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hardly worth mentioning
Crashes / Fires:
0 / 2
Injuries / Deaths:
0 / 0
Average Mileage:
114,368 miles

About These NHTSA Complaints:

This data is from the NHTSA — the US gov't agency tasked with vehicle safety. Complaints are spread across multiple & redundant categories, & are not organized by problem.

So how do you find out what problems are occurring? For this NHTSA complaint data, the only way is to read through the comments below. Any duplicates or errors? It's not us.

2004 Ford F-150 engine problems

engine problem

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2004 Ford F-150 Owner Comments (Page 4 of 4)

« Read the previous 20 complaints

problem #8

Nov 212012

F-150 8-cyl

  • miles


The spark plugs on the 5.4L 3 valve Triton V8 are highly common to break while trying to back them out and replace the spark plugs. Ford is aware of the problem and that is it costing customers over $1,000 just to change spark plugs because if they break off, the head has to come off some times to extract the remainder of the broken plug. Ford has refused to fix their screw up and has stated that they will not do anything unless the NHTSA mandates that they fix the problem. I spoke with a local repair shop and he stated that at a bare minimum for a spark plug change on my truck is $700 due to the issue and that most shops wont even touch them. Ford needs to be held accountable for their design flaw and save their customers thousands of dollars in repair bills for a normal $150 job.

- Wheatland, IN, USA

problem #7

Aug 012011

F-150 8-cyl

  • 140,000 miles
I experience a blown spark plug at a cost of $798 to repair. It seems to be something very popular with the larger engines. I have spoken to many people that have had the same issue. No local repair shop will do the work, they send them all to the dealerships, where as we know the price inflates. From all the mechanics I have spoken with, the general consensus is that it is a design flaw.

- Verona, KY, USA

problem #6

Jun 252012

F-150 4WD 8-cyl

  • 100,000 miles
The contact owns a 2004 Ford F-150. The contact stated that while driving at various speeds the vehicle stalled without any warnings. The vehicle was taken to the dealer who diagnosed that the left and lower cam sensors needed to be replaced. The failure recurred. The dealer stated that the vehicle could not be repaired since the failure was a manufacturer defect and suggested that the failure might be a direct result of a defective engine. The manufacturer was made aware of the failure who filed a report and did not offer any additional assistance. The failure mileage was 100,000 and the current mileage was 129,000. Updated 1/15/13 updated 1/24/2013

- Pikesville, MD, USA

problem #5

Jul 292012

F-150 4WD 8-cyl

  • Automatic transmission
  • 73,000 miles


The contact owns a 2004 Ford F150. The contact stated that the vehicle made a loud noise when started. The contact inspected the vehicle and noticed that the noise emitted from the engine area. The vehicle was taken to the dealer who located the failure as the intake manifold being warped and leaking. The manufacturer was made aware of the failure and denied assistance with the repair. The vehicle was repaired. The approximate failure and current mileage was 73,000. Updated 09/11/12 the consumer stated exhaust gases was leaking into the engine area and could enter into the passenger compartment. Updated 09/13/2012

- Newark , DE, USA

problem #4

Jan 182012


  • 73,000 miles
The contact owns a 2004 Ford F-150. The vehicle was included in the recall under NHTSA campaign id number: 11V107000 (air bags:frontal:driver side inflator module). After the recall repairs were performed, the air bag warning light illuminated on the instrumental panel. The contact heard a ticking noise coming from the engine while the vehicle was parked. The vehicle was taken to the dealer for diagnostics where the technicians advised that the engine would have to be replaced because it was beginning to fracture. The vehicle was not repaired. The VIN was not available. The approximate failure mileage was 73,000.

- Midvale, UT, USA

problem #3

May 162012


  • 72,000 miles
Driving 55 on freeway for about 6 minutes when the spark plug ejected out of the head. Pulled over had towed. Only 72,000 miles with perfect maintenance records. There needs to be a recall or a class action lawsuit against Ford. There are thousands of complaints with the same problem.

- Capistrano Beach, CA, USA

problem #2

May 122012

F-150 8-cyl

  • 41,500 miles
Engine failure due to sludge in motor caused by poor engine design and overly high rate of failure of cam phaser(vct)...

- Harrisburg, PA, USA

problem #1

Dec 132011

F-150 8-cyl

  • 41,000 miles
Drop in speed caused by engine failure caused by cam phaser or vct valve. Was in rush hour traffic at the time.

- Harrisburg, PA, USA

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