Problems owners report
Complaints filed with NHTSA about the 2004 Ford E-150, by the system named in each complaint. One complaint can name several.
- Service brakes, hydraulic7
- Power train4
- Vehicle speed control4
- Wheels2
- Latches/locks/linkages2
- Visibility2
- Engine2
- Seat belts1
- Fuel system, gasoline1
- Electrical system1
NHTSA ODI complaints (public domain) · updated 23 Oct 2026 · 2 injuries and 0 deaths reported
Compared with other years
NHTSA ODI complaints by model year
Fatal crashes in the US
From 2020 to 2023, 5 2004 E-150 vehicles were involved in crashes on US public roads in which someone died; 2 people died inside them. This is a count, not a crash rate: it grows with the number of cars on the road.
NHTSA Fatality Analysis Reporting System (FARS), crash years 2020–2023 (public domain)
New York safety inspections
At its first New York inspection the 2004 Ford E-150 failed the safety check 1.55% of the time — 30% less often than the average 2004 passenger car (2.21%). Median odometer at inspection: 128,054 miles.
NY DMV Vehicle Inspections (vezn-fmmk), initial inspections since Aug 2021 · how we count
Recalls
VAN CONVERSIONS IS RECALLING 52 MY 2004-2007 FORD E-150, E-250 E-350 AND MY 2006 GM SAVANNA 3500 VANS BUILT ON FORD AND GM CHASSIS AND EQUIPPED WITH RICON PLATFORM STYLE WHEELCHAIR LIFTS. THESE LIFTS FAIL TO COMPLY WITH THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 403, "PLATFORM LIFT SYSTEM ACCESSIBLE FOR MOTOR VEHICLES," THE ANTI-STOW INTERLOCK MAY NOT DETECT THE PRESENCE OF A WHEELCHAIR OR MOBILITY AID USER. THE PRESSURE SENSING SWITCH THAT DETECTS THE PRESENCE OF WEIGHT ON THE PLATFORM WAS NOT ADJUSTED TO THE NECESSARY SENSITIVITY LEVEL. THE LIFT COULD STOW EVEN THOUGH SOMEONE OR SOMETHING IS STILL ON THE LIFT.
VAN CONVERSIONS IS RECALLING 74 MY 2004-2007 FORD E-150, E-250 E-350 AND MY 2006 GM SAVANNA 3500 VANS BUILT ON FORD AND GM CHASSIS AND EQUIPPED WITH RICON PLATFORM STYLE WHEELCHAIR LIFTS. THESE VEHICLES FAIL TO COMPLY WITH THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 404, "PLATFORM LIFT INSTALLATIONS IN MOTOR VEHICLES." THE THRESHOLD WARNING SYSTEM MAY NOT DETECT THE PRESENCE OF A WHEELCHAIR OR MOBILITY AID USER IN A CERTAIN SPOT WITHIN THE DEFINED THRESHOLD AREA.
ON CERTAIN VANS, THE AIR FILTER ELEMENT MATERIAL PROCESS RESULTED IN AN AIR FILTER PAPER ELEMENT THAT CAN SMOLDER OR BURN. THIS CHANGE IN FILTER PAPER COMPOSITION COMBINED WITH THE CONFIGURATION OF THE AIR INDUCTION SYSTEM, MAY ALLOW HOT CARBON PARTICLES TO CONTACT THE AIR FILTER ELEMENT DURING CERTAIN DRIVING CONDITIONS THAT CREATE HOT PARTICLES.
ON CERTAIN VANS, A DIODE IN THE ANTI-LOCK BRAKING SYSTEM (ABS) MODULE MAY EXPERIENCE AN ELECTRICAL SHORT.
Whether a recall was fixed on a particular car is known only to the manufacturer: check the VIN at nhtsa.gov/recalls.
NHTSA recalls · summaries in NHTSA's own words
Service bulletins
What Ford told its dealers about the 2004 Ford E-150: known faults, fixes and updates.
| Bulletin | Summary |
|---|---|
| 10243490 | When performing any transmission fluid changes or topoffs involving MERCON SP, MERCON LV has replaced all versions of MERCON SP and can be used going forward. Mixing MERCON LV and MERCON SP in the same transmission is acceptable. After 30-Jun-2023, MERCON SP ATF will no longer be manufactured and will only be available until inventory depletes. |
| 10056196 | FORD: WHEN SHIFTING BETWEEN PARK, REVERSE AND/OR DURING 2-3 SHIFT, AN INTERMITTENT CLUNK OCCURS WITH A TORQSHIFT TRANSMISSION. MODEL 2003-2014 F-SUPER DUTY, E SERIES, EXCURSION, F-53 MOTORHOME CHASSIS, LOW CAB FORWARD. *PE |
| 10055629 | FORD: ON SOME TRUCKS, THERE IS A NO CRANK SITUATION AND IF VOLTAGE ON TRANSMISSION RANGE SENSOR AT PIN 21, IS LESS THAN 5 VOLTS, DISCONNECT THE ENGINE COOLING FAN CLUTCH, ELECTRONICALLY, AND RECHECK VOLTAGE. MODEL 2003-2007 F SUPER DUTY, 2004-2010 E SERIES, 2003-2005 EXCURSION. |
| 10022675 | BRAKE BOOSTER SYSTEM MAY EXHIBIT A BRAKE PEDAL KICKBACK AND/OR GRABBING CONDITION WHEN APPLYING THE BRAKES. *NJ |
| 10022243 | LACK OF POWER DUE TO LOW FUEL PRESSURE - FUEL TANK LINER SEPERATION. *KB |
| 10022232 | HEADLIGHT ADJUSTMENT NEEDED. *KB |
| 10021621 | LACK OF POWER DUE TO LOW FUEL PRESSURE, FUEL TANK LINER SEPERATION. *KB |
| 10021229 | WATCH FOR OIL FLOW FROM THE BASE ENGINE OIL PUMP. VEHICLES EQUIPPED WITH A 6.0L DIESEL ENGINE. *KB |
| 10021173 | OIL FLOW FROM THE BASE ENGINE OIL PUMP. *KB |
| 10020671 | SLOW FUEL FILL ON VEHICLES WITH A 4.6L OR 5.4L ENGINE AND MID-SHIP FUEL TANK. *KB |
| 10020069 | MISFIRE, LACK OF POWER, BUCK/JERK, EXCESSIVE SMOKE OR CRANK/NO START. *TT |
| 10019949 | WATER-IN-FUEL (WIF) LAMP ON. *TT |
| 10019810 | LACK OF POWER OR MIL ON - TURBOCHARGER STICKING - REVISED DIAGNOSTICS. *TT |
| 10019795 | P0404 SERVICE TIP. *TT |
| 10019385 | COOLANT DEGAS BOTTLE OVERFLOW - 6.0L. *TT |
| 10019380 | WHITE SMOKE, LACKS POWER, EXHAUST ODOR, SURGES, RUNS ROUGH, OR NO START - 6.0L. *TT |
| 10019079 | LOW BATTERY VOLTAGE - 6.0L DIESEL WITH SINGLE ALTERNATOR. *TT |
| 10019075 | FUEL CONDITIONER. LOW POWER, POOR FUEL ECONOMY, FUEL GELLING IN COLD WEATHER, EXCESSIVE WHITE SMOKE ON COLD START, HARD START, OR COKING OF COMPONENTS EXPOSED TO EXHAUST. *TT |
| 10018941 | VIBRATION/HARSHNESS ABOVE 45 MPH (72 KM/H) AFTER TIRE BALANCE. *TT |
| 10018939 | COOLANT DEGAS BOTTLE OVERFLOW. *TT |
| 10018745 | WDS COP KIT DIAGNOSTIC TIP - COIL ON PLUG (COP) IGNITION SYSTEMS - ENGINE MISFIRE OR ROUGH RUNNING. *TT |
| 10018073 | FLUTTER NOISE ON DECELERATION. *TT |
| 10018070 | TORQSHIFT TRANSMISSION - INTERMITTENT CLUNK WHEN SHIFTING FROM REVERSE GEAR OR DRIVE GEAR TO PARK. MULTIPLE VEHICLES. FORD OASIS. TO INCLUDE 2006 FORD F-53. *TT |
| 10018062 | COOLANT DEGAS BOTTLE OVERFLOW. *TT |
| 10017921 | DAYTIME RUNNING LIGHTS INOPERATIVE AND A/C NOT COOLING. *TT |
NHTSA manufacturer communications (public domain)
NHTSA investigations
SPARK PLUG EJECTION FROM CYLINDER HEAD
NHTSA Office of Defects Investigation