One problem related to ignition switch has 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.
Normal driving, dry, clear, daytime. Going thru parking lot 5-8mph, bump and pot holes. My 2004 Ford f150, supercrew cab, died. No power to restart. Towed to local automotive shop. They found a blown maxi 20 amp fuse (#102 in fuse box) replaced it. Two days later, again going up a hill with some wash board ripples in road, truck dies/fuse blown. Tow it home, replace same fuse as before, attempt to start truck, fuse blown again & again. Call Ford motor dealer, they suggest to replace "ignition switch", I do so and new fuse, attempt to start truck, fuse blown again, call Ford dealer, they say to replace "transmission range sensor", I unplug that connector-due to a new part is very costly and you can not return electrical parts. New fuse, attempt to start w/o connection to trs. Fuse blown. So transmission range sensor, not the problem. This is a costly ongoing repair with no satisfaction. (now luckily when the "fuse" blows, I have not been in los angeles rush hour traffic) how ever I was on a very busy up hill grade when the second time it blown the fuse and my family and I were nearly hit several times due to traffic that couldn't see over the hill top, nor would the same direction of traffic from behind slow down. We were lucky, I researched web sites for answers to a fix. I found other individuals with f150 trucks have the same issue. Ford motor CO. Has no technical service bulletins for this problem, why not? I have spent 5 weeks researching my wires, parts and informational sites and mechanics, very unsuccessful. I heard that Toyota made their pcm so it would malfunction after so many miles, could this be what Ford is doing to collect money for repairs? I am a certified mechanic & smog tech in California, I am lost as far as how to repair this problem, before I pay to tow to a Ford dealer and get reamed on expense for an electrical problem that is probably an easy fix. Can you help? thank you for your valuable time.