2004 Ford F-150
Safety record from NHTSA: recalls, owner complaints, investigations and service bulletins.
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Vehicles › Ford › F-150 › 2004
These records cover every 2004 Ford F-150. To see whether one car still needs a recall repair, decode its VIN or check it with NHTSA.
Recalls
16 recalls name the 2004 Ford F-150. Newest first.
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…
Risk and remedy
Risk
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.
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 repairs will be performed free of charge. the safety recall began on september 16, 2011. owners may contact ford motor company customer relationship center at 1-866-436-7332. ford's recall campaign number IS 11s21
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…
Risk and remedy
Risk
The driver side frontal air bag could inadvertently deploy increasing the risk of injury or loss of vehicle control if occurring while in motion.
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 contact the ford motor company customer relationship center at 1-866-436-7332.
Dope, inc. IS recalling 42,540 combination corner and bumper lamp assemblies of various part numbers sold for use as aftermarket equipment for various passenger vehicles. these headlamps fail to conform to the requirements of federal motor vehicle safety standard no. 108, "lamps, reflective devices, and associated equipment." these lamps do not contain…
Risk and remedy
Risk
Decreased lighting visibility may result in a vehicle crash.
Remedy
Dope, inc. Will notify owners and offer a full refund for the noncompliant combination lamps. the safety recall began on july 28, 2009. owners may contact dope, inc. At 1-626-272-1798.
Sabersport IS recalling 16,270 combination corner and bumper lamp assemblies of various part numbers sold for use as aftermarket equipment for various passenger vehicles. these headlamps fail to conform to the requirements of federal motor vehicle safety standard no. 108, "lamps, reflective devices, and associated equipment." these lamps do not contain…
Risk and remedy
Risk
Decreased lighting visibility may result in a vehicle crash.
Remedy
Sabersport will notify owners and offer a full refund for the noncompliant combination lamps. the safety recall began on may 11, 2009. owners may contact sabersport at 1-909-598-7589.
Certain spyder headlamp replacement assemblies sold for use on 2004 through 2007 ford F150 pickup trucks. during production, the headlamps were internally misaligned and they fail the photometry requirements of federal motor vehicle safety standard no. 108, lamps, reflective devices, and associated equipment.
Risk and remedy
Risk
The purpose of this standard IS to reduce traffic crashes and deaths and injuries by providing adequate illumination of the roadway.
Remedy
Spyder will notify owners and offer a full reimbursement for any noncompliant headlamps. the recall IS expected to begin during november 2007. owners can contact spyder at 866-558-4264.
Certain headlamp assemblies imported and sold as aftermarket equipment by sonar auto parts for use on 2004-2007 ford F150 pickup trucks. during production, the headlamps were internally misaligned and they fail the photometry requirements of federal motor vehicle safety standard no. 108, lamps, reflective devices, and associated equipment.
Risk and remedy
Risk
The purpose of this standard IS to reduce traffic crashes and deaths and injuries by providing adequate illumination of the roadway.
Remedy
Sonar will notify owners and offer a full reimbursement for any noncompliant headlamps. the recall began on december 14, 2007. owners can contact sonar at 866-558-4264.
Certain eagle eyes headlamp assemblies, p/nos. Fr390-b001l and fr390-b001r, sold for use as replacement equipment for the above listed passenger vehicles. the thickness IS unstable inhibiting the performance of the upper and lower beams which fails to conform to the photometric requirements of federal motor vehicle safety standard no. 108, lamps…
Risk and remedy
Risk
Decreased lighting visibility may result in a vehicle crash.
Remedy
Eagle eyes will notify owners and offer reimbursement for any noncompliant headlights. the recall began on november 6, 2007. owners may contact eagle eyes at 1-800-568-1098.
Certain cequent 90 degree 7-WAY right angle adaptors sold by distributors in tow packages for aftermarket sales to tow 5TH wheel rv travel trailers. due to incorrect wiring of the harness, the trailer lights may not operate properly.
Risk and remedy
Risk
If the trailer lights are not working properly, a vehicle crash can occur.
Remedy
All of the defective tow packages are still at the distributor level and have not been sold to any consumers.
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.
Risk and remedy
Risk
This could result in an underhood fire.
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. the recall began on august 13, 2007, and mailing completed by september 19, 2007. owners may contact ford at 1-888-222-2751.
Certain tradesonic combination lamps sold as replacement lamps for use on the above listed passenger vehicles. combination lamps not equipped with amber side reflectors fail to conform with the requirements of federal motor vehicle safety standard no. 108, lamps, reflective devices, and associated equipment.
Risk and remedy
Risk
Lack of amber side reflectors in the lamps will decrease lighting visibility to other drivers and may possibly result in a vehicle crash.
Remedy
Tradesonic will notify owners and replace the lamps free of charge. the recall IS expected to begin during july 2006. owners may contact tradesonic at 626-934-8884.
Certain aai motorsports combination lamps sold as replacement lamps for use on the above list passenger vehicles. combination lamps not equipped with amber side reflectors fail to conform with the requirements of federal motor vehicle safety standard no. 108, "lamps, reflective devices, and associated equipment."
Risk and remedy
Risk
Lack of amber side reflectors in the lamps will decrease lighting visibility to other drivers and may possibly result in a vehicle crash
Remedy
Aai motorsports will notify owners and replace the lamps free of charge. the recall began on august 1, 2006. owners may contact aai motorsports at 909-923-9188.
Certain aftermarket fuel filters sold under the purolator brand name, p/n f65277, shipped from january 16 through june 2, 2006, for use on the above listed passenger vehicles. due to incorrect design, the quick connectors may not fully seat with the tube interface, even though the person making the connection may believe that the quick connector IS fully…
Risk and remedy
Risk
Failure of this connection could lead to fuel spillage and, in the presence of an ignition source, a fire could occur.
Remedy
Ufi will notify owners and replace the filters free of charge. the recall began on august 4, 2006. owners may contact ufi filters USA at 800-230-5876.
Certain eagle eyes headlamps, p/nos. Fr208-b101r, fr208-b101l, fr208-b001r, and fr208-b001l, sold for use as replacement equipment for the passenger vehicles listed above. these headlamps fail to conform to the photometric requirements of federal motor vehicle safety standard no. 108, lamps, reflective devices, and associated equipment.
Risk and remedy
Risk
Decreased lighting visibility may result in a vehicle crash.
Remedy
Sabry lee will notify owners and offer full credit for any noncompliant headlamp. the recall IS expected to begin on june 14, 2006. owners may contact sabry lee account executive at 1-866-467-2279.
Certain anzo combination headlamp assemblies sold as replacement lamps for use on certain passenger vehicles. some combination lamps are not equipped with amber side reflectors which fail to conform to federal motor vehicle safety standard no. 108, "lamps, reflective devices, and associated equipment."
Risk and remedy
Risk
Without the amber reflectors, the vehicle will be poorly illuminated, possibly resulting in a vehicle crash.
Remedy
Anzo will notify owners and replace the headlamps free of charge. the recall began may 9, 2006. owners may contact anzo USA at 909-468-3688.
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.
Risk and remedy
Risk
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.
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.
Risk and remedy
Risk
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.
Owner complaints
2,029 complaints75 involved a crash40 involved a fire74 injuries6 deaths
What owners report most
Latest complaints
- Air bags
Vehicle was in an accident with major front and damage and none of the airbags deployed
- Air bags · Seat belts
The contact owns a 2004 Ford F-150. The contact stated that the seatbelt pretensioners for all seats failed, and the frontal airbags for the driver seat and front passenger seat were inoperable. The seatbelt warning light illuminated. The vehicle was taken to an independent mechanic, where it was…
The contact owns a 2004 Ford F-150. The contact stated that the seatbelt pretensioners for all seats failed, and the frontal airbags for the driver seat and front passenger seat were inoperable. The seatbelt warning light illuminated. The vehicle was taken to an independent mechanic, where it was diagnosed with faulty seatbelt pretensioners. A dealer was contacted and informed that parts were unavailable for the failure. The manufacturer was not made aware of the failure. The failure mileage was approximately 49,800.
- Unknown or other
Rear-end. The rear drivers side tire fell off while driving on a side street. With no noise or wobble or evidence of a problem. 2 days earlier my family and I were going 70 on an express way. Upon shops inspection the bearing was no longer working but wheel kept rolling, it egged out the housing of the axle shaft and heated up that point of axle and snapped the shaft at that spot. The picture will show this point.
- Air bags · Electrical system · Unknown or other
There is a recall on this vehicle
- Air bags · Seat belts
My Teenage daughter was in a car accident and the airbags did not deploy and her seatbelt did not lock , and smashed into her steering wheel.
- Electrical system · Service brakes · Visibility/wiper
Electrical malfunction with fuses , problems with brake light, engine light and air bag light . Some fuses blown out after brake light fuse popped wipers don't work at all air bog turns on and off every day not sure why
- Seat belts · Unknown or other
The vehicle rolled and killed the occupant because the roof caved in. The shoulder portion of the seat belt did not hold the occupant (only the lap portion) and the occupant was partially ejected out of the rear of the cab. The vehicle was inspected and purchased by State Farm insurance since the…
The vehicle rolled and killed the occupant because the roof caved in. The shoulder portion of the seat belt did not hold the occupant (only the lap portion) and the occupant was partially ejected out of the rear of the cab. The vehicle was inspected and purchased by State Farm insurance since the vehicle was totaled. The 2000's Ford F-150s have roofs that are too weak to support the weight of the vehicle, thereby putting the occupants in danger of injury or death. This is well documented. There were no warnings.
- Engine · Engine and engine cooling
The contact owns a 2004 Ford F-150. The contact stated that while driving at undisclosed speeds, the vehicle shuddered and failed to accelerate while the accelerator pedal was depressed. The check engine warning light was illuminated. The contact pulled over to the shoulder of the roadway and was…
The contact owns a 2004 Ford F-150. The contact stated that while driving at undisclosed speeds, the vehicle shuddered and failed to accelerate while the accelerator pedal was depressed. The check engine warning light was illuminated. The contact pulled over to the shoulder of the roadway and was able to restart the vehicle. The contact scanned the vehicle with a scanner and retrieved an unknown camshaft phaser error code. The local dealer was not contacted. The vehicle was not repaired. The manufacturer was notified of the failure and referred the contact to the NHTSA Hotline for assistance. The failure mileage was approximately 100,000.
- Unknown or other
Frame on 2004 new body style ford f-150 rusted to the point no longer safe to drive according to 2 licensed repair shops. There is no recall on vin number [XXX] However I have been told there are other recalls on frame rust on this same model from 2004-2008. Please know I bought this truck…
Frame on 2004 new body style ford f-150 rusted to the point no longer safe to drive according to 2 licensed repair shops. There is no recall on vin number [XXX] However I have been told there are other recalls on frame rust on this same model from 2004-2008. Please know I bought this truck brand new and only have operated on roadway no off roading. This is my primary vehicle. Please advice what can be done. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)
- Power train
The contact owns a 2004 Ford F-150. The contact stated that while driving at approximately 50 MPH, the engine began revving: however, the vehicle to accelerate properly. The transmission fault warning light was illuminated. The vehicle was taken to the residence. The vehicle was inspected by…
The contact owns a 2004 Ford F-150. The contact stated that while driving at approximately 50 MPH, the engine began revving: however, the vehicle to accelerate properly. The transmission fault warning light was illuminated. The vehicle was taken to the residence. The vehicle was inspected by independent mechanic at the residence, and it was determined that the transmission needed to be replaced. The vehicle was not repaired. The manufacturer was notified of the failure. The failure mileage was 145,000.
- Service brakes
I have a suspect that keeps adding air in brake lines of this vehicle. Police gave me permanent case number, but the guy is still breathing. Idk what to do, as he has done it on all our cars and on this F150 about 4 different times. The name of suspect is [XXX] , [XXX] . INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)
- Electrical system › Ignition › Coil › Spark plugs
The contact owns a 2004 Ford F-150. The contact stated that while driving at an undisclosed speed, the vehicle made an abnormal popping sound and then lost motive power. The contact was able to drive to the residence. The vehicle was taken to an independent mechanic, who determined that the spark…
The contact owns a 2004 Ford F-150. The contact stated that while driving at an undisclosed speed, the vehicle made an abnormal popping sound and then lost motive power. The contact was able to drive to the residence. The vehicle was taken to an independent mechanic, who determined that the spark plug had blown out of the cylinder and determined that the spark plug needed to be replaced. The manufacturer was made aware of the failure and advised the contact to file a complaint with the NHTSA Hotline. The failure mileage was approximately 364,000. The VIN was unavailable.
- Electrical system · Forward collision avoidance › Warnings
I get a warning message which indicates the the Crash Sensor is not working on my Ford truck - this component inflates the Air Bag in the event of a crash. The part number for the Crash Sensor is Motorcraft 6L3Z-14B004-AA. I attempted to purchase a replacement Crash Sensor from a local Ford…
I get a warning message which indicates the the Crash Sensor is not working on my Ford truck - this component inflates the Air Bag in the event of a crash. The part number for the Crash Sensor is Motorcraft 6L3Z-14B004-AA. I attempted to purchase a replacement Crash Sensor from a local Ford dealer. I was told that Ford no longer makes this part. The parts manager suggested that I check with local aftermarket parts stores; Advance Auto Parts, AutoZone, Fisher and NAPA. Nobody makes an aftermarket Crash Sensor for my vehicle. I also searched Amazon without success. I am therefore driving a vehicle with Air Bags which will not deploy - possibly causing a fatality. It seems like the manufacturer, Ford, should be required to sell replacement Crash Sensors until they become available as an Aftermarket Product.
- Air bags
The contact owns a 2004 Ford F-150. The contact stated that while driving at an undisclosed speed, the air bag warning light illuminated. The vehicle was not diagnosed or repaired by an independent mechanic or dealer. The manufacturer was made aware of the failure and advised the contact to report…
The contact owns a 2004 Ford F-150. The contact stated that while driving at an undisclosed speed, the air bag warning light illuminated. The vehicle was not diagnosed or repaired by an independent mechanic or dealer. The manufacturer was made aware of the failure and advised the contact to report the failure to the NHTSA Hotline. The contact was also informed that the repair could not be covered under NHTSA Campaign Number: 11V107000 (Air Bags) because the VIN was not included. The failure mileage was approximately 93,000.
- Firerelated
The contact owns a 2004 Ford F-150. The contact stated that while the vehicle was parked in the driveway, the vehicle caught on fire inside the cab. The contact stated that she attempted to put the fire out with a water hose. The fire department was called and was able to put out the fire. No…
The contact owns a 2004 Ford F-150. The contact stated that while the vehicle was parked in the driveway, the vehicle caught on fire inside the cab. The contact stated that she attempted to put the fire out with a water hose. The fire department was called and was able to put out the fire. No injuries were reported. No warning lights were illuminated. The vehicle was not taken to a local mechanic or dealer. The vehicle was not diagnosed nor repaired. The manufacturer was made aware of the failure. The failure mileage is unknown.
- Service brakes · Steering · Suspension
There are large holes in the frame, and the shackles are ready to fall off. suspension IS falling apart. Brakes are not safe for stopping power for the vehicle. mastertech at ziegler tire.
- Air bags · Unknown or other
N/a
- Engine
The contact owns a 2004 Ford F-150. The contact stated that while driving at an undisclosed speed, the contact observed the spark plug being ejected from the fuel compartment. The check engine warning light was illuminated. The vehicle was taken to an independent mechanic, who was unable to…
The contact owns a 2004 Ford F-150. The contact stated that while driving at an undisclosed speed, the contact observed the spark plug being ejected from the fuel compartment. The check engine warning light was illuminated. The vehicle was taken to an independent mechanic, who was unable to diagnose the failure. The vehicle was repaired, but the failure reoccurred. The manufacturer was notified of the failure but referred the contact to the NHTSA Hotline for assistance. The failure mileage was 150,000.
- Latches/locks/linkages › Doors › Latch
The contact owns a 2004 Ford F-150. The contact stated that the rear driver's side door failed to open. The contact removed the door and replaced the plastic ends with new metal ends. The local dealer was not contacted. The vehicle was not diagnosed or repaired. The manufacturer was contacted and referred the contact to the NHTSA Hotline for assistance. The failure mileage was approximately 160,472.
- Structure › Body
The underbody frame is 95% rusted out, this vehicle is available for inspection upon request. I could have been fatally injured, not knowing the under frame was gone, until vehicle was taken in for new tires. The vehicle was inspected by Firestone tire and Gene Butman Ford. There were no warning…
The underbody frame is 95% rusted out, this vehicle is available for inspection upon request. I could have been fatally injured, not knowing the under frame was gone, until vehicle was taken in for new tires. The vehicle was inspected by Firestone tire and Gene Butman Ford. There were no warning messages and the problem was first noticed in 2019 and was told the vehicle was unsafe to drive, a hazard and should not be driven.
- Engine · Service brakes · Unknown or other
Truck stalls in traffic. Also when hitting the brake. it stalls in reverse. it stalls while idling. Worst truck ever!! Severe safety issue 😕
- Unknown or other
Got into accident I lent my vehicle to Daniel LeBlanc he has had my vehicle since October 2022 He gave permission to his girlfriend at the time she got into accident from black ice
- Air bags
Air bag deployed suddenly while i was in the parked vehicle, it is available for inspection, has not been brought up to dealerships attention, no warning or light up on dash board to indicate problem
- Suspension
Frame Failure, A licensed technician said my vehicle is dangerous to drive and cannot be fixed because of the advanced rusting of the frame. As I read the history of some Ford Trucks I find this is a continuing problem with no recalls and wonder why they can continue to manufacture faulty, dangerous products
- Air bags
Problem is already a recall item, took in to get fixed and the warning light continues to stay on.
Defect investigations
NHTSA’s Office of Defects Investigation opened these reviews into vehicles including this one.
- 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…
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 from which gasoline can spill.When the tank drops, it remains attached to the vehicle only by the fuel filler hose and/or supply lines, or in rare instances, by the skid plate, if present.In some cases the weight of the tank sufficiently strained the hoses and fittings and caused separation and subsequent fuel leaks from those connections.The fire hazard created by leaking gasoline is increased by the possible presence of sparks created by the metal tank being dragged along the road.Corrosion of the straps appears to be caused by prolonged exposure to road deicers, frequently road salt, used to treat snow or ice covered roads.States in which large quantities of deicers are applied to roads during the winter season (salt belt states) account for the predominant portion of strap failures.Vehicles in these salt belt states are prone to experience corrosion related failures more frequently and earlier in a vehicle?s life cycle.Ford reports approximately 97 percent of reports it received relating to strap failure involve vehicles that were operated in these high corrosion areas, and 95 percent of the reports to NHTSA involved such vehicles.Approximately one-third of F-150 U.S. production was sold in salt belt states.ODI has included in the above counts reports it has received from consumers and reports it has received from Ford in which either the complaint involved confirmed strap corrosion or ODI's assessment of available information suggests corrosion caused the reported problem.Among the incidents reported to NHTSA, 441 involved one or both straps failing due to corrosion, 353 involved the fuel tank dropping and/or dragging on the ground, and 180 involved fuel leakage.ODI has received four reports of strap failure in which the leaking fuel ignited but self-extinguished, and one incident in which fire destroyed the vehicle and injured its driver.Ford reported the same injury incident and three other unique fire incidents, including two in which the leaking fuel ignited and fire destroyed the vehicle.There were no injuries associated with the three unique Ford incidents.Ford has agreed to conduct a recall to repair the subject vehicles.The recall will cover vehicles that were originally sold or are currently registered in salt belt states (regardless of vehicle age).The vehiclesincluded in the recall are those subject vehicles that are, or have ever been, registered in Connecticut, Delaware, Iowa, Illinois, Indiana, Kentucky, Maine, Maryland, Massachusetts, Michigan, Minnesota, Missouri, New Hampshire, New Jersey, New York, Ohio, Pennsylvania, Rhode Island, Vermont, West Virginia, Wisconsin, or the District of Columbia.Ford's recall action appears to adequately address the problem at this time.The above vehicle population (1,340,349) includes subject vehicles originally delivered or sold in salt belt states.ODI does not know the current or historical locations of all subject vehicles.According to Ford approximately 73% of the recall population is currently registered (a 27% attrition rate).Ford is also recalling certain MY 1997-1999 F-250 vehicles (under 8,500 GVWR), and MY2002-2003 Lincoln Blackwood vehicles for the same condition, resulting in an estimated 1.1 million total vehicles
- 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…
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 on the sharp edge could cause a short circuit condition.As a result the airbag light may illuminate and/or the airbag may inadvertently deploy.Inadvertent deployments are most likely to occur during the airbag system's self-diagnostic test that initiates when the ignition switch is turned on.Ford modified the vehicle design in late January 2006 adding a protective tape over the sharp metal edge of the horn plate.Ford made additional design changes on MY 2007 vehicles to the horn plate, the clockspring jumper, and the connector layouts to further address this issue.ODI identified 318 deployment incidents with 121 alleged injury reports from subject vehicles.All but one of the incident and injury reports occurred in vehicles built before the January 2006 modification.In addition, there was one incident and alleged injury reported in the MY 2006 Mark LT vehicles that share the same design. In letters dated February 21 and April 11, 2011, Ford announced a recall of all of the approximately 1.3 million MY 2004-2006 F-150 vehicles built prior to January 24, 2006, the date the initial vehicle modification was made.In addition, approximately 14,000 MY 2006 Mark LT vehicles built prior to January 24, 2006 will also be recalled.Vehicles built after that date, which contain the modification, are not within the recall scope.Accordingly the investigation is closed.
- 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…
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 allowing release of excess amounts of natural gas into the engine compartment.ford reports that the regulator contains an over pressure relief valve that will vent natural gas should the pressure exceed a set threshold.the complaint reports and data reviewed by the agency indicate that an improperly operating pressure regulator can result in an overpressure condition and activate the regulator pressure relief valve.the released natural gas IS directed through a vent hose that discharges the natural gas in the vicinity of the right front wheel house and away from the engine compartment's extremely hot areas/surfaces.owners are normally aware of this problem by the presence of an illuminated warning light inside the vehicle, odor of natural gas or the sound of venting gas.when the operator turns the engine off, the natural gas supply tank solenoid will close and the regulator will not release natural gas.at vehicle restart, the solenoid valve will remain closed to prevent leakage and the vehicle will only operate in the gasoline mode.a safety-related defect has not been identified at this time and further use of agency resources does not appear to be warranted.accordingly, this investigation IS closed.the closing of this investigation does not constitute a finding by nhtsa that a safety-related defect does not exist.the agency will monitor this issue and reserves the right to take further action if warranted by the circumstances.
- 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…
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 cylinder and/or ejected from the engine.as of december 8, 2005, odi IS not aware of any allegations where the alleged defect resulted in a loss of vehicle control, a crash, an injury, or a fatality in any of the 10,319,810 subject vehicles.in addition, odi IS aware of only two incidents where the vehicle stalled without restart.information contained in the odi consumer complaints and obtained from 72 telephone interviews with complainants showed the following:(1) 99% of the complaints were on my 1997 to 2002 subject vehicles.(2) most the complainants reported hearing a loud pop while driving or upon starting up the vehicle followed by a loud, repetitive clicking or popping sound.(3) many of the complainants reported that the popping sound was accompanied by some loss of vehicle power; however, in 99% of the incidents reported, the vehicle did not stall.in the very few incidents where the vehicle did stall, most vehicles could be restarted.(4) only a small percentage of the complainants cited that they smelled gas or a slight burning smell when the incident occurred.(5) in all but a very few incidents, vehicle damage was limited to the engine.in one incident, the complaint reported that the fuel rail was damaged and replaced after one of the spark plugs ejected from the engine; however, the complainant reported that the damage did not result in any type of fuel leak or fire.in another incident, the only incident where a fire was alleged, the complainant reported that no fluid leak was observed, but that a fire resulted after the spark plug had ejected from the engine and he had restarted the vehicle and driven to another location.none of the complainants reported any damage to the vehicle hood.(6) only two complainants reported that they observed what appeared to be some drops of fuel coming from the cylinder where the spark plug had failed or on the spark plug itself; however, each of these complainants reported that there was no smoke or flames as a result of his incident.as the petitioner noted, and odi?s analysis showed, it IS possible for a spark plug to detach from the engine cylinder threads in the subject vehicles.however, odi?s analysis of 474 complaints describing such incidents found only a very few alleged any safety-related consequences.none of these showed any evidence of a serious safety consequence.given the large population and relatively long exposure time of the subject vehicles, the complaint analysis indicates that the risk to motor vehicle safety from the alleged defect IS very low.in view of the foregoing, it IS unlikely that nhtsa would issue an order for the notification and remedy of the alleged defect at the conclusion of the investigation requested in the petition.therefore, in view of the need to allocate and prioritize nhtsa?s limited resources to best accomplish the agency?s safety mission, the petition IS denied.
Service bulletins
Technical service bulletins and other communications the manufacturer sent dealers about this vehicle. Ask a dealer for the full document by its number.
- 10235153For 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 followed when diagnosing the condition prior to all module replacements and only order modules using the correct VIN.
- 10205038Safety recall 11S21 - Fuel tank strap fracture - requests for recall service action
- 10177863This 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.
- 10172885This 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.
- 10165713Some 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 back to the system utilities page. Navigate to the toolbox tab and run the Programmable Module Installation (PMI) on the VSM. The procedure will prompt you to manually enter the as-built into the VSM. Obtain the as-built data from PTS > OASIS > As-Built.
- 10156863Some 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
- 10155551Some 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
- 10143079Various 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.
- 10109070The 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 to historical DTCs and the PC/ED, Section 3 No DTCs Present Index chart for further information.
- 10092370Some 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.
- 10058101Ford/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.
- 10056148Lincoln/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.
- 10045340Ford/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.
- 10039074Ford: there may be chaffing on a wire harness between the clockspring and driver airbag which cause the airbag warning light to come on.
- 10030866Ford 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. Updated 4/12/10.
- 10029205Ford/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.
- 100248651999-2008 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.
- 10024843Intermittent vehicle vibration--parking brake disengagement concerns.
- 100248284.6L/5.4l--mil p0506 and/or p0505--hesitation/loss of rpm/difficulty starting/low idle rpm.
- 10024324Erratic fuel gauge operation - mil on --dtcs p040/p0463 or instrument cluster module dtc b1201--vehicles built before 12/3/2007.
- 10023943Some 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. This includes F-53 motorhome chassis. Updated 2/23/10.
- 10023854High pressure power steering line seepage-cold climates only (excluding heritage F-150).
- 10022279Rear axle tube fracture at center carrier.
- 10022160Vibration from the driveline at highway speeds.
- 10021178Shudder/vibration on moderate to hard acceleration.
- 10021048Spark plug removal instructions - 5.4 3V.
- 10020792Diagnostic trouble codes (dtc) p0340, p0344, p0345, p0349. Are found.
- 100201754X4 front differential bracket repair.
- 10019947Neutral tow capability - service kit requirements.
- 10019916Alternate tires approved for off road use.
- 100193835.4L 3V with p030x and/or p0316 accompanied by spark knock.
- 10019378Diagnostic trouble codes p0340/p0344/p0345/p0349 - 4.6L 3V and 5.4L 3V.
- 10019074Vsm programming - service procedure update.
- 10018951Driveshaft slip-bump on deceleration or acceleration from a stop.
- 10018938Vibration diagnosis - tire/wheel runout.
- 100189355.4L 3V with p030x and/or p0316 accompanied by spark knock.
- 10018934Neutral tow capability -- service kit requirements.
- 10018745Wds cop kit diagnostic tip - coil on plug (cop) ignition systems - engine misfire or rough running.
- 10018741Malfunction indicator lamp on with diagnostic trouble code p1131 and/or p1151 - 4.2L engine.
- 10018062Coolant degas bottle overflow.
Every Ford F-150 model year
Bars are owner complaints, dots mark years with recalls. Select a year to open its report.