The contact owns a 2004 Ford F-150. The contact stated that the engine hesitated on several occasions and that there was a tapping noise that progressed. The vehicle was taken to an independent mechanic, who replaced the spark plugs, fuel injectors and the plug wires. The contact stated that the failure recurred. The vehicle was taken to an authorized dealer. The technician diagnosed that the head gasket needed to be replaced. The manufacturer was notified of the failure. The approximate failure mileage was 110,000.

The contact owns a 2004 Ford F-150. The vehicle was included in the recall under NHTSA campaign id number: 11v107000 (air bags:frontal:driver side inflator module). After the recall repairs were performed, the air bag warning light illuminated on the instrumental panel. The contact heard a ticking noise coming from the engine while the vehicle was parked. The vehicle was taken to the dealer for diagnostics where the technicians advised that the engine would have to be replaced because it was beginning to fracture. The vehicle was not repaired. The VIN was not available. The approximate failure mileage was 73,000.

I purchased my truck six months ago, at the time of purchase I noticed a ticking in the engine, after inquiring to the salesman about the engine noise he informed me that his service tech's had inspected the problem and there wasn't a problem. The noise has progressively worsened since purchase. I was at an engine re-builders place of business with a friend and the mechanic asked if I knew what the ticking was, I replied no and he took me into his office and printed a tech bulletin (aera tb2471) that addressed the camshaft and lash adjuster design change for Ford 5. 4l VIN 5 engines. These were redesigned in 2005 to correct the ticking noise and keep valves from dropping, which the mechanic informed me he had 5 vehicles in his shop due to this issue. I went to my local dealership for a recall issue (clockspring in air bag) the service advisor mentioned the ticking as I drove up, I asked if he knew of the service bulletin and showed him the copy I had, his comment was to not tow anything! I called the service manager for this location and was told to contact Ford directly, which I have and am waiting for a response. The mechanic I spoke with said this is a common occurrence with this engine, look for the number 5 as the eighth digit in your VIN number. I feel that this truck has been completely misrepresented to me during and after purchase and feel lemon laws or recalls should be used or in place.

The contact owns a 2004 Ford F-150. The contact stated that while driving at the speeds of 45 mph, there was a popping noise heard coming from the engine compartment. The contact stopped the vehicle and noticed that a spark plug and coil pack detached from their cylinder. The vehicle was driven to the contact’s residence and then taken into the dealer where the failure was diagnosed. The dealer replaced the spark plug and coil pack, but the failure recurred. The contact did not feel safe driving the vehicle. The failure mileage was 71,000 and the current mileage was 84,266.

The contact owns a 2004 Ford F-150. The contact stated that there was a ticking noise coming from the engine. The vehicle was taken to the dealer where it was found that the cam phasers had failed. The vehicle was being repaired. The manufacturer was contacted about the failure. The vehicle was the failure mileage was 58,000. The VIN was not available.

Engine has had a ticking noise in engine since day I bought the truck. Talked to dealership and they said normal noise from 04 F-150 trition they have since closed. Went to another dealership was told same thing. Broke down went to hometown mechanic replaced cam gears after another dealership asked if it sounded like a diesel. Also pulled valve cover off to find valve spring and rocker arm on cam. Total discounted cost from friend was $2400 not counting machining heads.

Engine makes a tapping noise at head covers.