2004 Ford F-150 Power Train

TL* THE CONTACT OWNS A 2004 FORD F-150. THE CONTACT STATED THAT THE DRIVER WAS EXITING A PARKING AREA WHEN A LOUD NOISED WAS HEARD FROM UNDERNEATH THE VEHICLE. THE CONTACT INSPECTED THE VEHICLE AND FOUND THAT THE DRIVE SHAFT WAS FRACTURED IN HALF AND CAUSED DAMAGE TO THE FUEL TANK AND MUFFLER. THE VEHICLE WAS TOWED TO THE CONTACT'S HOME. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURE. THE APPROXIMATE FAILURE AND CURRENT MILEAGE WERE 146,000.

HAD A LOUD WHINNING NOISE I COULD HEAR WHEN DRIVING, BUT WHEN I LET OFF THE GAS IT WOULDN'T BE AS LOUD AND PRETTY MUCH GO AWAY. IT WAS NOT TIRE NOISE OR HUM. JUST HIT A 100,000 MILES AND THE NOISE HAD GOTTEN A LOT LOUDER. I READ LOTS INFORMATION ONLINE AND FOUND IT TO BE THE PINION BEARING. TOOK IT TO LOCAL REPAIR SHOP AND THEY CONFIRMED THAT THE PINION BEARING HAD GONE BAD. THIS IS VERY SURPRISING THAT SO MANY 2004 AND NEWER F150 OWNERS ARE HAVING THIS SAME PROBLEM AND NOTHING IS BEING DONE BY FORD. I THINK THEY ARE TURNING A BLIND EYE BECAUSE OF THE COST OF PARTS AND AMOUNT OF TIME OF LABOR. BESIDES THE PINION BEARING, ALSO HAD TO DO OTHER BEARINGS AND SEAL. TRUCK IS NOT DRIVEN HARD AT ALL. *TR

HAD THE SAME PROBLEM AS MENTIONED MULTIPLE TIMES IN THIS LIST. ACCELERATING PAST 40 MPH, THE TRUCK SLIPPED OUT OF GEAR AND REV'D UP TO ABOUT 4000RPM. DID THE SAME THING REPEATEDLY AFTER THE FIRST INCIDENT. APPARENTLY A BROKEN SNAP RING. HARD TO BELIEVE THIS IS NOT CONSIDERED A SAFETY HAZARD, AND SOMETHING THAT SHOULD BE FIXED VIA RECALL?? *TR

WHILE STARTING FROM A DEAD STOP NOTICED A RUMBLING SOUND COMING FROM THE REAR END. I HAD THE REAR DIFFERENTIAL FLUID REPLACED, U-JOINTS CHECKED, AND BRAKES INSPECTED. (HAVE HAD THIS DONE 3 TIMES IN THE LAST 18 MONTHS AT A COST OF SEVERAL HUNDRED DOLLARS)I MENTIONED THIS PROBLEM DURING A CASUAL CONVERSATION WITH A FRIEND WHO HAPPENED TO BE A RETIRED FORD MECHANIC. HE TOLD ME THAT WHILE HE WAS WITH FORD AS A MECHANIC HE REPLACED OR REBUILT NUMEROUS REAR SLIP DIFFERENTIALS, AND THAT IT WAS A MAJOR PROBLEM ESPECIALLY WITH THE 2004 F-150, AND THAT I SHOULD INVESTIGATE IT FURTHER. I WENT ON-LINE AND FOUND MANY MANY COMPLAINTS ABOUT THE 2004 F-150 REGARDING REAR SLIP DIFFERENTIAL \WITH VERY EXPENSIVE REPAIR PROBLEMS. OBVIOUSLY FORD HAS KNOWN ABOUT THIS PROBLEM FOR A VERY LONG TIME, AND HAS DONE NOTHING ABOUT EXCEPT TO OFFER LAME EXCUSES AND CHARGE EXORBITANT PRICES FOR REPAIRS. I AM CONCERNED ABOUT THE REAR END LOCKING UP AT HIGHWAY SPEED AND CAUSING A FATAL ACCIDENT. WHY HASN'T A RECALL BEEN REQUIRED? *TR

DEVELOPED DIFFERENTIAL CHATTER RELATIVELY SOON AFTER PURCHASE. CARRIED BACK TO DEALER AND COMPLAINED. THEY REPLACED THE DRIVE SHAFT AND UNIVERSALS, SAID PROBLEM WAS CORRECTED. THIS DID NOT LAST NO MORE THAN 6-8 MONTHS BEFORE CHATTER CAME BACK, THINK THEY ALSO REPLACED DIFFERENTIAL OIL ALSO. CARRIED BACK TO DEALER FOR REPAIR, THEY CLAIMED NOTHING WAS WRONG. DISGRUNTLED WITH DEALER, STATED I WOULD NEVER PURCHASE ANOTHER FORD TRUCK AGAIN. TEN YEARS HAVE PASSED, TO THE DAY ALMOST, CHATTER JUST AS BAD IF NOT WORSE. CHANGED DIFFERENTIAL OIL 2 TIMES SINCE, SEEMS TO HELP FOR A WHILE. DO NOT PULL A BOAT, PULL A TRACTOR, TRAVEL TRAILER OR DO ANY TYPE OF CONSTRUCTION WORK WITH THIS TRUCK. IT IS DRIVEN TO WORK AND BACK AND OCCASIONALLY TAKEN ON HIGHWAY TRIPS TO BEACH AND BACK, 500 MILE ROUND TRIP. TRUCK IS PAMPERED SO THAT IT WILL LAST, NOT DRIVEN HARD WELL MAINTAINED, DRIVEN BY ADULT MALE, BASICALLY IN PERFECT SHAPE OTHER THAN DIFFERENTIAL. DO NOT UNDERSTAND WHY THERE HAS NOT BEEN A RECALL WITH THIS PROBLEM. HAVE READ ABOUT MANY OTHERS WITH THE SAME ISSUE. THESE ARE GOOD TRUCKS WITH ONE PROBLEM, THE DIFFERENTIAL, THAT SEEMS TO ME TO BE A FACTORY ISSUE. YOU WOULD THINK FORD WOULD STEP-UP TO THE PLATE TO FIX THIS PROBLEM. HAVE BEEN A FORD FAN FOR MANY YEARS,OWN A 2013 FUSION NOW ALSO. WOULD LIKE TO SEE ACTION TAKEN TO REMEDY THIS PROBLEM. DATES AND MILEAGE APPROXIMATE. *TR

DRIVING UP A HILL AT ABOUT 35MPH , AND NOTICED THE TRANSMISSION SLIPPING . IT KEEP GOING IN AND OUT OF GEAR . FINALLY THE OD SHUT OFF AND WAS ABLE TO GET IT BACK TO MY HOUSE . LUCKILY I WAS ONLY 4 BLOCKS AWAY .AFTER DIAGNOSIS FROM THE DEALERSHIP , IT TURNS OUT THAT THE OD RETAINER CLIP WENT OUT ,TOOK OUT MY 2ND GEAR AND CRACKED THE HOUSING . FROM LOOKING ONLINE THIS APPEARS TO BE A COMMON PROBLEM THAT FORD IS NOT AKNOWLEDGING . *TR

TRUCK VIBRATED HORRIBLY ON A STRAIGHTAWAY STARTING AT 40 MPH CAUSING ME TO SLOW DOWN QUICKLY. HAPPENS IRREGULARLY. TRANSMISSION SHOP CAN'T FIND ANYTHING WRONG. PREVIOUSLY HAD ONGOING PROBLEMS WITH SHUDDERING WHEN TURNING AROUND CORNERS. JUST WAITING FOR SOMETHING BAD TO HAPPEN WHEN I AM ON THE INTERSTATE. *TR

TL* THE CONTACT OWNS A 2004 FORD F-150. THE CONTACT STATED THAT THE VEHICLE BEGAN TO VIOLENTLY SHAKE WHILE DRIVING 35 MPH. THE VEHICLE WAS MANEUVERED TO THE SHOULDER AND THE CONTACT NOTICED THAT THE REAR DIFFERENTIAL FAILED. THE DEALER MADE THREE ATTEMPTS TO DUPLICATE THE FAILURE. THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURE. NO REPAIRS WERE PERFORMED. THE FAILURE MILEAGE WAS 4,000 AND THE CURRENT MILEAGE WAS 62,000.

TRANSMISSION WILL NOT GO INTO REVERSE. *TR

I STARTED TO GET A VIBRATION IN THE REAR OF THE TRUCK AT 45 MPH. I HAD JUST REPLACED THE TIRES NOT LONG BEFORE AND THOUGHT THEY MIGHT BE OUT OF BALANCE. THEY ARE NOT. THEY HAVE BEEN CHECKED MANY MULTIPLE TIMES AND ROTATED. THE PROBLEM STILL EXIST. THE DEALER DOESN'T KNOW WHAT THE PROBLEM IS AND CLAIMS IT'S NOT THE DIFFERENTIAL OR REAR AXLE. I HAVE REPLACED THE BEARINGS, SEALS, GEAR LUBE AND REAR SHOCKS. NOW THERE IS A KNOCKING SOUND COMING FROM THE REAR END. IT IS A 4X2 AND HAS NOT BEEN DRIVEN HARD. THE VIBRATION, WHICH WAS ANNOYING AT FIRST, HAS PROGRESSIVELY GOTTEN WORSE. THE WHOLE BED OF THE TRUCK SHAKES WHEN I HIT 45 TILL ABOUT 55.*TR

STARTED HAVING PROBLEMS LAST YEAR WITH TRANSMISSION. OVERDRIVE WOULD GO OUT AND SOMETIMES TRANSMISSION WOULD NOT ENGAGE AT HIGHWAY SPEEDS. JULY OF THIS YEAR WAS AT A STOPLIGHT TRUCK WOULD NO MOVE , AFTER RACING ENGINE TRUCK MOVED , FAULT CODE SHOWED ON DASH. WHEN GOT TRUCK HOME REVERSE WOULD NOT ENGAGE, I FINALLY GOT IT TO ENGAGE INSTEAD OF GOING BACKWARDS IT WENT FORWARD. *TR

WAITING AT STOP LIGHT PROCEEDED ON GREEN ALL OF A SUDDEN BIG BANGING NOISE UNDERSIDE OF TRUCK STOPPED IN TRAFFIC BY TRAFFIC LIGHT LOOKED UNDER TRUCK TO SEE DRIVE SHAFT BROKE IN HALF CALL 911 TO HELP DIRECT TRAFFIC CALLED TOW CO. TO TOW VEHICLE TO REPAIR SHOP HEAD MECHANIC CONFIRMED DRIVE SHAFT BROKE IN HALF DUE TO RUST. DRIVE SHAFT CRACKED IN HALF AT THE MIDDLE AND NOT AT THE U JOINTS HEAD MECHANIC CONFIRMED TO ME AND ALSO THE DEALERSHIP WHERE I BOUGHT THE TRUCK SAID ITS THE FIRST FOR THEM OF THE RUST AND BREAKAGE.MY ISSUE IS THAT I HAD A HARD TIME FINDING A DRIVE SHAFT AND WAS TOLD NOTHING IN STOCK THEY HAD TO MAKE ONE SPECIAL. I HAD TO PAY THE PRICE ALSO WAS GLAD I WAS NOT DRIVING ON THE HWY WITH MY GRAND KIDS. MY ISSUE IS THAT I BELIEVE THE DRIVE SHAFT WAS FAULTY NOT A WEAR AND TEAR ISSUE LIKE FORD CUSTOMER SERVICE SAID. FURTHER MORE THEY SAID THEY CANNOT DO ANYTHING BECAUSE MY TRUCK WARRANTY EXPIRED. *TR

I STARTED MY TRUCK ONE DAY AND RECEIVED A "TRANS FAULT NO O/D" DASH CODE. THE VEHICLE HAS DRIVEN FINE AND SHIFTED FINE, BUT I WANTED TO TAKE IT TO THE DEALER TO HAVE IT LOOKED AT. THEY PULLED A CODE FOR THE TRANSMISSION TEMPERATURE SENSOR BUT SAID THEY NOTICED METAL IN THE TRANSMISSION PAN. THE RECOMMENDATION WAS A NEW TRANSMISSION ($3000) OR A REBUILT TORQUE CONVERTER. I WAS SUSPICIOUS THAT IT COULD BE SO SERIOUS AND CALLED A FAMILY MEMBER THAT WORKED WITH A MECHANIC AT ANOTHER FORD DEALER. HE MENTIONED REPLACING A TRANSMISSION IN A 2005 F-150 IN THE PAST SIX MONTHS FOR THE SAME SITUATION. I NOTICED SEVERAL RELATED TRANSMISSION ISSUE REPORTS AT CARCOMPLAINTS.COM AS WELL AS SEVERAL FORD FORUMS. FOR A TRUCK WITH LOW MILES, TRANSMISSION FLUID THAT ISN'T BURNT, AND 66% HIGHWAY MILES WITH NO TOWING, THIS IS UNBELIEVABLE AND A HUGE FINANCIAL BURDEN. *TR

WAITING AT A STOP LIGHT THAN PROCEEDED TO GO WHEN LIGHT TURNED GREEN ALL OF A SUDDEN BIG BANGING AND GRINDING NOISE COMING FROM UNDER TRUCK LOOKED UNDER AND SEES DRIVE SHAFT BROKE IN HALF POLICE WERE CALLED TO HELP DIRECT TRAFFIC AND CALLED TOW TRUCK! MECHANIC OF THE REPAIR SHOP TOLD ME WHY IN HIS REPORT THAT THE DRIVE SHAFT BROKE HE SAID THE DRIVE SHAFT HAD RUSTED IN THE MIDDLE TO CAUSE IT TO BREAK IN HALF!! MY SAFETY ISSUE IS I BOUGHT THE TRUCK BECAUSE ITS BIG I DRIVE MY GRAND KIDS IN IT NOW CAN YOU IMAGINE WHAT WOULD HAPPEN ON A HIGHWAY AT 55 MPH!!! EVERYONE I SPOKE TOLD ME THEY NEVER HEARD OF A DRIVE SHAFT BREAK AND RUST LIKE THAT ESPECIALLY ITS ONLY A 2004 MODEL!! CAN YOU HELP ME ON THIS ISSUE I HAVE WITH FORD! THANK YOU....... *TR

TRANSMISSION FAILED AND WAS REPLACED. REAR DIFFERENTIAL NEEDS TO BE REPLACED. *TR

TL* THE CONTACT OWNS A 2004 FORD F-150. WHILE DRIVING APPROXIMATELY 20 MPH, THE VEHICLE BEGAN TO DECELERATE. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC FOR DIAGNOSTIC WHERE THE MECHANIC STATED TO THE CONTACT THAT THE TRANSMISSION WOULD HAVE TO BE REPLACED. THE VEHICLE WAS REPAIRED. THE APPROXIMATE FAILURE MILEAGE WAS 69,000. UPDATED 03/23/12*LJ

THE CLUTCH PACK IN THE DRIVEN TRAIN REAR DIFFERENTIALS LOCK UP WHEN TURNING CORNERS AND HOWLS WHEN GOING DOWN THE ROAD. THESE FAILURES ARE SO COMMON ON FORD TRUCK THAT FORD IS NOW ADDING FRICTION MODIFIERS TO THE REAR DIFFERENTIALS TO REAR THE PROBLEM AND AFTERMARKET SUPPLIERS ARE MAKING REPLACEMENTS FOR THE CLUTCH PACK LIKE DETROIT LOCKER TO ELIMINATE THE PROBLEM. THIS LOCK UP ON WINTER SURFACES CAUSE THE WHEELS TO LOOSE TRACTION INCREASING THE POTENTIAL FOR ACCIDENTS. THE HOWLING SOUND IS ALSO A DRAG ON THE DRIVE TRAIN COMPONENTS, REDUCING MPG AND CAPABILITY OF THE VEHICLE TO HANDLE ADVERSE CONDITIONS. FORD HAS KNOWN ABOUT THIS PROBLEM FOR SEVERAL YEARS AND HAS DONE NOTHING TO FIX THE PROBLEM OR REIMBURSE OWNERS FOR THE COST OF REPAIR. ON MY TRUCK, TOTAL REAR END REPAIR COSTS HAVE EXCEEDED $3700. *TR

TRANSMISSION FAILED. ONE OWNER VEHICLE. FORD WILL NOT ACCEPT ANY RESPONSIBILITY EVEN THOUGH IT APPEARS THAT THIS IS DEFINITELY A PROBLEM FOR THIS YEAR TRUCK. *TR

TRUCK WOULD NOT START EVEN THOUGH LIGHTS, DASH INDICATORS, & RADIO CAME ON. CHECKED UNDER HOOD & THEN PLACED IN NEUTRAL TO TRY & START. VEHICLE STARTED IN NEUTRAL. PLACED VEHICLE IN PARK AND UPON TAKING FOOT OFF BRAKE, VEHICLE LURCHED BACKWARD (IN REVERSE) ALMOST GOING OVER AN EMBANKMENT WHEN I SLAMMED BRAKES. VEHICLE SHIFT INDICATOR SHOWED IT IN PARK BUT, TRANSMISSION WAS ACTUALLY STILL IN REVERSE. COULD NOT GET SHIFT TO ENGAGE INTO PARK. PLACED VEHICLE INTO GARAGE WITH EMERGENCY BRAKE SECURED UNTIL COULD DETERMINE PROBLEM. RESEARCH INDICATED FORD HAD A RECALL (RECALL - #97V171000) FOR THIS EXACT ISSUE ON 1997-1998 MODELS ONLY. BUT, APPARENTLY IT IS STILL A PROBLEM ON LATER MODELS. COULD NOT FIND A RECALL ON 2004 MODEL. NOTE THAT THIS CONDITION ALMOST CAUSED A SERIOUS ACCIDENT. *TR

STARTED MY TRUCK AS USUAL TO GO TO WORK, PUT IT IN REVERSE AND IT WAS LIKE I PUT IT IN NEUTRAL, NO ENGAGEMENT AT ALL. GLAD I WASN'T IN A SITUATION WHEN THIS HAPPENED THAT COULD HAVE PUT MYSELF OR SOMEONE ELSE IN DANGER. FORD KNOWS THEY HAVE A PROBLEM, IT IS WIDE SPREAD. SURE MY TRUCK HAS 124000 MILES ON IT BUT THE TRANSMISSION MALFUNCTION LIGHT HAS BEEN GOING ON AND OFF FOR THE LAST 70000 MILES AND THE DEALER SAID THEY COULD NOT FIND ANY TROUBLE CODES OR MALFUNCTIONS DURING THIS PERIOD. I CAN REV MY MOTOR TO ABOUT 2000 RPM AND IT WILL FINALLY GENTLY START TO ROLL INTO REVERSE BUT MY FAILSAFE MODE ENGAGES, CHECK ENGINE LIGHT COMES ON AND THE MOTOR STUMBLES BADLY UNTIL I PUT THE VEHICLE IN DRIVE GEAR AND GO ABOUT 2 MILES AT WHICH TIME THE FAILSAFE MODE GOES OFF AND IT SMOOTHES OUT. FOR THE MOST PART MY VEHICLE HAS BEEN DEALER MAINTAINED. *TR

THE REAR DIFFERENTIAL IS MAKING A CHATTERING NOISE AT LOW SPEEDS. IT HAS A POSI-TRAC REAR DIFFERENTIAL, AND I CAN FEEL A 'STOP AND GO' TYPE ACTION AS I AM DRIVING IN A STRAIGHT LINE AT LOW SPEEDS. EVEN AFTER I ADDED A LIMITED SLIP ADDITIVE, THE PROBLEM IS STILL THERE. IT TENDS TO BE WORSE AFTER A COLD START, AND WHEN I AM GOING UP HILLS OF AFTER I GO OVER A SPEED BUMP. *TT

(SUMMER, 2007, 28K) AT HIGHWAY SPEED (60 MPH) HUGE GRINDING NOISE AND VIBRATION, LIGHT IN DASH CAME ON BY ITSELF SHOWING, "4X4" TURNED ON, SLOWED TO 20 MPH, HUGE CLUNK AS 4 WHEEL DRIVE SYSTEM ENGAGED WITHOUT DRIVERS REQUESTING IT TO ENGAGE. FORD ROADSIDE ASSISTANCE WAS CONTACTED AND FORD TOWED VEHICLE TO FORD DEALER, FORD DEALER "REPROGRAMMED" SOMETHING, SAID IT HAD MOISTURE IN A SENSOR, CAUSING THE 4X4 TO TRY TO ENGAGE. (SEPTEMBER 12, 2011, 69,980 MILES) AT HIGHWAY SPEED, (58 MPH) DURING MILD ACCELERATION, 1500 - 1800 RPM, A MILD GRINDING SOUND FROM UNDER FRONT END, BY TAKING FOOT OFF GAS PEDDLE THEN REAPPLYING GAS THE GRINDING SOUND STOPS. CONTACTED FORD DEALER, THEY SAID DRIVE IT IN, CONTACTED FORD CUSTOMER SATISFACTION DEPARTMENT, THEY SAID TO HAVE DEALER CHECK IT OUT, FORD DEALER INVESTIGATED AND SAID THERE IS A PROBLEM WITH VOLUME OF VACUUM THAT IS NECESSARY TO PREVENT THE 4X4 SYSTEM FROM ENGAGING WHILE DRIVING ON THE HIGHWAY AT HIGHWAY SPEEDS. FORD DEALER INDICATED THAT IT MAYBE UNSAFE TO DRIVE LIKE THIS AND THAT THIS IS NORMAL FOR THE VACUUM SYSTEM TO FAIL LIKE THIS, REPRESENTATIVE AT FORD CUSTOMER SATISFACTION DEPARTMENT SAID THAT THEIR DEALER KNOWS HOW TO DIAGNOSE AND CURE PROBLEMS BEST, AND SINCE THE VEHICLE HAS MORE THAN 36K IT IS NOT A CONCERN TO FORD. MY CONCERN IS THAT STEEL GEARS THAT ARE SUGGESTED TO BE ENGAGED AT A WALKING PACE ON SOFT PAVEMENT ARE AUTOMATICALLY FORCING THEMSELVES TO LOCK TOGETHER ON DRY PAVEMENT AT 60 MPH, AND FORD AND THE FORD DEALER SHOW LITTLE CONCERN FOR THIS CONDITION SINCE THE VEHICLE HAS MORE THAN 36K AND SINCE NO EXTENDED WARRANTY PURCHASED FROM THE DEALERSHIP. *TR

ORIGINAL OWNER OF TRUCK, 37,000 MILES. TERRIBLE VIBRATION/SHUDDER WHEN TURNING. NOW IT ALSO DOES THIS DRIVING DOWN THE ROAD AT OVER 45 MPH. FEELS LIKE IT IS GOING TO FREEZE UP. WAS TOLD IT IS ISSUES WITH THE DIFFERENTIAL. THIS IS WRONG FOR A VEHICLE WITH LOW MILES. PLEASE INVESTIGATE. I'VE READ LOTS OF OTHER PEOPLE HAVE HAD THE SAME ISSUE WITH THIS MODEL. *TR

SEVERE SHUDDERING FROM REAR END DURING LOW SPEED TURNS.

STARTED TO NOTICE SHAKING WHEN TURNING TO RIGHT, THEN LEFT AND AS SOON AS I STARTED TO MOVE FORWARD. THIS IS THE THIRD TIME I HAVE HAD THIS FAILURE AND EACH TIME THE DEALER HAS REPLACED THE REAR END CUTCHES AND ALL BEARINGS IN THE REAR END HOUSING. THE LAST TIME IT TOTALED OVER $900.00 AND 17,000 MILES AFTER IT IS HAPPENING AGAIN. THIS IS APPARANTY A COMMON PROBLEM SINCE THE DEALERS STOCK AL REQUIRED PARTS AND ARE NOT UNAWARE OF THIS FAIURE. I HAVE HAD THIS SAME FAIURE HAPPEN 3 TIMES IN 70,000 MILES AND THE MORE PEOPLE I TALK TO THE MORE I FIND THAT MOST HAVE HAD AT LEAST 1 FAIURE. FORD NEEDS TO STEP UP AND CORRECT A PROBLEM THAT EXISTS YET TODAY IN 2011 MODELS. *TT