NHTSA lists 2,029 complaints for the 2004 Ford F-150, 75 of them mention a crash and 40 mention a fire. 58 complaints mention an injury, with 74 injuries and 6 deaths reported.
Data build 2026-10-09.
NHTSA lists this vehicle as FORD F-150.
Model-generated complaint tags: This model year has not been tagged.
Recalls
See new recalls and investigations this week.
5 recalls.
Date: 2011-07-29. Systems: FUEL SYSTEM, GASOLINE.
Defect: 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, (excerpt)
Consequence: AS A RESULT OF THE CORROSION, ONE OR BOTH STRAPS MAY FAIL ALLOWING THE FUEL LINES TO SEPARATE FROM THE TANK, OR IN SOME CASES, CAUSING THE TANK TO CONTACT THE GROUND. EITHER SCENARIO MAY RESULT IN A FUEL LEAK PRESENTING A FIRE HAZARD. (excerpt)
Remedy: FORD WILL NOTIFY OWNERS AND INSTRUCT THEM TO TAKE THEIR VEHICLES TO A FORD OR LINCOLN DEALER TO HAVE THE FUEL TANK STRAPS REPLACED WITH STRAPS THAT HAVE INCREASED CORROSION PROTECTION. EARLY IN THIS CAMPAIGN, IF REPLACEMENT STRAPS ARE NOT AVAILABLE, DEALERS MAY INSTALL A CABLE SUPPORT UNDER THE STRAP AS AN INTERIM REPAIR OR A STEEL REINFORCEMENT OVER THE EXISTING STRAP AS A PERMANENT REPAIR. ANY (excerpt)
Do not drive: No. Park outside: No.
Date: 2011-02-23. Systems: AIR BAGS.
Defect: 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 REQU (excerpt)
Consequence: THE DRIVER SIDE FRONTAL AIR BAG COULD INADVERTENTLY DEPLOY INCREASING THE RISK OF INJURY OR LOSS OF VEHICLE CONTROL IF OCCURRING WHILE IN MOTION. (excerpt)
Remedy: FORD WILL NOTIFY OWNERS AND INSTRUCT THEM TO TAKE THEIR VEHICLES TO A FORD OR LINCOLN/MERCURY DEALER TO HAVE A NEW CLOCKSPRING JUMPER WIRE INSTALLED THAT INCORPORATES A PROTECTIVE MESH COVER. REPAIRS WILL BE PERFORMED FREE OF CHARGE. THIS SAFETY RECALL BEGAN ON SOME VEHICLES IN MARCH 2011. THE RECALL CAMPAIGN ON THE EXPANDED POPULATION IS EXPECTED TO BEGIN ON OR ABOUT MAY 9, 2011. OWNERS MAY (excerpt)
Do not drive: No. Park outside: No.
Date: 2007-08-03. Systems: VEHICLE SPEED CONTROL.
Defect: 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. (excerpt)
Consequence: THIS COULD RESULT IN AN UNDERHOOD FIRE. (excerpt)
Remedy: DEALERS WILL INSTALL A FUSED WIRING HARNESS. OWNERS OF THE PASSENGER CARS INCLUDED IN THIS CAMPAIGN WILL BE INSTRUCTED TO RETURN THEIR VEHICLES TO THEIR DEALERS TO HAVE THE SPEED CONTROL DEACTIVATION SWITCH DISCONNECTED AS AN INTERIM REPAIR. AS SOON AS REPAIR PARTS ARE AVAILABLE (EXPECTED OCTOBER 2007), OWNERS WILL BE INSTRUCTED TO RETURN TO THE DEALERS FOR INSTALLATION OF A FUSED WIRING HARNESS (excerpt)
Do not drive: No. Park outside: No.
Date: 2004-09-13. Systems: FUEL SYSTEM, GASOLINE.
Defect: 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.
Consequence: FUEL LEAKAGE, IN THE PRESENCE OF AN IGNITION SOURCE, COULD RESULT IN A FIRE.
Remedy: DEALERS WILL REPLACE THE FUEL TANK. THE RECALL BEGAN SEPTEMBER 17, 2004. OWNERS SHOULD CONTACT FORD AT 1-800-392-3673.
Do not drive: No. Park outside: No.
Date: 2004-04-26. Systems: FUEL SYSTEM, GASOLINE.
Defect: 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.
Consequence: IF LEFT UNCORRECTED, A FUEL LEAK COULD EVENTUALLY DEVELOP.
Remedy: DEALERS WILL REPLACE THE FUEL TANK ON THESE VEHICLES. OWNER NOTIFICATION BEGAN ON MAY 6, 2004. OWNERS SHOULD CONTACT FORD AT 1-800-248-0186.
Do not drive: No. Park outside: No.
Investigations
4 investigations; 0 open.
EA11006
Opened: 2011-05-04. Closed: 2011-08-19.
Fuel Tank Strap Failure Due to Corrosion
One or both of the steel straps holding up the fuel tank and attaching it to the truck frame can corrode and fail (break or separate).If one strap fails, the tank may tilt and drop and possibly contact the road surface.If both straps break, the entire tank may drop to the road.If either failure occurs while the vehicle is being driven, contact with the road can abrade the tank and create a hole fr
Systems: FUEL SYSTEM, GASOLINE, FUEL SYSTEM, OTHER.
Linked campaign numbers: 11V385000.
EA10001
Opened: 2010-01-13. Closed: 2011-04-25.
Inadvertent airbag deployment
ODI opened this investigation based on reports of inadvertent airbag deployment.Data provided by Ford indicated that the airbag clockspring jumper wire, which is situated inside the steering wheel assembly, was installed in a manner that would allow it to rub (abrade) against a sharp metal edge on the nearby horn plate.Because the horn plate is electrically grounded the abrasion of an airbag wire
Systems: AIR BAGS.
Linked campaign numbers: 11V107000.
PE08063
Opened: 2008-10-31. Closed: 2009-02-27.
CNG REGULATOR LEAK
THE AGENCY HAS CLOSED THIS INVESTIGATION BASED ON ITS REVIEW OF COMPLAINT REPORTS, DISCUSSIONS WITH COMPLAINANTS AND FIELD AND TECHNICAL DATA PROVIDED BY FORD.THE SUBJECT VEHICLES ARE 1/2 TON PICKUP TRUCKS AND ARE NATURAL GAS VEHICLES (NGV) THAT ARE FUELED BY GASOLINE OR COMPRESSED NATURAL GAS.THE AGENCY HAS RECEIVED REPORTS ALLEGING IMPROPER OPERATION OF THE NATURAL GAS FUEL PRESSURE REGULATOR AL
Systems: FUEL SYSTEM, OTHER.
Linked campaign numbers: None listed.
DP05005
Opened: 2005-09-22. Closed: 2006-01-04.
SPARK PLUG EJECTION FROM CYLINDER HEAD
ON SEPTEMBER 6, 2005, ODI RECEIVED A PETITION REQUESTING THAT THE AGENCY INVESTIGATE ALLEGATIONS OF ENGINE SPARK PLUG EJECTION IN CERTAIN MODEL YEAR 1997 THROUGH 2004 FORD VEHICLES WITH TRITON V-8 AND V-10 ENGINES.ODI RECEIVED A TOTAL OF 474 NON-DUPLICATIVE COMPLAINTS ON THE SUBJECT VEHICLES WHERE THE COMPLAINANT, OR THE DEALER REPAIRING THE VEHICLE, REPORTED THAT A SPARK PLUG DETACHED FROM THE CY
Systems: ENGINE AND ENGINE COOLING.
Linked campaign numbers: None listed.
Manufacturer communications
148 manufacturer communications.
Communications by system| System | Count |
|---|
| ENGINE AND ENGINE COOLING | 35 |
|---|
| POWER TRAIN | 26 |
|---|
| ELECTRICAL SYSTEM | 23 |
|---|
| STRUCTURE | 14 |
|---|
| SUSPENSION | 10 |
|---|
| EQUIPMENT | 7 |
|---|
| SERVICE BRAKES, HYDRAULIC | 7 |
|---|
| STEERING | 6 |
|---|
10177863
Date: 2020-07-13. Type: Service Bulletin/Repair Instructions. Systems: STRUCTURE.
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
10172885
Date: 2020-02-07. Type: Service Bulletin/Repair Instructions. Systems: ENGINE AND ENGINE COOLING.
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
Date: 2019-09-02. Type: Service Bulletin/Repair Instructions. Systems: ELECTRICAL SYSTEM.
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 conf
10155551
Date: 2019-02-07. Type: Service Bulletin/Repair Instructions. Systems: STRUCTURE.
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
10156863
Date: 2019-02-07. Type: Service Bulletin/Repair Instructions. Systems: EQUIPMENT, STRUCTURE.
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
Date: 2018-06-01. Type: Service Bulletin/Repair Instructions. Systems: ENGINE, EQUIPMENT.
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, rep
10109070
Date: 2016-09-21. Type: Service Bulletin/Repair Instructions. Systems: ENGINE, ENGINE AND ENGINE COOLING.
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
10092370
Date: 2016-08-16. Type: Service Bulletin/Repair Instructions. Systems: POWER TRAIN.
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.
10205038
Date: 2016-04-21. Type: Service Bulletin/Repair Instructions. Systems: FUEL SYSTEM, GASOLINE.
Safety recall 11S21 - Fuel tank strap fracture - requests for recall service action
10058101
Date: 2014-09-09. Type: Service Bulletin/Repair Instructions. Systems: EQUIPMENT, FUEL SYSTEM, GASOLINE.
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