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really awful
Crashes / Fires:
1 / 8
Injuries / Deaths:
0 / 0
Average Mileage:
69,403 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 1 of 6)

problem #113

Aug 282014

F-150 8-cyl

  • 88,000 miles


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.

- Massena , NY, USA

problem #112

Nov 102013


  • 105,000 miles
Replaced fuel pump driver module (fpdm) mounted on a support above the spare tire on a 04 Ford F150.first engine code was P0191 for the fuel rail pressure sensor, engine would crank but not start. Ran scan tool and found code P1237 for the fuel pump driver module. The cast housing of the fpdm is corroded and cracked almost splitting it in two pieces. Had to grind off fpdm and the mounting bolts and drill and tap new mounting holes. After replacing fpdm, truck starts and no longer has a rough idle.

- Bloomville, OH, USA

problem #111

Sep 272012

F-150 8-cyl

  • 59,764 miles
The truck just stopped got it going lasted 3 weeks now the engine light came on and it is in the shop and the can not figure it out the engine is a lemon I can not afford to spend alot of money I don't have.

- Swans Island, ME, USA

problem #110

Jun 172012

F-150 8-cyl

  • 64,000 miles


Vehicle had been driven earlier that morning. While parked in the rear of the home the vehicle caught on fire in the motor area. It started about 20 min after being parked. There was also damage to the house. Not sure the cause and thankful for no injuries.

- Enterprise, AL, USA

problem #109

Feb 092010

F-150 8-cyl

  • 120,000 miles
Since approximately 120,000 miles, this vehicle has experienced spark plug failure at a rate of about two each 5,000 miles. Prior to this period, the vehicle had no history of spark plug failure. The plugs were changed in accordance with the manufacturer's recommended service schedule around 101,000 miles. Between 120,000 and 142,000 miles, eight spark plugs and two coils failed during normal driving conditions. An additional tuneup and complete spark plug replacement was performed at 142,000 miles after two failed during normal freeway driving conditions. Another spark plug blew out and was replaced at 148,000 miles. In addition to spark plug failure, several of these plugs have broken while being extracted, causing needlessly expensive repairs.

- Atlanta, GA, USA

problem #108

Jan 052012


  • 89,000 miles
The contact owns a 2004 Ford F150. While driving approximately 40 mph, a loud clicking noise emitted from under the vehicle. The failure progressed and could be heard whenever the vehicle was in operation. The noise would increase as the speed was increased. The vehicle was taken to an independent mechanic who advised the contact that the exhaust manifold would need to be replaced. The vehicle was in the process of being repaired. The manufacturer was notified of the defect. The approximate failure mileage was 89,000.

- Sagamore Beach , MA, USA

problem #107

Mar 072012

F-150 4WD 8-cyl

  • 105,000 miles


I purchased the truck used with an odometer reading of 86,782 miles. I was not told that I needed to replace the sparkplugs or that there is a major issue with the sparkplugs breaking. I assumed that if there was any issue of this nature the dealership would have to disclose this problem on the purchasing agreement. I went to the dealership last week due to the window motor seizing/breaking. I paid for the service to repair that issue, which is another problem as well. During that visit I was informed about the spark plug problem, which Ford has issued a tsb report about. The plugs become fused to the engine block at 100,000 miles, and I am now at 105,000 and just finding out about this! the problem that I am experiencing is that the dealership wants to charge an absorbent amount of money to change the spark plugs, and if any break, its an extra $100 to remove each broken plug. That could potentially be an additional $800 extra to change the spark plugs. That is absolutely ludicrous for Ford to charge an owner for such a task! also it is important to note that the dealership that I purchased the truck from obviously knew about this issue and neglected to inform me in any fashion. I am considering taking legal action as I believe the dealer should be liable to cover the cost of this task, as they did not disclose these problems that according to the dealer had to be addressed within 10,000 additional miles. That is a very short amount of miles to drive for such a major expenditure. I do believe that I should have to pay a typical fee for parts and service to replace the sparkplugs as they are a maintenance item. However, I believe that if the dealer has any problem changing the sparkplugs, it should rest on their shoulders to cover those costs.

- Erie, CO, USA

problem #106

May 012011

F-150 4WD 8-cyl

  • 24,000 miles
The contact owns a 2004 Ford F-150. The contact was driving approximately 55 mph when there was an abnormal increase of acceleration to 80 mph for a brief moment. The vehicle then resumed normal operation. On a separate occasion while driving, the brake pedal was engaged with a rapid increase in rpms, followed by an unexpected increase in speed. The gear was shifted into park in order to stop the vehicle. The failure recurred fifteen times and was taken to an authorized dealer who was unable to duplicate the failure. The contact planned to take the vehicle back to the dealer for a second diagnosis. The manufacturer was notified of the problem. The approximate failure mileage was 24,000...updated 04/16/12 the consumer also stated there were times when he started the vehicle and the engine raced at high RPM's and it was not related to the engagement of the choke in cool or cold weather. Also in relation to increased RPM's above after the vehicle was shifted into par, the engine continued to race at 5,000 RPM's.

- New Tripoli, PA, USA

problem #105

Oct 252011

F-150 8-cyl

  • 94,486 miles
2 1/2 years ago my husband purchased a used 2004 F-150 FX4 with the 5.4 tritan engine (with a 5 for the 8th digit in the VIN) along with a 2 year extended warranty (that covered the engine among other things), from a Ford dealership. It had just under 50,000 miles. Over time, we had the suggested oil changes, put new tires on, new battery and had the spark plugs changed. The problem I am most upset about is the "?ticking?? sound I heard the day my husband brought the truck home. When I asked about it he said he already asked the dealership what the sound was and they said it was just how ??this engine sounds??. it was such a strange sound, we asked two other Ford dealership and they stated the same thing, but they never looked into it. One morning in October, my husband was driving to work and the truck started shaking severely. It was so bad he had difficulty controlling the vehicle. If it wasn't on a back road, we know he would have been in an accident. We took it to court street Ford and they said they had to run diagnostics on it. They received a code of 340, but couldn't find anything wrong. The Ford dealership brought Ford engineers in to help identify what was wrong with the vehicle. Per the engineers?" suggestion, the mechanic would ask for permission to run a test. Each time, we were told, this test will tell us if it is this repair or that. After 2 weeks and almost $700 in tests, imagine our surprise at the final diagnosis "catastrophic engine failure" due to clogged oil passages. Now we find that this particular sound is a symptom for this engine that has nothing but problems and even has a tsb for it (06-19-08). This tsb replaces parts that would prevent this problem, but was never part of a recall.

- Grant Park, IL, USA

problem #104

Sep 012011


  • 95,000 miles
The contact owns a 2004 Ford F-150. While driving approximately 40 mph the vehicle noticed the vehicle began to hesitate while accelerating and a heard a knocking noise in the engine. The vehicle was taken to the dealer for diagnostic testing. The technician stated the spark plugs had to be replaced. The dealer attempted to remove the spark plugs but one of the spark plugs was stuck in the head gasket and could not be removed; however, the head gasket would have to be replaced. The vehicle was not repaired. The approximate failure mileage was 95,000.

- Fort Mill, SC, USA

problem #103

Apr 152011


  • 71,000 miles


The contact owns a 2004 Ford F-150. The contact stated that while driving at the speeds of 45 mph, there was a popping noise heard coming from the engine compartment. The contact stopped the vehicle and noticed that a spark plug and coil pack detached from their cylinder. The vehicle was driven to the contact's residence and then taken into the dealer where the failure was diagnosed. The dealer replaced the spark plug and coil pack, but the failure recurred. The contact did not feel safe driving the vehicle. The failure mileage was 71,000 and the current mileage was 84,266.

- Sanbury , OH, USA

problem #102

Sep 272011

F-150 8-cyl

  • 16,256 miles
I was stopped at a red light and had just put my foot on the accelerator when there was a loud pop and the sudden smell of gas inside the cab of the truck. When I got it to the dealership I was told that the spark plug had blown out of the head and the coil pack was damaged. I was told that the head that Ford decided to use only had three threads to hold the spark plug in place and that the plugs seemed to blow out of 1997-2004 models. They could use a helicoil to repair the threads but they couldn't make any guarantees about the repair. After I had it repaired I discovered thousands of other complaints on the internet about the same issue of spark plugs being blown out of the heads and other people having to replace the heads on their vehicles. I spoke to a buddy of mine in topeka who told me of his neighbor who just bought a used 2004 model Ford truck and had an engine fire because of this same issue. I got lucky with the cost of this repair but because of the poor construction design of this head, that it should have been covered under a warranty of courtesy coverage. This issue needs to be seriously looked at as a recall because of the potential of a fire hazard and a safety issue because if someone is looking under the hood when this occurs, they can be seriously hurt by flying debris.

- Burlington, KS, USA

problem #101

Dec 282011

F-150 8-cyl

  • 75,000 miles
To whom it may concern, I have a problem with my F150 with a 5.4 Triton motor. The truck has some valve train noise that I fear will get worse and cause the engine to fail. I found that Ford issued two different tsb's related to this very problem which advised their technicians of the problem and how to fix it down to the parts required. It was such a problem that Ford updated the parts to be replaced in May 2005 according to the information provided in the tsb issued by Ford. This truck has been well maintained and should not have this kind of valve train noise at 75000 miles. I feel Ford only took care of the problem for those that complained under warranty and Ford should be required to fix an engine problem they knew had faulty parts and is evident by their tsb releases. I have contacted Ford, but my complaint has fallen on deaf ears. They want me to sink $1500-$2000 into a fix that I feel they knew about but chose to ignore. Ford should, instead, recall the trucks on the road with this engine. Thank you in advance for your time.

- Cleveland, OH, USA

problem #100

Dec 172011

F-150 4WD 8-cyl

  • 96,000 miles
The contact owns a 2004 Ford F-150. The contact stated that the vehicle was taken to the dealer for service and a tune-up. Six of the eight spark plugs that were being replaced fractured during the repair. The dealer informed the contact that the failure was common in the particular model because the manufacturer recommended that the sparks plug be replaced every 100,000 miles but the dealer stated that spark plugs should never be in a vehicle for that long of a period before being replaced. The failure and the current mileage was 96,000. Updated 01/25//12 the consumer stated the repair was performed by an auto mechanic, not the dealer, because their price was excessive.updated 04/18/12

- Kingston, PA, USA

problem #99

Nov 212011

F-150 8-cyl

  • 75,246 miles
I just had to pay my Ford dealership $1,270 to replace the "spark plugs" on my 2004 F-150, the Ford Motor Company states that they have an issue with the spark plugs in their technical service bulletin 08-7-6 in Ford F-150 trucks, Ford mustangs, Ford Explorer, Ford Expedition, Lincoln Navigator, Lincoln mark lts, and Mercury Mountaineer model years 2004-2008. The plugs will break or snap during the removal process in turn the owner is expected to eat the cost of their labor and material to correct the problem. The owners manuals state that the plugs will last for 100,000 miles before replacement, I spoke to the relations department with the Ford Motor Company and they state that they know that the problem exists but that is all they will say.

- Monrovia, MD, USA

problem #98

Nov 092011

F-150 8-cyl

  • 79,290 miles
On the highway, as I hit 40 mph, the engine didn't upshift and disengaged with the drivetrain. When I pressed the accelerator, the engine revved, but there was no power to the wheels. After a couple of failed attempts of shifting to neutral and back into drive (while on the highway), I turned the overdrive function off and the engine engaged with the drivetrain again. I was able to drive home safely. Today, the same problem is happening. I called the local Ford dealer and they can't get me into the shop for a week due to a high volume (their words to me) of transmission problems. I have found numerous complaints on the web indicating the same problem by other owners. I'm not sure if they are filing a complaint, but it appears that this is a larger issue potentially due to poor quality parts in the transmission.

- New Albany, OH, USA

problem #97

Oct 292011

F-150 8-cyl

  • 20,231 miles
While driving my 2004 Ford F150 on Saturday 10/29/2011 I started smelling gas and then the number 6 spark plug blew out. After finding the problem back home there were 3 other plugs loose.

- Carriere, MS, USA

problem #96

Sep 102011

F-150 8-cyl

  • 145,000 miles
Truck blew out plugs from # 3 at 50 mph truck shut off, I got a H coil got it put in, it blew it out I done that 4 more times, then got repair kit from Ford put in it didn't stay in 1300 miles and blew out.

- Middleburg, FL, USA

problem #95

Oct 112010

F-150 4WD 8-cyl

  • 110,000 miles
The contact owns a 2004 Ford F-150. The contact stated that the vehicle would make an abnormal noise while in motion. The dealer diagnosed that the cam-phasers would need to be replaced. The manufacturer was notified, but denied any assistance with repairs to the defect. The vehicle was not repaired. The failure mileage was 110,000 and the current mileage was 117,000.

- Boise, ID, USA

problem #94

Jul 142011


  • 120,833 miles
The engine has ejected a spark plug twice in two months.

- Coon Valley, WI, USA

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