Five problems related to manifold/header/muffler/tail pipe 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.
The contact owns a 2004 Ford f150. The contact stated that the vehicle made a loud noise when started. The contact inspected the vehicle and noticed that the noise emitted from the engine area. The vehicle was taken to the dealer who located the failure as the intake manifold being warped and leaking. The manufacturer was made aware of the failure and denied assistance with the repair. The vehicle was not repaired. The approximate failure and current mileage was 73,000.
We always take our truck to the Ford dealer for service. I had been telling the service advisor for years that we heard an air bubble noise when accelerating. They kept saying everything is fine. As soon as our extended warranty was over, they then said I had an exhaust leak. I took it to a 3rd party mechanic and immediately they were able to determine it was both exhaust manifolds and is very common in f150's. The problem is with the bolts breaking when trying to get out, and due to Ford's poor design more than likely will warp again. This repair cost is over $1000 (Ford dealer quoted $2165) and should have been covered under our extended warranty if dealer would have admitted it had leak when we mentioned the sound before. The 3rd party mechanic said any mechanic should have been able to diagnose the distinct sound just by hearing it for a few seconds. Manifold leaks are apparently fairly normal in trucks however once again Fords design makes it much more difficult than most other truck makes to repair, adding much more additional cost to the consumer.
The contact owns a 2004 Ford f150. While driving approximately 40 mph, a loud clicking noise emitted from under the vehicle. The failure progressed and could be heard whenever the vehicle was in operation. The noise would increase as the speed was increased. The vehicle was taken to an independent mechanic who advised the contact that the exhaust manifold would need to be replaced. The vehicle was in the process of being repaired. The manufacturer was notified of the defect. The approximate failure mileage was 89,000.
My vehicle has low power, stutters, and cuts off. A service bulletin was said to has come out about possible defective pushrod or rocker arms am not sure but I am sure that the problem come from the point of original assembly and I should not have to pay for an issue that starts from manufacturing.
Re NHTSA's response dated 10/21/04 re defective intake manifold in 1997 Ford f-series trucks. Reply duplicate to midlothian, va office. The consumer attempted to start the vehicle and the intake manifold exploded into many pieces. No flames were seen but thick black smoke from under the hood for twenty minutes. The consumer stated that there was a fire inside the engine fueled by oil.