2004 Ford F-150 Engine
Owner-reported problems and safety issues filed with NHTSA. Review common failures, severity levels, and complaint trends over time.
Complaint Timeline
Chronological view of owner reports
TL* THE CONTACT OWNS A 2004 FORD F-150. WHILE AN INDEPENDENT MECHANIC WAS PERFORMING A ROUTINE TUNE-UP ON THE VEHICLE, THE NUMBER THREE SPARK PLUG FRACTURED INSIDE THE ENGINE AND WAS UNABLE TO BE RETRIEVED. THE MANUFACTURER WAS NOTIFIED. THE FAILURE MILEAGE WAS 127,000.
TRUCK STARTS MAKING A LOUD TICKING NOISE COMING FROM ENGINE, I HAVE ALWAYS GOTTEN OIL CHANGES AND HAVE NO CLUE WHAT THIS IS BUT IT HAS LOWERED POWER ALSO. IT IS STILL MAKING THE TICKING/RATTLING NOISE AND ITS LOUD. CARRIED TO FORD DEALERSHIP AND WAS TOLD IT WOULD COST $2000.00 OR MORE. TOLD THIS IS NORMAL. I DON'T THINK A GASOLINE ENGINE SHOULD SOUND LIKE A DIESEL. THIS SEEMS TO BE A MANUFACTURER ISSUE AND FORD NEEDS TO TAKE RESPONSIBILITY FOR THE PROBLEM.
I HAVE 2004 F-150 WITH 92,000 MILES ON IT , I BOUGHT IT 3 YEARS AGO WITH 70,000 ON IT MAKING A SLIGHT TAPPING NOISE . I TALKED WITH MANY PEOPLE AND AND THE DEALER SAYING THAT THIS IS THE WAY THE ENGINE IS DESIGNED AND SHOULD BE FINE.YESTERDAY DRIVING DOWN A MAJOR HIGHWAY IN NORTHERN VIRGINIA TRAVELING AT 65 MPH MY TRUCK STARTED MAKING A NOISE FROM THE ENGINE AND SHUT OFF , I HAD GOOD OIL PRESSURE ,WATER TEMP WAS FINE I PULLED IT OFF THE HIGHWAY, NEVER TO START AGAIN. I HAD IT TOWED TO A LOCALE FORD DEALER IN FAIRFAX VA.AFTER READING FROM FORD FORUM WEB SITE AND HEARING THE HORROR STORIES I FEEL I AM IN FOR A HUGH REPAIR BILL.I ALSO SEE THERE IS A CLASS ACTION SUIT AGAINST THE FORD MOTOR COMPANY FOR NOT STANDING BEHIND THEIR VEHICLES WHEN THERE SEEMS TO BE A MAJOR FLAW IN THE ENGINES DESIGN. APROX. COST OF A NEW ENGINE IS BETWEEN 7 AND 10,000 SOME CONSUMERS STARTED TO HAVE PROBLEMS AS EARLY AS 12,000 MILES, I BABY MY TRUCK, THE HEAVIEST THING I HAVE HAULED IN IT IS A 6 FT. CHRISTMAS TREE FOR MY LIVING ROOM.I BABIED MY TRUCK TO WHAT MEANS JUST TO HAVE A HIGH REPAIR BILL LIKE SO MANY OTHERS??? I HOPE YOU CAN HELP . PLEASE/THANK -YOU IN ADVANCE *TR
DRIVING DOWN THE ROAD AT NORMAL SPEED OF 55 WHEN MY 2004 FORD F-150 4.2 V-8 BLEW A SPARK PLUG OUT OF HEAD!!
I AM NOW A VICTIM OF THE 2004-2008 5.4L CAM PHASER PROBLEM. IT STARTED OUT WHEN I CAME TO A STOP LIGHT AND THE TRUCK STARTED SHACKING REALLY BAD AND MAKING A LOUD KNOCKING SOUND. AS SOON AS I ACCELERATED IT WENT AWAY SO I THOUGHT IT WAS A FLUKE. NOPE!! IT STATED DOING IT MORE AND MORE BUT I WAS NOT GETTING A CHECK ENGINE LIGHT. FINALLY THE LIGHT CAME ON AND GAVE ME THE CODE P0012-INTAKE CAMSHAFT POSITION TIMING OVER RETARDED ON BANK 1. THE ONLY PLACE TO TAKE IT WAS FORD BECAUSE THEY HAVE THE MOST UP TO DATE AND COMPLETE DIAGNOSTICS TOOL. IT IS STILL IN THE SHOP RIGHT NOW BUT TO LOOK AT THE PHASERS TO SEE IF I NEED BOTH IT IS RUNNING ME $600 JUST FOR THEM TO REMOVE THE VALVE COVERS TO LOOK. HE SAID IT WAS GOING TO COST ME CLOSE TO $1500 JUST TO FIX THE ISSUE! I HAVE READ ALL OVER THE INTERNET ABOUT THIS ISSUE AND IT SEEMS LIKE FORD KNOW ABOUT THIS ISSUE BECAUSE IN 2013 THEY GOT SUED BECAUSE OF THIS SAME PROBLEM! IF YOU LOOK 2004 HAS THE MOST COMPLAINTS OF EVERY YEAR BY FAR! PLEASE STAY AWAY FROM THE 5.4L ENGINE OR FORD IN GENERAL. I DON'T EVEN WANT TO GET STARTED WITH THE SPARK PLUGS THAT BREAK IN THE ENGINE IF YOU DON'T KNOW WHAT YOU ARE DOING. THAT WAS ANOTHER $600 BILL THAT FORD HAD TO DO. THE 4WD SYSTEM AS WELL HAD MANY ISSUES WITH THE IWE BECAUSE ITS A VACUUM SYSTEM AND WAS BRAND NEW IN 2004. TO MANY PROBLEMS WITH FORD!
ALL THE SUDDEN THE TRUCK STARTS MAKING A LOUD TICKING NOISE COMING FROM ENGINE, I HAVE ALWAYS GOTTEN OIL CHANGES AND HAVE NO CLUE WHAT THIS IS BUT IT HAS LOWERED POWER ALSO. IT IS STILL MAKING THE TICKING/RATTLING NOISE AND ITS LOUD.
TL*THE CONTACT OWNS A 2004 FORD F-150. THE CONTACT STATED THAT THE ENGINE HESITATED ON SEVERAL OCCASIONS AND THAT THERE WAS A TAPPING NOISE THAT PROGRESSED. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC, WHO REPLACED THE SPARK PLUGS, FUEL INJECTORS AND THE PLUG WIRES. THE CONTACT STATED THAT THE FAILURE RECURRED. THE VEHICLE WAS TAKEN TO AN AUTHORIZED DEALER. THE TECHNICIAN DIAGNOSED THAT THE HEAD GASKET NEEDED TO BE REPLACED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 110,000.
IN ALL 04-10 F150 TRUCKS WITH THE 5.4, LACK OF OIL PRESSURE CAN AND WILL CAUSE CAM PHASER FAILURE RESULTING IN THE MOTOR LOCKING UP OR EVEN SHUTTING OFF DAMAGING THE TIMING CHAIN GUIDES AND TENSIONERS. THIS CAN BECOME EXTREMELY DANGEROUS AS ALL 04-10 5.4 MOTORS EXPERIENCE OIL PRESSURE PROBLEMS TO THE TOP END AND ALL EXHIBIT A KNOCKING SOUND. I'M SURE I'M NOT THE FIRST TO COMPLAIN AS HUNDREDS OF THOUSANDS OF PEOPLE HAVE HAD ISSUES AND ACCIDENTS BECAUSE OF THIS INCIDENT. PLEASE INSTIGATE AND READ THE COUNTLESS ARTICLES OF THESE SITUATIONS. FORD IS CAUSING PEOPLE TO PAY UP TO 8 THOUSAND DOLLARS TO REPAIR THIS. IT IS A RIP OFF SCENE BY FORD AND SOMETHING SHOULD BE DONE. *TR
FORD F150'S HAVE A KNOWN PROBLEM WITH THE SPARK PLUG BEING BLOWN OUT OF THE HEAD. THE FORD DEALERSHIP HAS TOLD US THIS IS A KNOWN PROBLEM AND THERE HAS BEEN NO RECALL ISSUED. WE HAVE CONTACTED FORD ABOUT THIS ISSUE AND KNOW OF MANY OTHER FORD OWNERS THAT HAVE COMPLAINED. THIS HAS NOW HAPPENED 4 TIMES TO US ALONE! WE HAVE BEEN TOLD THAT IT WILL CONTINUE TO HAPPEN UNTIL FORD CHANGES THE HEAD SO THIS CAN'T HAPPEN. THE PROBLEM WE NOW ARE RUNNING INTO IS THAT WE ARE HAVING TO REPLACE PLUGS THAT HAVE ALREADY BEEN REPLACED, THEREFORE THE HEAD HAS TO BE REPLACED WITH THE SAME DEFECTIVE ONES THAT FORD IS PUTTING IN THEM! CONSUMERS SHOULD NOT HAVE TO PAY FOR THE DEFECTS. FORD ([XXX]) INFORMED ME THAT THE NHTSA IS NOT ISSUING THE RECALL, THAT THERE IS NOTHING FORD CAN DO ABOUT IT UNTIL NHTSA DOES SOMETHING. THIS IS COSTING PEOPLE THOUSANDS OF DOLLARS! IT IS VERY UNSAFE BECAUSE THIS HAPPENS WHEN YOU ARE DRIVING AND THE TRUCK LOSES POWER. WHY ISN'T THIS BEING RECALLED AND TAKEN CARE OF? IS THIS A FORD PROBLEM OR NHTSA? WHAT NEEDS DONE ON OUR PART TO GET THIS PROBLEM RESOLVED? INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6). *TR
TL* THE CONTACT OWNS A 2004 FORD F-150. WHILE DRIVING APPROXIMATELY 65 MPH, THE ENGINE STALLED WITHOUT WARNING. INTERMITTENTLY, THE ENGINE RPM'S INCREASED AND A LOUD NOISE WAS PRESENT. THE FAILURES OCCURRED MULTIPLE TIMES. THE VEHICLE WAS TAKEN TO VARIOUS INDEPENDENT MECHANICS. ONE TECHNICIAN STATED THAT THE WIRING HARNESSES AND CAM PHASERS NEEDED TO BE REPLACED. IN ADDITION, THE INTAKE AND THROTTLE BODY NEEDED TO BE CLEANED. THE VEHICLE WAS REPAIRED, BUT THE FAILURES RECURRED. THE MANUFACTURER WAS NOTIFIED. THE VIN WAS UNAVAILABLE. THE APPROXIMATE FAILURE MILEAGE WAS 120,000.
I WENT TO START THE TRUCK AND THE CHECK ENGINE LIGHT CAME ON SO I TOOK IT IN FOR SERVICE AND IT PULLED A CYLINDER 6 MISFIRE CODE ,TURNS OUT THAT THE SPARK PLUGS THAT WERE NOT SUPPOSED TO BE CHANGED FOR ANOTHER 20000MI NEEDED TO BE CHANGED AND I WAS INFORMED AT THE FORD DEALER THAT LABOR WOULD BE $85.PER HR X 6 HRS PROVIDING THE PLUGS DID NOT BREAK AT THIS TIME HE TOLD ME I COULD COUNT ON AT LEAST HALF OF THEM BREAKING AS THEY ARE NOTORIOUS FOR THIS ALSO I WAS INFORMED THAT THE NEW PLUGS WERE $19.50 EA. *TR
THE TRUCK HAVE ONLY 55K MILES WHICH THE ENGINE SHOULD NOT HAVE ANY PROBLEMS BUT THIS IS A VERY COMMON PROBLEM WHICH SHOULD BE A RECALL. IT'S KNOWN FOR THE CAMSHAFT PHASERS TO START MAKING A KNOCKING NOISE AND MAKE THE VEHICLE SOUND LIKE A DIESEL TRUCK. I DON'T THINK IT'S RIGHT THAT WE PAY TONS OF MONEY FOR A VEHICLE AND WE HAVE PROBLEMS LIKE THIS THAT COST US CUSTOMERS MORE MONEY. I'VE DONE SOME RESEARCH AND I'M NOT THE ONLY PERSON WITH THIS PROBLEM. PLEASE TAKE THE TIME TO REVIEW THIS PROBLEM BECAUSE THERE ARE MANY OTHER CUSTOMERS OUT THERE WITH THIS PROBLEM AND CANT AFFORD TO HAVE IT FIXED. EVEN WITH THE AFTERMARKET PARTS THE CAM PHASERS GO BACK OUT AGAIN AFTER 60 MILES. *TR
TL* THE CONTACT OWNS A 2004 FORD F-150. WHILE DRIVING APPROXIMATELY 65 MPH, THE VEHICLE SHOOK VIOLENTLY WITHOUT WARNING AND THE ENGINE STALLED. THE ENGINE WARNING INDICATOR ILLUMINATED AND THE EMERGENCY BRAKE HAD TO BE APPLIED IN ORDER TO STOP THE VEHICLE. THE VEHICLE WAS TOWED TO THE DEALER WHO STATED THAT THE VALVE FRACTURED IN THE NUMBER ONE CYLINDER AND DESTROYED THE ENGINE. THE ENGINE NEEDED TO BE REPLACED. THE VEHICLE WAS REPAIRED AND THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 140,000.
ENGINE KNOCKING - OIL PRESSURE DROPPING - TIMING CHANGE BAD. *JS
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. *TR
WE ALWAYS TAKE OUR TRUCK TO THE FORD DEALER FOR SERVICE. RECENTLY THEY GOT NEW MANAGEMENT AND THEY SAID OH BY THE WAY SOMEONE SHOULD HAVE TOLD YOU EVEN THOUGH THE SPARK PLUGS ARE 100,000 MILES YOU SHOULD HAVE HAD THEM CHANGED ALREADY BECAUSE THEY GET STUCK. SO I WENT TO THE INTERNET AND READ THE NIGHTMARES ABOUT MY 5.4 ENGINE SPARK PLUGS. TOOK IT TO A 3RD PARTY MECHANIC AND ALL 8 GOT STUCK AND WERE NOT EASY TO REMOVE USING FORD'S SPECIAL TOOL THEY DEVELOPED BECAUSE THEY KNOW OF THIS PROBLEM. I APPARENTLY MADE PUT A LOT BETTER THAN MOST, MY BILL WAS ONLY A WHOPPING $700 FOR HAVING SPARK PLUGS CHANGED WITHIN 100,000 MILES THEY ARE SUPPOSED TO BE GOOD FOR. MECHANICS ARE RECOMMENDING GETTING THEM CHANGED AT LEAST EVERY 50,000 MILES NOW AND SOME WON'T EVEN TOUCH THE FORD 5.4 ENGINES. MANY OTHER CUSTOMERS HAVE HAD BILLS IN THE THOUSANDS FOR THIS ROUTINE MAINTENANCE ALL DUE TO FORD'S BAD DESIGN. THERE HAVE EVEN BEEN MULTIPLE CLASS ACTION LAWSUITS BUT WHEN I CALLED FORD FOR MORE INFORMATION ABOUT THEM AND WHY I WASN'T NOTIFIED TO JOIN, THEY SAY THEY CAN'T PROVIDE ANY INFORMATION. I DON'T MIND ROUTINE MAINTENANCE BUT A KNOWN ISSUE LIKE THIS THAT FORD REFUSES TO ASSIST CONSUMERS WITH IS RIDICULOUS. *TR
TL- THE CONTACT OWNS A 2004 FORD F-150. THE CONTACT STATED WHILE DRIVING VARIOUS SPEEDS, THE VEHICLE WOULD SPONTANEOUSLY HESITATE. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC FOR DIAGNOSTIC TESTING. THE MECHANIC WAS UNABLE TO DIAGNOSE THE FAILURE. THE CONTACT INDEPENDENTLY PERFORMED A TUNE UP ON HIS VEHICLE AND WHEN HE ATTEMPTED TO SERVICE THE SPARK PLUGS HE WAS UNABLE TO REACH THEM. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE VEHICLE WAS NOT REPAIRED. THE FAILURE MILEAGE WAS 119,000.
TL* THE CONTACT OWNS A 2004 FORD F-150. THE CONTACT STATED THAT THE VEHICLE BURNED AND WAS COMPLETELY DESTROYED AFTER BEING PARKED FOR SEVEN HOURS. THE FIRE DEPARTMENT DETERMINED THAT THE FIRE ORIGINATED UNDERNEATH THE ENGINE COMPARTMENT. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE FAILURE AND CURRENT MILEAGE WERE 47,000.
ATTEMPTED TO START VEHICLE. ENGINE MADE A CLUNK AND HYDROLOCKED WITH NO WARNING. CHANGED STARTER ASSUMING THE STARTER SET UP. ATTEMPTED TO START VEHICLE AGAIN WITH SAME RESULT. NOW IN PROCESS OF FINDING A MOTOR. I LOOKED INTO THIS ISSUE. SEEMS LIKE THIS IS COMMON ISSUE??? *TR
FORD HAS A KNOWN ISSUE WITH THE SPARK PLUGS. THIS IS THE SECOND "TUNE-UP I HAVE HAD ON THIS TRUCK. BOTH TIMES, PLUGS HAVE BROKEN IN THE ENGINE. IT IS NOT MY DESIGN, IT IS FORDS, SO WHY DO I HAVE TO PAY 891.99 IN LABOR TO HAVE PLUGS REMOVED. *TR
TL* THE CONTACT OWNS A 2004 FORD F-150. THE CONTACT STATED WHILE STARTING THE VEHICLE, THERE WAS A LOUD POPPING NOISE COMING FROM THE ENGINE WITHOUT WARNING. THERE WAS ALSO SMOKE COMING FROM THE ENGINE. THE VEHICLE WAS TAKEN TO A DEALER WHO STATED THAT THE ENGINE COILS NEEDED TO BE REPLACED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE VEHICLE WAS REPAIRED. THE APPROXIMATE FAILURE AND CURRENT MILEAGE WAS 149,000.
TL* THE CONTACT OWNS A 2004 FORD F-150. THE CONTACT STATED THAT WHILE DRIVING APPROXIMATELY 65 MPH, THE CHECK ENGINE LIGHT ILLUMINATED. THE VEHICLE WAS TAKEN TO THE DEALER FOR DIAGNOSIS. THE TECHNICIAN STATED THE ENGINE WOULD HAVE TO BE REPLACED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE VEHICLE WAS NOT REPAIRED. THE APPROXIMATE FAILURE MILEAGE WAS 80,000.
AS VEHICLE WARMS UP AFTER DRIVING SEVERAL MILES COMING TO A STOP. THE ENGINE BEGINS TO KNOCK ATTEMPTING TO STALL OUT. WHEN GIVING THE VEHICLE GAS IT KICKS ALMOST CAUSING SEVERAL AUTO ACCIDENTS. I HAVE TAKEN THE VEHICLE TO SEVERAL MECHANICS REPLACING THE CAM PHASERS DUE TO A CODE. THE ISSUE IS STILL HAPPENING AND THE CODE STILL SAYS REPLACE CAM PHASER. FROM WHAT I UNDERSTAND I'M NOT THE ONLY ONE WITH THIS PROBLEM WHICH CAN'T BE FIXED. AS FAR AS THE KNOCKING SOUND THE FORD DEALERSHIP HAS TOLD ME ITS A FORD TRITON THAT'S THE KNOCKING SOUND IM HEARING. BUT FROM MECHANICS THE SOUND IS FROM AIR ESCAPING FROM THE BOTTOM OF THE ENGINE IS A COMMON PROBLEM WITH THE VEHICLE. FORD REFUSES TO ACCEPT THE DEFECT FIXING ISSUES SINCE BUYING THE VEHICLE NEW IN 2004. *TR
TL* THE CONTACT OWNS A 2004 FORD F-150. THE CONTACT STATED THAT AFTER HAVING AN OIL CHANGE, THE ENGINE FAILED. THE CONTACT TOOK THE VEHICLE TO A LOCAL MECHANIC, WHO ADVISED THE CONTACT THAT THE ENTIRE ENGINE NEEDED TO BE REPLACED. THE CONTACT DID NOT HAVE THE ENGINE REPLACED. THE FAILURE MILEAGE WAS 100,207.
TL* THE CONTACT OWNS A 2004 FORD F-150. THE CONTACT STATED THAT THERE WAS A TICKING NOISE COMING FROM THE ENGINE. THE VEHICLE WAS TAKEN TO THE DEALER WHERE IT WAS FOUND THAT THE CAM PHASERS HAD FAILED. THE VEHICLE WAS BEING REPAIRED. THE MANUFACTURER WAS CONTACTED ABOUT THE FAILURE. THE VEHICLE WAS THE FAILURE MILEAGE WAS 58,000. THE VIN WAS NOT AVAILABLE.
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Quick Summary
The 2004 Ford F-150 has 198 Engine complaints on file. 2 crashes have been reported. Review the timeline above for detailed owner experiences.