2004 Ford F-150 Structure

THE FRAME UNDER MY F150 IS RUSTED THROUGH. I ONLY HAVE 81K MILES ON IT AND I DON'T UNDERSTAND WHY THE FRAME IS RUSTING SO BADLY. IT HAS ALREADY COST ME 2,400 TO HAVE A CERTIFIED WELDER REPLACE SOME OF THE SECTIONS THAT WERE RUSTED OUT. I KNOW JUST FOUND ANOTHER PART OF THE FRAME THAT IS RUSTED UNDER THE LEAF SPRING. THAT IS NOW GOING TO COST ME ANOTHER $500.00.

WHEN IT RAINS WATER COMES IN AND DRIPS ON THE PASSENGER SIDE REAR SEAT. I HAVE REPLACE THE THIRD BRAKE LIGHT LENS TWICE AND THE REAR WINDOW. I HAVE READ FORUMS AND IT SEEMS LIKE THIS PROBLEM IS COMMON. I HAVE A TRUCK THAT SMELLS LIKE MILDEW. I HAVE TO DRIVE IT NOW WITH THE INTERIOR PULLED OUT. *TR

TL* THE CONTACT OWNS A 2004 FORD F-150. THE CONTACT STATED THAT THERE WAS RUST FORMING ON THE REAR DRIVER AND PASSENGER SIDE TIRE WELLS. THE FAILURE RECURRED CONTINUOUSLY. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC WHERE IT WAS DIAGNOSED THAT THE ENTIRE REAR PANEL NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 84,800.

THE FRAME OF MY 2004 F150 IS ALMOST COMPLETELY ROTTEN FROM THE FRONT OF THE LEAF SPRING ALL THE WAY UP TO THE DRIVERS DOOR. THE BED SUPPORTS ARE ALSO ROTTED COMPLETELY OFF MAKING THE BED UNSAFE AND UNABLE TO USE.

TL* THE CONTACT OWNS A 2004 FORD F-150. THE CONTACT STATED THAT THE FRAME MEMBERS WERE EXTREMELY CORRODED. THE VEHICLE WAS NOT TAKEN TO A DEALER OR INDEPENDENT MECHANIC. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE FAILURE AND CURRENT MILEAGE WAS 109,000.

MY TRUCK IS ONLY 10 YEARS OLD AND THE FRAME IS ALL ROTTEN OUT I THINK IT IS A VERY SERIOUS THING IF YOU ARE DRIVING ALONG AND IT BREAKS. *TR

WHEN DRIVING AT RELATIVELY LOW SPEED, THE HOOD LIFTED VIOLENTLY. THE DRIVER WAS ABLE TO STOP THE TRUCK SAFELY. THE PORTION OF THE HOOD WHICH SECURES THE HOOD STRIKER GAVE WAY, ALLOWING THE HOOD TO OPEN SO VIOLENTLY THAT THE GRILLE FLEW OFF. THE HOOD WAS PROPERLY CLOSED/LATCHED BEFORE THE INCIDENT, AND THE STRIKER WAS STILL IN THE LATCH (COMPLETE WITH PIECES OF ALUMINUM TORN OFF OF THE HOOD) AFTER THE INCIDENT. IT APPEARS THAT GALVANIC CORROSION (STEEL STRIKER ON ALUMINUM HOOD) LIKELY CAUSED THE ISSUE. SINCE THIS TRUCK IS IN A FLEET, THE REMAINDER OF THE F-150S OF THE SAME BODY STYLE (MY2008 AND OLDER) WERE CHECKED, 65 OF 580 TRUCKS HAD EITHER CRACKING OR CORROSION AROUND THE STRIKER BAR WHICH MAY LEAD TO THIS ISSUE. NOTE - THIS IS AN ONTARIO, CANADA FLEET BUT THESE ISSUES LIKELY AFFECT US-SOLD VEHICLES. *TR

RUST IN THE REAR PASSENGER QUARTER PANEL DUE TO A KNOW FACTORY DEFECT OF A RUBBER PAD BEING INSTALLED IMPROPERLY, CONTACTED FORD ABOUT THE PROBLEM, THEY REFUSE TO REPAIR OR ASSIST IN ANY WAY. *TR

REAR PASSENGER SIDE QUARTER PANEL RUST DUE TO RUBBER PANEL BEING IMPROPERLY INSTALLED AT FACTORY. FULL RUST THROUGH IN THE MIDDLE OF THE PANEL, FROM THE INSIDE OUT. *TR

IS ANYBODY DOING ANYTHING ABOUT THE FORD WINDOW REGULATOR PROBLEM. OVER THE YEARS ALL OF MY SONS WINDOWS HAVE ALL FALLEN DOWN. AT TIMES LEAVING THE KIDS WITH EXPOSURE TO WHOEVER PASSES BY...THIS IS NOT SAFE. TWO WINDOWS FAILED ON THE SAME DAY. TRIED TO CALL FORD AND GOT NO REASONABLE RESPONSE... *JS

I AM THE OWNER OF A 2004 F-150. THIS IS MY FIFTH FORD PRODUCT ON A ROW, TWO OF THEM PURCHASED NEW. RECENTLY THE PASSENGER SIDE REAR WINDOW REGULATOR FAILED, CAUSING THE WINDOW TO SLIDE DOWN INTO THE DOOR. IN DECEMBER. I PURCHASED A REPLACEMENT REGULATOR/MOTOR ASSEMBLY AND JUST FINISHED THE INSTALLATION. WHEN I EXAMINED THE OLD UNIT I FOUND THE OPERATING CABLE INCORRECTLY SPOOLED ONTO THE PRIMARY PULLEY. WHEN THE CABLE OVERLAPPED ITSELF THE END PULLED OUT OF THE LIFTING BLOCK. WHEN I WAS SEARCHING FOR INFORMATION ABOUT THE REPLACEMENT PROCEDURE, I CAME ACROSS NUMEROUS WEBSITES DETAILING COMPLAINTS ABOUT THE FAILURE OF F150 WINDOW REGULATORS. THIS LEADS ME TO BELIEVE THAT THE PROBLEM IS DUE TO A FAULTY DESIGN AND SHOULD BE ADDRESSED BY FORD WITH A REDESIGNED PART AND A RECALL TO REPLACE EXISTING UNITS. I WILL BE CONTACTING MY CONGRESSMAN, ABOUT THIS EXPENSIVE AND ANNOYING DEFECT.WEBSITES DETAILING THE ISSUE ARE LISTED BELOW: HTTP://WWW.JEREBEASLEYREPORT.COM/2011/08/PROBLEMS-WITH-FORD-F-150-WINDOW-REGULATORS/ HTTP://WWW.CARCOMPLAINTS.COM/FORD/F-150/2005/WINDOWS_WINDSHIELD/POWER_WINDOW_REGULATOR_FAILURE.SHTML INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6) *TT

TL* THE CONTACT OWNS A 2004 FORD F-150. THE CONTACT STATED THAT THE VEHICLE FRAME WAS NOT PROPERLY ALIGNED WITH THE BODY OF THE VEHICLE. THE CONTACT DISCOVERED THE FAILURE WHEN HE NOTICED THAT THE REAR TIRES WERE PROTRUDING OUTWARD ABNORMALLY. THE VEHICLE WAS TAKEN TO THE DEALER WHO DID NOT DIAGNOSE THE FAILURE. THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURE AND THE VEHICLE WAS NOT REPAIRED. THE FAILURE MILEAGE WAS 83,000 AND CURRENT MILEAGE 99,000.

THERE ARE FACTORY MADE SQUARE HOLES UNDER THE SIDES OF THE TRUCK. WHEN IT RAINS, THE WHEELS SPLASH WATER INTO THESE HOLES. THE WATER COMES UP INTO THE FLOOR OF THE TRUCK. INSIDE THE TRUCK THERE IS A PLASTIC PANEL ALONG THE EDGES OF THE DOOR THAT POPS OUT. IT IS THE SQUARE HOLES THAT IT POPS OUT OF THAT THE WATER COMES IN THROUGH. I CAN STICK MY FINGER FROM THE UNDER OUTSIDE IF THE TRUCK AND SEE THEM THRU THE HOLES THAT HOLD THE PLASTIC PANELING ON THE INSIDE. THE WATER COLLECTS ALONG WHERE ALL THE ELECTRICAL WIRES ARE RUNNING AND SOAKS UP INTO THE CARPET. *TR

I PURCHASED A USED 2004 FORD XL F 150 4 X 4 WHCIH WAS MANUFACTURED IN THE U.S. BUT SOLD IN CANADA SER # [XXX]. THE TRUCK HAS A CONSTANT VIBRATION AT 50 MPH AND I HAVE SPENT $2,500 TRYING TO FIX IT WITH OUT SUCCESS. WHAT REALLY SCARED ME WAS THAT ON ONE OCCASSION THE VIBRATION INSTANTLY BECAME SO SEVERE, THAT I ALMOST LOST CONTROL OF THE TRUCK AND HAD TO PULL OFF THE ROAD.. ARE THERE OTHER COMPLAINTS WITH THIS SAME PROBLEM? ARE YOU AWARE OF WHAT CAUSES THIS PROBLEM? MY INVESTIGATION LEADS ME TO BE CONVINCED THAT IT IA AN INHERENT FORD MANUFACTURING DEFECT. ANYTHING THAT YOU HAVE THAT WOULD SUPPORT MY BELIEF WOULD BE OF GREAT ASSISTANCE, OR ANY INFO AT ALL WOULD HELP. I HAVE SUED FORD AND THE TRIAL IS JUNE 12 A FEW WEEKS FROM NOW SO IF YOU HAVE ANYTHING PLEASE FORWARD IT ASAP [XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6). *TR

2004 FORD F-150 SUPERCREW WINDOW REGULATOR FAILURE. DRIVING SAFETY HAZARD, DISTRACTIONS DURING DRIVING AT HIGHWAY SPEEDS. COULD LEAD TO POSSIBLE SEVERE INJURY OR DEATHS. SECOND TIME IN 10,000 MILES. POOR DESIGN AND FLIMSY PARTS USED BY FORD. EXPENSIVE REPAIR. *TR

THE PAINT ON MY 2004 FORD F150 IS BUBBLING AND RUSTING ON THE REAR QUARTER PANEL AND FORD REFUSES TO FIX IT DESPITE THE FACT THAT ITS A KNOWN ISSUE. *TR

I WAS DRIVING DOWN I-35 IN THE RAIN WHEN A LOUD BANG STARTLED ME. I NOTICED RIGHT AWAY THAT MY 2 YEAR OLD GIRL WAS CRYING AND HER WINDOW WAS DOWN WITH RAIN POURING IN. I HAD TO PULL OVER IN TRAFFIC ON THE INTERSTATE IN THE RAIN TO TRY AND FIX THE PROBLEM. THE BANG HAD SCARED HER AND SHE WAS GETTING WET. WE MOVED THE CARSEAT OVER TO THE OTHER SIDE AND I WAS ABLE TO PULL THE WINDOW UP. MY WIFE HAD TO HOLD IT UP WITH HER HAND ALL THE WAY HOME. FROM THE SOUND OF THAT BANG I AM SUPRISED THE WINDOW DIDN'T SHATTER. IF IT WOULD HAVE MY LITTLE GIRL COULD HAVE LOST AN EYE OR BEEN CUT BADLY. I WAS ABLE TO LOOK AT IT TODAY AND IT SEEMS THAT THE LITTLE CABLE THAT PULLS THE WINDOW UP HAS BROKEN LOOSE FROM THE PLASTIC PULLEY IT WINDS UP ON. I HAVE DONE A BIT OF RESEARCH TONIGHT AND THIS IS A VERY COMMON PROBLEM. FORD KNOWS ABOUT THE PROBLEM SINCE THEY TEND TO KEEP PLENTY OF THESE WINDOW REGULATORS IN STOCK. MANY OF THE PEOPLE ON THESE WEBSITES HAVE HAD MULTIPLE FAILURES. ONE HAD REPLACED ALL FOUR WINDOW REGULATORS ON HIS F-150. THE PROBLEMS STARTED WHEN THEY CHANGED FROM A SOLID METAL SCISSORS TYPE TO THIS MOUSE TRAP LOOKING THING WITH PLASTIC PULLEYS. THE ENGINEER THAT DESIGNED THIS THING SHOULD HAVE HIS P.E. LICENSE REVOKED. IT IS A TERRIBLE PIECE OF ENGINEERING. FORD SHOULD FIX THIS PROBLEM AND DO A RECALL ON THIS PROBLEM BEFORE ONE OF THESE WINDOWS SHATTERS AT HIGHWAY SPEED AND THROWS GLASS INTO THE FACE OF A SMALL CHILD. *TR

OWN A FORD F-150 YEAR 2004 AND A WINDOW IN ONE OF THE DOORS HAS FALLEN. THIS TIME IT WAS THE BACK PASSENGER WINDOW THAT SCARED MY WIFE WHILE DRIVING WHEN IT FELL TO THE BOTTOM OF THE INSIDE DOOR. I HAVE ALREADY HAD EVERY WINDOW REPLACED ONCE AND THE DRIVER WINDOW TWICE, AND THIS WILL BE TWICE FOR THIS DOOR, IN TOTAL IT HAS BEEN 6 TIMES WINDOWS HAVE FELL. THIS REQUIRES A RECALL. WHEN DRIVING THIS CAN BE A SAFETY HAZARD WHEN YOU THINK SOMEONE HAS SHOT YOUR WINDOW OR SOMETHING HAS CRASHED BEHIND YOU AND IT HAPPENS THAT YOUR WINDOW HAS FELL DOWN MAKING LIKE A CRASHING SOUND. IT CAN BE VERY FRIGHTENING WHILE DRIVING AND COULD CAUSE A SAFETY PROBLEM. AND BEING THE 6TH TIME, NEEDS REDESIGNED PROPERLY. *TR

A RUST AND PANEL PERFORATION ON THE RIGHT BOX OUTER OF 2004 FORD F-150'S. RUST DEVELOPS UNDER THE PAINT ON THE RIGHT BOX OUTER PANEL BEHIND THE RIGHT REAR WHEEL OPENING AND ABOUT AT THE CENTER FOR HEIGHT OF THE PANEL. THIS HAS HAPPENED ON SEVERAL TRUCKS OF FRIENDS AS WELL AS MY TRUCK. THE DEALERS ARE SAYING IT IS BECAUSE THERE IS A BRACE WELDED TO THE PANEL DURING PRODUCTION AND THE WELD ID THE ROOT OF THE RUST. FORD IS SAYING THAT THEY HAVE NO RESPONSIBILITY AND WON'T HELP TO COVER THE COST OF REPAIR. AS A RETIRED ENGINEER FROM ANOTHER MANUFACTURER AND ALSO HAVING WORKED FOR THE OTHER OF THE BIG THREE, I KNOW THAT WELDING DESTROYS THE RUST PREVENTABLE ON THE SHEET METAL. THE WELD PROCESS FLOWS GALVANIZE AWAY FROM THE WELD AREA AND THEN HELPS TO PRECIPITATE THE RUST TO FORM. THE TRUCKS HAVE ALL HAD NO PAINT DAMAGE OR ACCIDENTS IN THE AREA OF THE RUST FORMING. BUBBLES APPEAR UNDER WHAT LOOKS LIKE GOOD SOLID PAINT AND THEN BREAKS THROUGH AND SHOWS RUSTED METAL. WITH THE NUMBER OF TRUCKS HAVING THE SAME ISSUE IT LOOKS TO BE A SYSTEMIC ISSUE FROM THE MANUFACTURING PROCESS. THE OTHER TWO DOMESTIC MANUFACTURERS WILL NOT WELD ON WHAT IS KNOWN AS A CLASS A OUTER PANEL SURFACE. A CUSTOMER?S LINE OF SIGHT WALKING UP TO A VEHICLE IS CONSIDERED TO BE CLASS A SURFACE. THERE SHOULD NOT ANY BE WELDS ON IT AND LITTLE OR NO METAL FINISH. THAT, METAL FINISHING, ALSO WOULD REMOVE THE RUST PROTECTING GALVANIZE. ANOTHER CONCERN IS THAT SOME STATES HAVE ANNUAL INSPECTIONS THAT WOULD CAUSE THIS TO HAVE TO BE REPAIRED. THE OWNER WOULD BE STUCK WITH THIS COST THROUGH NO FAULT OF HIS OR HER OWN. *TR

NOTED THAT DRIVERS DOOR DID NOT LINE UP CORRECTLY AS BEFORE. BODY SHOP NOTED THAT DOOR HAD EVIDENCE OF A WELD FAILING IN AREA WHERE THE HINGES INSERT INTO THE DOOR. THAT WAS 2/27/06 AND TRUCK HAD APPROX. 62,000 MILES ON IT. THEN THIS SPRING (2008) I BEGAN TO NOTICE THAT THE DOOR BEGAN TO FIT EVEN WORSE THAN BEFORE AND PUT MY CAMERA BETWEEN DOOR AND DOOR POST TO TAKE PHOTOS AS MY HEAD WOULD NOT FIT IN THAT AREA TO GET A GOOD VIEW. PHOTOS SHOWED NUMEROUS CRACKS HAD DEVELOPED IN AREA OF HINGE INSERTIONS ON THE DOOR AND THE ENTIRE DOOR END HAD WARPED OUT OF SHAPE IN AREA OF HINGE ATTACHMENTS. NOW TRUCK HAS 113,000 MILES AND WHEN MY DEALER SPOKE TO CORPORATE FORD, THEY WERE TOLD THAT THE WARRANTY FOR BODY DEFECTS HAD EXPIRED AT 36,000 MILES. I SPOKE TO CUSTOMER ASSISTANCE AND WAS TOLD THEY WOULD DO NOTHING AS THERE WAS NO RECALL ISSUED. THAT WAS SOMETIME IN MAY 2008. MY CONTENTION IS THAT THIS IS A SAFETY ISSUE NOT A BODY DEFECT AND PUTS ME IN DANGER SHOULD THERE BE A CRASH. THIS DOOR WILL NOT PROTECT ME IN A SIDE IMPACT AS IT IS NOT PROPERLY ATTACHED TO THE VEHICLE. *TR

I PURCHASED A 2004 FORD F150 SUPERCREW FX4 IN DECEMBER OF 2007. SINCE OWNING THE VEHICLE I HAVE FOUND THAT THE HOOD SHAKES VIOLENTLY ON THE FREEWAY AT SPEEDS OF OVER 50 MPH, OFTEN SCARING EACH INDIVIDUAL IN THE TRUCK. I HAVE NOTICED A LOUD IRRITATING NOISE COMING FROM THE WINDSHIELD AREA, UNABLE TO PIN POINT EXACTLY WHAT IS CAUSING IT., ALSO CAUSING ME TO BE A LITTLE NERVOUS THAT ONE DAY IT WILL COME FLYING IN AT ME. THESE ARE THE TWO MAJOR PROBLEMS WITH THE VEHICLE, THE MINOR ISSUE IS THE 12V OUTLET NOT WORKING AT ALL. I HAVE TAKEN THE VEHICLE BACK TO THE DEALERSHIP SEVERAL TIMES IN AN ATTEMPT TO HAVE THESE ISSUES LOOKED INTO. MY LAST VISIT TO THE DEALERSHIP RESULTED IN THEM KEEPING THE TRUCK AND SUPPLYING US WITH A RENTAL WHILE THEY LOOKED INTO THE ISSUES AND RESOLVED THEM. SINCE HAVING THE TRUCK BACK THE WINDSHIELD OR WHATEVER IS CAUSING THE IRRITATING NOISE HAS ONLY GOTTEN LOUDER, THERE IS NO DIFFERENCE CONCERNING THE HOODS VIOLENT SHAKING, AND THE 12V OUTLET STILL DOES NOT WORK. I'VE COME TO THE CONCLUSION THAT GOING TO THE DEALERSHIP IS A WASTE OF TIME AND ENERGY ONLY CAUSING MORE STRESS TO MY LIFE WITH HIGHER INSECURITIES CONCERNING MY TRUCK. I REALLY WOULD LIKE TO FIND AS MUCH INFORMATION CONCERNING THE HOOD AND WINDSHIELD ISSUES SO I CAN ENSURE MY SAFETY AND THOSE OF WHOM ARE RIDING WITH ME. THIS TRUCK IS A NICE TRUCK, MY DREAM TRUCK, AND ALL I WANT IS TO MAKE SURE THAT I'M SAFE WHILE I'M DRIVING IT. *TR

FINGER CRUSHED UNDER DRIVERS DOOR HANDLE. THE LEVER THAT OPENS THE REAR DOOR OF THE 2004 - F150 WHILE TRYING TO OPEN IT FROM THE INSIDE PASSENGER SEAT. SURGERY NEEDED TO PLACE TIP OF FINGER BONE BACK INTO PLACE. *TR

NOTICING WATER LEAK FROM EITHER THE 3RD BRAKE LIGHT OR THE TOP OF THE REAR WINDOW INTO THE CAB OF THE TRUCK. REAR WINDOW IS NOT THE STYLE THAT OPENS. *JB

DT*: THE CONTACT STATED THAT THE SPEEDOMETER AND GAUGES FROM THE DASHBOARD PANEL ARE UNREADABLE DURING THE DAY. THE DASHBOARD BACKGROUND IS BLACK WITH RED NEEDLES AND NUMBERS. THE DEALER DETERMINED THAT THE PANEL COULD NOT BE CHANGED.*AK THE CONSUMER STATED HE MUST USE A FLASH LIGHT TO SEE HOW FAST HE IS GOING, OR TO READ ANY OTHER GAUGES. UPDATED 07/25/06. *JB

POOR PAINT FROM FACTORY, RUNS IN CLEAR COAT. THEY ONLY WANTED TO REPAINT IT AND THE SHOP THEY WANTD TO USE WAS NOT EVEN A FORD SHOP. 2004 F-150. JOPLIN FORD LINCOLN MERCURY WAS THE DEALER.