general problems of the 2004 Ford F-150 - part 1

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.

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).

N/a.

Truck stalls in traffic. Also when hitting the brake. It stalls in reverse. It stalls while idling. Worst truck ever!! severe safety issue ??.

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.

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

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.

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 .

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.

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?.

Frame is rotting huge holes in frame. Vehicle has less than 110k miles.

The frame is rotting on the in side of the frame.

Frame of truck is completely rusted all the way thru at rear leaf spring attachment points. This will cause a total failure of the rear suspension and drive train.

Trailer hitch rusted away and broke towing a 26 ft RV trailer. Truck has 140,000 miles and is in good shape no body rust. Hitch is very unsafe and could have been very bad if it broke going down the highway. I have read other people having the same problem. . Read more...

The frame is totally rusted through.

Hercules tire recall 15t011000 included all trac a/t tires of various sizes for tread separation but not my size. My size tires 275/65r18 have plenty of tread however are suddenly showing signs of tread separation on all four tires. Hercules was contacted and they said my tires are out of warranty.

Takata recall, I was parking my truck in a parking lot, I started the engine and put it on r, when I heard parking sensors sound I pushed the brake, put truck didn't stop and there was no brake. I put it to n then d to move it forward after touch for the car behind me. When I put it to d , the pedal hanged and engine went crazy to 4000 rpm and truck came like wild horse with no control, it crossed the parking lot and hit another car was parking in front of me in the other parking lot. After hitting the car in front, I succeeded to put it on p and turn the engine off. This crazy sudden increase in rpm and pedal stick and loosen brakes all in one second with out any warning could kill someone. Loosing control in such truck for seconds is something scary and unbelievable. Please check this gas stick and break sudden failure issue , as it is really dangerous. After the accident, the truck returned to normal operation without a sign for that instance crazy failure.

The manifold split and caused my vehicle to stall while completing a right hand turn. The truck doesn't want to drive starting from a light or stop sign. The truck is extremely loud. Wants to stall while sitting at a red light or stop sign.

Premature frame rot. I took my truck to a welder after failing my state safety inspection because of frame rot. The welder said he has worked on hundreds of frames for 2004 f150's. He said he started working on them in 2006. "worst frame ever," he said. He couldn't believe they were never recalled based on how poorly they were designed.

Excessive shaking at 40 mph+ , trans fault light came on & off . Trouble using reverse would jerk & slip. Have replaced many parts recently.

When braking springs made noise and it takes several brakes to stop.

The frame on my truck has split in half always been taken care of. Ive had it for 6 years and it been good. Until recently the bed has started to shake very violently. My dad and I have figured out that the frame on my truck has split in half! I did some research on this issue of frames failing. Most 11th gen owners like me have or had this kind of problem. Some frames have rotted out completely due to Ford. This truck is very unsafe! and ive asked Ford if they could do anything and they couldn't do anything. They wont back up their products.

Think I bought a lemon truck from Ford after spending a lot of money to try and keep truck running but after all the time and effort I put into the truck it will only go in reverse and engin sounds rough .

The frame is showing serious signs of rust and rot. The vehicle is unable to be inspected with only 84,000 mile on it. Disgraceful.

Frame rusted out with holes you can see through. Truck now flexes and will probably break the frame while driving does not seem safe to drive.

Vehicle frame rusted out on both sides. Could not pass PA. Inspection.

I was driving down the road when my left rear window went crashing down inside the door. After doing a lot of searching on the net I found this is happening a lot on a number of the Ford F-150 trucks, a cheap plastic part fails and the window falls down. No warning the window just falls down in the door.

I was pulling a trailer over the continental divide with my family and stopped to get gas in leadville, colorado. As I was pumping gas I saw smoke coming from under my truck bed. I looked under the truck and saw flames near my spare tire. I stopped pumping gas and ran to get a fire extinguisher. After the fire was out I observed that my tail-pipe had broken away from my muffler. The heat from my exhaust had melted the rubber coating on my rear right brake cable. The heat had also melted some plastic near my spare tire. The mechanic in leadville who welded my tail pipe back to the muffler told me the melted plastic came from an evaporative fuel emissions system mounted near my spare tire. (bad place to put it if you ask me) my truck bed-liner also started to melt from the heat. I called Ford to notify them of the safety problem and they only recommended that I take it to a Ford dealer and have it looked at. I doubt I will ever hear from them again. I'm not going to pay out of my pocket to have this problem officially diagnosed. I guess I'm just lucky to be alive and that the whole gas station didn't blow up.

My truck felt like it was driving really well, I was driving from a to b which was about 6 miles. Im almost home & I stop at a light,when it turned green I accelerated &when I did I heard a knocking sound&so I pulled over& I couldn't pin point exactly where it was coming from,just it was coming from the back of the engine on the right side. Im guessing maybe the 3rd or 4th spark plug. I checked my oil I was maybe 1quart low. So hoping that was it, I bought a quart&some oil repair to go in with it. The guy at autozone thought the same. As u could guess that didn't work. It sound almost like a lawn mower. Which is baffling cuz there was no warning, no check engine light,no prior noise. I'm lost. I've been reading about spiting spark plugs&a lot of the same stuff happening in these trucks. I'm wondering if there was a recall? if not why? if there are complaints from over 1000 people saying the exact samething,why hunt Ford done anything about it?I use this truck to take my71 year old vietnam veteran grandpa to his dr appointments&use it for work. From what I'm reading no one is gonna help but I have to try. Please let me know if there is any advice or hopefully do the right thing & help me work with the dealership I bought the truck from. My# is 6614419336. Thanks.

We've had a lot of issues with this truck but the main issue is when we drive down the road it misses a lot and the smell of fuel in the truck. We've taken it in and they said a lot of other people have had the same issues with there truck like ours. Please contact us ASAP.

I bought this vehicle used with 139000 miles on Saturday 05/16/15. Now I was not expecting a new vehicle but not one with so many problems either. First of all it has a very rough idle, I found that there is a serious problem with this engine and removal of the spark plugs. The repair shop will not even give an estimate for changing the spark plugs as there are very well known problems with them breaking off in the engine. Ford knows about this and has put out a notice about this known problem. I had to take it for a lower steering arm replacement on Monday 05/18/15 as the wheel was not returning to the straight position without assistance. Now there is a humming noise from the rear differential that the repair guy said is the pinion barring and that it needs to be fixed. The dealer window sticker had everything checked as good and no notes to say there was anything wrong with the vehicle. No surprise there. After checking this web site I found an open recall for the airbag which was repaired. I also found all the reports of problems with this vehicle. My question is why the NHTSA is not requiring Ford to recall these vehicles for the numerous problems that were reported from day one and allowed to continue through 2008. Ford was allowed to keep building these vehicles along with others with the same defective parts for over 4 years. That is just wrong. I can not believe they are allowed to get away with this kind of crap.

When it rains water comes in and drips on the passenger side rear seat. I have replace the third brake light lens twice and the rear window. I have read forums and it seems like this problem is common. I have a truck that smells like mildew. I have to drive it now with the interior pulled out.