Problems owners report
Complaints filed with NHTSA about the 2004 Ford F-150, by the system named in each complaint. One complaint can name several.
- Visibility841
- Power train232
- Engine and engine cooling167
- Suspension118
- Structure104
- Electrical system99
- Service brakes, hydraulic95
- Engine92
- Air bags85
- Unknown or other81
NHTSA ODI complaints (public domain) · updated 23 Oct 2026 · 74 injuries and 6 deaths reported
Compared with other years
NHTSA ODI complaints by model year
Fatal crashes in the US
From 2020 to 2023, 274 2004 F-150 vehicles were involved in crashes on US public roads in which someone died; 134 people died inside them, and 63 of the vehicles rolled over. 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 F-150 failed the safety check 2.37% of the time — 7% more often than the average 2004 passenger car (2.21%). Median odometer at inspection: 158,289 miles.
NY DMV Vehicle Inspections (vezn-fmmk), initial inspections since Aug 2021 · how we count
Fuel consumption
Official Canadian test results for 16 variants: combined 14.3–20.6 L/100 km (about 11–16 mpg US), CO₂ 329–449 g/km.
| Variant | City | Highway | Combined |
|---|---|---|---|
| F-150 · Pickup truck: Standard · Regular gasoline | 15.7 | 12.5 | 14.3 |
| F-150 · Pickup truck: Standard · Regular gasoline | 16.6 | 13.3 | 15.1 |
| F-150 · Pickup truck: Standard · Regular gasoline | 17.6 | 13.3 | 15.6 |
| F-150 4X4 · Pickup truck: Standard · Regular gasoline | 17.4 | 13.4 | 15.6 |
| F-150 4X4 · Pickup truck: Standard · Regular gasoline | 17.2 | 13.7 | 15.7 |
| F-150 4X4 · Pickup truck: Standard · Regular gasoline | 18.1 | 13.7 | 16.1 |
| F-150 3-Valve · Pickup truck: Standard · Regular gasoline | 18.1 | 13.8 | 16.2 |
| F-150 4X4 3-Valve · Pickup truck: Standard · Regular gasoline | 18.3 | 13.8 | 16.3 |
| F-150 Lightning # · Pickup truck: Standard · Premium gasoline | 20.6 | 15.3 | 18.2 |
| F-150 NGV · Pickup truck: Standard · Natural gas | 21.1 | 15.7 | 18.6 |
| F-150 · Pickup truck: Standard · Regular gasoline | 21.2 | 16.0 | 18.8 |
| F-150 4X4 · Pickup truck: Standard · Regular gasoline | 21.1 | 16.0 | 18.8 |
| F-150 Bi-Fuel · Pickup truck: Standard · Regular gasoline | 21.3 | 16.1 | 19.0 |
| F-150 4X4 Bi-Fuel · Pickup truck: Standard · Regular gasoline | 21.8 | 16.6 | 19.5 |
| F-150 Bi-Fuel · Pickup truck: Standard · Natural gas | 22.5 | 16.8 | 20.0 |
| F-150 4X4 Bi-Fuel · Pickup truck: Standard · Natural gas | 23.0 | 17.6 | 20.6 |
Litres per 100 km. Natural Resources Canada, Fuel consumption ratings (open.canada.ca) · Open Government Licence – Canada
Recalls in Canada
5 Transport Canada recalls for the 2004 Ford F-150.
| 2019420 21 Aug 2019 | Other Issue: This recall is for aftermarket replacement rear window glass produced by Vitro Automotriz. Certain rear window glass may not have been properly tempere… |
| 2011281 1 Aug 2011 | Fuel System On certain 1997-2003 F-150, 2004 F-150 Heritage, 1997-1999 F-250, and 2002-2003 Lincoln Blackwood vehicles that were originally sold in or are currently operate… |
| 2011073 21 Feb 2011 | Airbag On certain vehicles, the airbag clockspring jumper wire may be oriented in a way that allows contact with the lower horn mounting plate. In this position the w… |
| 2004317 10 Sept 2004 | Fuel System Certain vehicles may have a fuel tank with a depression at the seam between top and bottom halves of the tank (not visible from outside the fuel tank). If a de… |
| 2004141 22 Apr 2004 | Fuel System On certain vehicles, localized depressions in the fuel tank wall at the seam between the top and bottom halves of the tank may allow fuel to permeate resulting … |
Transport Canada Vehicle Recalls Database · Contains information licensed under the Open Government Licence – Canada
Recalls
FORD IS RECALLING CERTAIN 1997 THROUGH 2003 MODEL YEAR FORD F-150, 2004 MODEL YEAR FORD F-150 HERITAGE, 1997 THROUGH 1999 MODEL YEAR F-250 LESS THAN 8,500 LBS. GROSS VEHICLE WEIGHT RATING (GVWR), AND 2002 AND 2003 LINCOLN BLACKWOOD VEHICLES MANUFACTURED FROM JUNE 20, 1995, THROUGH AUGUST 4, 2004, ORIGINALLY SOLD, OR CURRENTLY REGISTERED IN, CONNECTICUT, DELAWARE, ILLINOIS, INDIANA, IOWA, KENTUCKY, MAINE, MARYLAND, MASSACHUSETTS, MICHIGAN, MINNESOTA, MISSOURI, NEW HAMPSHIRE, NEW JERSEY, NEW YORK, OHIO, PENNSYLVANIA, RHODE ISLAND, VERMONT, WEST VIRGINIA, WISCONSIN, AND THE DISTRICT OF COLUMBIA. PROLONGED EXPOSURE TO ROAD DEICING CHEMICALS MAY CAUSE SEVERE CORROSION OF THE FUEL TANK STRAPS WHICH SECURE THE TANK TO THE VEHICLE.
FORD IS RECALLING CERTAIN MODEL YEAR 2004-2006 F-150 PICK UP TRUCKS AS WELL AS CERTAIN MODEL YEAR 2006 LINCOLN MARK LT VEHICLES. IF THE CLOCKSPRING JUMPER WIRE COMES IN CONTACT WITH THE DRIVER SIDE FRONTAL AIR BAG LOWER HORN PLATE, THE WIRE INSULATION MAY BECOME CHAFED, CREATING A POTENTIAL FOR A SHORT CIRCUIT. IF THIS OCCURS THE AIR BAG WARNING LAMP MAY ILLUMINATE INDICATING THAT SERVICE IS REQUIRED.
ON CERTAIN PICKUP TRUCKS, PASSENGER VEHICLES, SPORT UTILITY VEHICLES, AND MOTOR HOMES CHASSIS, THE SPEED CONTROL DEACTIVATION SWITCH MAY, UNDER CERTAIN CONDITIONS, LEAK INTERNALLY AND THEN OVERHEAT, SMOKE, OR BURN.
ON CERTAIN TRUCKS EQUIPPED WITH 4.2L, 4.6L AND 5.4L GASOLINE ENGINES, THE FUEL TANK MAY HAVE A DEPRESSION AT THE SEAM BETWEEN THE TOP AND BOTTOM HALVES OF THE TANK. IF A DEPRESSION IS LARGE ENOUGH, FUEL MAY PERMEATE THE FUEL TANK WALL RESULTING IN A FUEL ODOR, ILLUMINATION, OF THE "SERVICE ENGINE SOON" INDICATOR LIGHT, OR A FUEL LEAK.
CERTAIN PICKUP TRUCKS MAY HAVE A FUEL TANK WITH LOCALIZED DEPRESSIONS IN THE FUEL TANK WALL AT THE SEAM BETWEEN TOP AND BOTTOM HALVES OF THE TANK. IF A DEPRESSION IS LARGE ENOUGH, FUEL MAY PERMEATE THE FUEL TANK WALL RESULTING IN A FUEL ODOR, OR THE "SERVICE ENGINE SOON" INDICATOR LIGHT IN THE INSTRUMENT CLUSTER MAY ILLUMINATE.
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 F-150: known faults, fixes and updates.
| Bulletin | Summary |
|---|---|
| 636417 | GUIDANCE FOR CNG TANK INSPECTION FOR VEHICLES PRODUCED AFTER DECEMBER 2, 1996. *TT UPDATE. *TT |
| 10235153 | For 2000-2024 Ford and Lincoln vehicles, swapping a module from a vehicle for diagnosis purposes is likely to cause errors and is not recommended. It is also not recommended to order a replacement module using a vehicle identification number (VIN) from a different vehicle. Most modules on these affected vehicles are VIN/vehicle specific and hardware variations between modules do exist. Swapping a module from a vehicle or ordering a module using a different vehicle/VIN can cause ineffective repairs and additional vehicle down time. Make sure all appropriate Workshop Manual (WSM) procedures are |
| 10205038 | Safety recall 11S21 - Fuel tank strap fracture - requests for recall service action |
| 10177863 | This article supersedes TSB 19-2026 to update the vehicle model years affected. Some 2000 and newer Ford/Lincoln/Mercury vehicles equipped with aluminum body panels may exhibit corrosion concerns appearing as bubbled and/or peeling paint with or without accompanying white dust. Panel replacement is recommended. |
| 10172885 | This SKU is an Oil Dipstick. The customer communication requested return of unsold inventory to inspect the dipstick tube. The dipstick tube inner diameter may be small enough that it prevents installation of the OE dipstick. |
| 10165713 | Some 2002-2008 F-Super Duty, F-150 and Mark LT vehicles may exhibit concern during or after programing the VSM. The programming may fail or vehicle symptoms such as inoperative door locks, dome lamps, door ajar indicators or auto lamps may occur after successful programing. To ensure the VSM is configured correctly, use the Integrated Diagnostic System (IDS) scan tool and select the blue ball and socket icon in the upper left corner. Select the utility knife in the bottom left corner. Select Update/Special Function and enter 53061 in the blue box then press the tick mark. The screen will go |
| 10156863 | Some 2000 and newer Ford, Lincoln and Mercury vehicles equipped with aluminum body panels may exhibit corrosion concerns appearing as bubbled and/or peeling paint with or without accompanying white dust. Panel replacement is recommended. Follow the Service Procedure steps to correct the condition |
| 10155551 | Some 2000 and newer Ford, Lincoln and Mercury vehicles equipped with aluminum body panels may exhibit corrosion concerns appearing as bubbled and/or peeling paint with or without accompanying white dust. Panel replacement is recommended. Follow the Service Procedure steps to correct the condition |
| 10143079 | Various vehicles equipped with a 4.6L, 5.4L, 6.8L modular 3 valve engine built on or before 8-Jan-2016 may exhibit symptoms that may include upper end engine noise, rough running, misfire and/or engine damage. If diagnosis leads to only camshaft/camshaft roller follower(s) requiring replacement, replace all of the camshaft roller followers on both banks/cylinder heads with part number 3L3Z-6564-A, not just the faulty roller follower(s). When replacing the camshaft roller followers, refer to Workshop Manual (WSM), Section 303-01. |
| 10109070 | The Powertrain Control/Emissions Diagnosis (PC/ED) manual has been revised for diagnosing electronic throttle bodies (ETBs). The ETC_ACT and ETC_DSD PIDs should not used to diagnose possible ETB concerns. The IDS has a limited refresh rate when reading these PIDs and cannot display quickly enough to validate a concern. The PCM automatically monitors these inputs more accurately and will set diagnostic trouble codes (DTCs) when appropriate. Using these PIDs for diagnostics will lead to inaccurate results and improper ETB replacements. If a concern is intermittent and no DTCs are present, refer |
| 10092370 | SOME 2004-2014 F-150 AND 2006-2008 MARK LT VEHICLES EQUIPPED WITH FOUR-WHEEL DRIVE (4WD) MAY EXHIBIT NOISY OR ENGAGED FRONT HUBS WHEN OPERATING IN TWO-WHEEL DRIVE (2WD) MODE. FOLLOW THE SERVICE PROCEDURE STEPS TO CORRECT THE CONDITION. |
| 10058101 | FORD/LINCOLN: SAFETY RECALL REGARDING HIGH CORROSION AREAS FOR OPERATING, FOR AN EXTENDED TIME, VEHICLES WHERE BOTH OR ONE STRAP OF FUEL TANK CAN FRACTURE, AFTER CONTACTING GROUND. MODEL 1997-99 F250 LD, 1997-03 F150, 2004 F150 HERITAGE, 2002-03 BLACKWOOD. *PE |
| 10056148 | LINCOLN/FORD: WHEN DRIVING FROM IDLE UP TO 1200 RPM, THERE MAY BE AN INTERMITTENT RATTLE NOISE COMING FROM ENGINE. 2004-2013 F-150, F-250, F-350, EXPEDITION, MARK LT, NAVIGATOR. *PE |
| 10045340 | FORD/LINCOLN/MERCURY: IF BATTERY WAS DISCONNECTED OR DEAD, VEHICLES/TRUCKS MAY EXPERIENCE HARD STARTS AND ENGINE IDLE RPM FLUCTUATION AND EXHIBIT DIAGNOSTIC TROUBLE CODES (DTCS) P0505, P0506, P2111 AND P2112. *PE |
| 10039074 | FORD: THERE MAY BE CHAFFING ON A WIRE HARNESS BETWEEN THE CLOCKSPRING AND DRIVER AIRBAG WHICH CAUSE THE AIRBAG WARNING LIGHT TO COME ON. *RM |
| 10030866 | FORD TRUCK SERVICE CAMPAIGN: SEE DOCUMENT SEARCH BUTTON FOR OWNER LETTER. IN THE CASE OF THE ROUSHCHARGER FOR THE F-150, THE TRUCKS CALIBRATION ENHANCEMENTS HAS BEEN DEVELOPED TO BETTER ACCOMMODATE REGIONAL VARIATIONS IN PREMIUM FUEL QUALITY. EVEN THOUGH NOT ALL F-150 ROUSHCHARGED TRUCKS WILL BE AFFECTED BY THESE VARIATIONS. CSC LETTER WAS REC'D. *PE UPDATED 4/12/10. *PE |
| 10029205 | FORD/MERCURY/LINCOLN: VEHICLES MAY EXHIBIT ONE OR MORE OF THE FOLLOWING SYMPTOMS: DRIVE AWAY HESITATION, LOSS OF RPM ON DECELERATION, DIFFICULTY STARTING, AND/OR IDLE RPM LESS THAN DESIRED. THE F53 MOTORHOME CHASSIS IS INCLUDED. *PE |
| 10024865 | 1999-2008 7.3L/6.0L/6.4L/4.5L DIESEL F-SUPER DUTY - CLEAN THE CHARGE AIR COOLER (CAC) SYSTEM AFTER CERTAIN TURBO OR ENGINE FAILURES - SERVICE TIP. *NJ |
| 10024843 | INTERMITTENT VEHICLE VIBRATION--PARKING BRAKE DISENGAGEMENT CONCERNS. *NJ |
| 10024828 | 4.6L/5.4L--MIL P0506 AND/OR P0505--HESITATION/LOSS OF RPM/DIFFICULTY STARTING/LOW IDLE RPM. *NJ |
| 10024324 | ERRATIC FUEL GAUGE OPERATION - MIL ON --DTCS P040/P0463 OR INSTRUMENT CLUSTER MODULE DTC B1201--VEHICLES BUILT BEFORE 12/3/2007. *NJ |
| 10023943 | SOME 1997-2008 VEHICLES EQUIPPED WITH A 4.6L 2V, 5.4L 2V, OR 6.8L 2V ENGINE--SPARK PLUG THREAD REPAIR PROCEDURE--NOT COVERED UNDER NEW VEHICLE LIMITED WARRANTY. *NJ THIS INCLUDES F-53 MOTORHOME CHASSIS. UPDATED 2/23/10. *PE |
| 10023854 | HIGH PRESSURE POWER STEERING LINE SEEPAGE-COLD CLIMATES ONLY (EXCLUDING HERITAGE F-150). *NJ |
| 10022279 | REAR AXLE TUBE FRACTURE AT CENTER CARRIER. *KB |
| 10022160 | VIBRATION FROM THE DRIVELINE AT HIGHWAY SPEEDS. *KB |
NHTSA manufacturer communications (public domain)
NHTSA investigations
Fuel Tank Strap Failure Due to Corrosion
Inadvertent airbag deployment
CNG REGULATOR LEAK
SPARK PLUG EJECTION FROM CYLINDER HEAD
NHTSA Office of Defects Investigation