Gas Recirculation Valve (egr Valve) problems of the 2004 Ford F-150

Driving 70mph, highway 41n-wisconsin, just north of oshkosh, legal speed limit, 35 degree weather, nearing end of a 90 mile trip with wife and granddaughter, early evening, when I heard a noise/thud, then had dash engine warning lights and alarms go off as well as severe vibrating and noises under the hood with loss of power. Managed to get my 4x4 truck out of center lane and into emergency lane without being hit. Tried restarting engine a couple of times, which it did, but I shut it down immediately both times because of severe vibration and noise. After arranging for emergency road service and a police officer to protect my backside from traffic approaching from the rear, the truck was towed to my Ford dealership of 12 years. I had purchased my truck there new and did all my maintenance there, except maybe a couple of oil changes when I have been out of state. There the truck was diagnosed to have cam phaser failure and needed a 5,000+ engine replacement @ 130,000 miles. Unbelievable. I've had the cracked windshield, the rear seal issues, the various electronic failures and yes, the Ford spark plug issue with broken plugs during a maintenance change. I still loved my truck until it nearly caused my family and I serious injury or death, or possibly some other undeserving soul. I'm not replacing the engine and am trying to extract whatever remaining value exists. The dealership has been indifferent to the situation and has done little. So yes, I'm livid about the money and the loss of it, but am also livid and concerned as to who has to be hurt or worse yet killed before something is done. There are literally 100s/1000s of cam phaser complaints for the triton 5. . 4l that I have read through as well as having talked to a few mechanics since the incident. Thank you Ford for taking my money and jeopardizing my family's safety. I am no longer a Ford customer!.

On my way home from the lake, my vehicle starting idling rough. Pulled over to check things out, couldn't find any noticable issues. Retarted vehicle and engine started smoking. I raised the hood and smoke was billowing out from the coil atop the number 2 spark plug, drivers side, looking from front to rear of engine. Had thevehicle towed to bill collins Ford of louisville,ky. They informed me that the spark plugs needed changing. Upon removal, 4 of the eight spark plugs broke off in the engine head. This cost me $857. 00 to change 8 spark plugs that normally I could do myself. The breaking of spark plugs in this type engine, 5. 4l triton, is a well known issue, that Ford motor company knew about. Yet they have yet to do a recall. Instead, they developed a tool to take these broken sprk plugs out, yet the consumer still has to pay sometimes upwards of $2,000. 00 for the repair. Ford used a substandard part in their vehicles and refuse to honor the customer. They no lonegr use that type engine, but anyone with a 5. 4l triton engine from Ford will have to pay a lot of money to change eight spark plugs when the time comes. I could not put my vehcile into gear when this happened, that seems like a safety concern to me!.

Accelerating through 60mph, heard loud engine noise, with subsequent rough running and heavy vibrations. Vehicle was taken to a mechanic, who found three broken/blown out spark plugs/coils, which were replaced. Approximately 8 months preceding this incident, two spark plugs disintegrated under similar circumstances. All spark plugs had been installed about 30,000 miles before the first incident.

I bought my 2004 Ford F-150 supercrew fx4 Feb. 17, 2004. I started having trouble with the a/c system as soon as it started to get hot[ above 85 degrees ] I brought it to the dealer[scarsdale Ford ] twice and they tell me it is in spec ,but it does not cool the cab, I checked the temp coming out of the vents and it stays at 43 degrees, my wifes pathfinder blows at 28 degrees, a big difference. I am now waiting for a Ford engineer to show up at the dealer ship. T o speak frankly I am very upset with the way this is being handle by Ford. I have had many different car over the years and never had this problem.