Ten problems related to frame rust 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.
This vehicle is otherwise in good condition with very little body rust limited to the back corner of the passenger cabin. However the left frame rail starting 14 inches ahead of the front attachment point of the leaf spring. The rust hole extends the width of the frame rail for a distance of 17 inches. One finger size hole was observed. The frame bottom steel was easily stripped away with two fingers and a thumb to the length and width described. The remainder of the frame has extensive surface rust but no hole and otherwise fair condition. The licensed state vehicle inspection shop failed the vehicle due to the frame rust at this location. Otherwise, with some minor mechanical issues, the truck is in good condition and could be safely used for a number of more years. Online this rust problem at this point has a large number of complaints in Ford F-150 trucks in 2004 and 2005. Obviously there was a manufacturing issue frame forming to cause this rust through in so many trucks at this frame location and not elsewhere.
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.
Same deal as every other memo I read. Major highlighting points: - premature frame corrosion and rust. - mechanic informed me that the frame on the rear half. - rusted and cracked under bed and rear wheel wells - frame would no longer support weight of vehicle - rust thru holes and longitudinal cracks formed on the bottom and side frame surfaces at the stress point before the rear wheel bend. - extremely unusual, truck has been generally been garage kept and maintained in good mechanical condition. - the exterior body does not exhibits spots or surface rust on visible body panels. - no evident signs of rust or degradation of structure. - meticulously maintained vehicle otherwise. (new transmission, drive shaft, engine retimed, spray bed liner, etc. ) - catastrophic failure of the frame structure was imminent and that the vehicle was no longer safe to drive. - cannot be repaired and is unsafe. - cannot pass a state safety inspection. - cannot even be put on a lift because it has no structural strength.
The truck was taken into mechanic. The mechanic put it up, and saw that entire frame was rusted. It is not fixable. Contacted john lance Ford, where it was purchased. They advised to take truck to nearest Ford dealer. We took it to Ford in port clinton, ohio. The service manager took pictures and sent it to corporate office. It has been longer than 6 weeks, and have not heard back.
Tl � the contact owns a 2004 Ford F-150. The contact stated that when he looked underneath the vehicle the entire bottom of the frame had rusted. The dealer (liberty Ford 1-410-504-2897) was contacted and informed that the frames are absolute and the vehicle was not repaired. The manufacturer was not notified. The failure mileage was approximately 78,000. Jc.
My trucks frame has rusted out from the cab corners to the rear part of the frame rails. Ford motor company wont do anything about this problem. Numerous complaints have been filed, yet they wont do anything about it. Im not selling my truck because its a rare version of the 04 new style F-150. This is a very serious problem that people can die from and Ford wont back them up on the 04-08 trucks.
Frame rusted in half,.
The frame under my f150 is rusted through. I only have 81k miles on it and I don't understand why the frame is rusting so badly. It has already cost me 2,400 to have a certified welder replace some of the sections that were rusted out. I know just found another part of the frame that is rusted under the leaf spring. That is now going to cost me another $500. 00.
Frame rusting out prematurely causing a safety hazard.
2004 Ford F-150. Consumer writes in regards to vehicle frame rust problems. Consumer sent additional correspondence. The vehicle had to be towed to the repair shop, because the brakes went out. The rear brake lines, hoses, calipers, master cylinder and pads were replaced. Updated 03/09/15.