Huge win for car owners! All TSBs to be made public. The Center for Auto Safety just made the NHTSA (US Government) make public the full text of all TSBs from now on. They are the same organization that has petitioned the NHTSA & filed lawsuits to protect car owners over exploding gas tanks & other major safety issues. Whenever you drive in your car, you are safer thanks in part to a lot of work over the years by this small but very effective consumer advocacy group.

Please take a moment & say thank you by donating $5 or whatever you can to the Center for Auto Safety.

8.5

pretty bad
Typical Repair Cost:
$1,032.00
Average Mileage:
106,018 miles
Total Complaints:
49 complaints

Most Common Solutions:

  1. not sure (20 reports)
  2. take it to the dealer to fix (15 reports)
  3. remove with specialty tool (9 reports)
  4. give Ford owners access to the special wrench (2 reports)
  5. replace sparkplugs (2 reports)
  6. don't change plugs while engine is still hot (1 reports)
2004 Ford F-150 engine problems

engine problem

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2004 Ford F-150 Owner Comments (Page 1 of 3)

problem #49

Jul 012016

F-150 FX4 5.4L V8

  • Automatic transmission
  • 195,000 miles

A D V E R T I S E M E N T S

A coil pack went out, and two spark plugs needed to be replaced. Both broke off. Glad to be a part of the group.

- , Jeff, AL, USA

problem #48

Apr 012016

F-150 FX4 5.4L

  • Automatic transmission
  • 112,000 miles

click to see larger images

spark plugs break off in head

Well known issue. Spark plugs break off in the motor making a simple maintenance procedure and major repair. Cost depend how bad the plugs get stuck with cost ranging at least $1000 to over $3000. I am selling the vehicle in order to avoid this cost and will never buy another Ford again.

- , Houston, TX, USA

problem #47

Mar 092016

F-150 XLT 5.4L

  • Automatic transmission
  • 115,000 miles

$700 to change spark plugs on a truck is F-ing nuts.

- , Baltimore, USA

problem #46

Feb 052016

F-150 Tt

  • Automatic transmission
  • 177,000 miles

A D V E R T I S E M E N T S

$1000.00 to replace the spark plugs. Ford should fix the problem for free. There are lists of these occurrence on the web. The mechanics are not for sure if that will fix the problem. That amount of money is crazy, for a plug change.

I used to swear by Ford as did my dad and both my grandfathers. Not going to any more. 2 of the plugs broke off plus the price of the special plugs.This better fix the problem, or I will be looking for another truck and a new brand. Ford fix the problem and then make it right with your consumers.

- , St joseph, MO, USA

problem #45

Jan 222016

F-150 Supercrew 5.4L

  • Automatic transmission
  • 149,555 miles

Had plugs removed from motor 3 of the first 4 broke off in head, still have to replace 4 more but ran out of time will get done next week, is there some type of refund for the work???

- , Crestwood, MO, USA

problem #44

Dec 282015

F-150 Lariot 5.4L V8

  • Automatic transmission
  • 212,000 miles

The design for the 2004 For F150 5.4L V8 Spark plugs is the worst design I have ever seen on any vehicle in the history of automobiles. I have spoken to multiple mechanics about getting a tune up, and some of them wouldn't even touch it for fear of the spark plugs breaking. Well, I found someone willing, and after letting the truck sit all night long with penetrating oil on the threads he began pulling the plugs. Unfortunately, even after all of the penetrating oil, one of them still broke off. Now I have to get the motor pulled apart to remove the piece that was left behind. Cost will be somewhere in the neighborhood of $2,000-$3,000. That is absolutely ridiculous. I heard there was a lawsuit filled for this issue.

- , Natchitoches, LA, USA

problem #43

Dec 262014

F-150 4.6L

  • Automatic transmission
  • 120,000 miles

A D V E R T I S E M E N T S

I have a 2004 Ford F150 with a 4.6 ltr engine. Iver the summer I was driving home from work and heard a loud pop and the truck started to run extremely loud. I drove it back to work where a truck mechanic said he can fix it and I had it done, it cost me $700.00 to fix.

This past Friday, 12/26/2014, I had a check engine light come on and was driving at 65 mph on a major highway when I heard that pop again and now knew from the past exactly what it was, that same plug that i just paid 700 dollars to replace had blown again. Each time that it blew it shot the ignition coil across the inside of the hood of the truck as well as half of the spark plug. I just had a mechanic look at it yesterday and he said and showed me that the aluminum block was stripped where the repair kit would not work again.

Now it is even a lot more money because I have to either replace the head, for about $2000.00 including labor, or replace the engine for about $5000.00. THIS IS SUCH A COMMON PROBLEM WITH THE TRITON ENGINES AND THE ASS HOLES AT FORD WILL NOT ISSUE A RECALL ON THIS. I SWEAR I WILL NEVER BUY ANOTHER FORD AGAIN, THEY SHOULD BE LIABLE FOR THE DAMAGES AND THE COST OF THE REPAIRS, SHAME ON THEM.. I FEEL THAT IF NO ONE BUYS FROM FORD AGAIN THEY WILL GET THE HINT THAT THEY DO SUCK,,,

- , carlstadt, NJ, USA

problem #42

Jul 082014

F-150 XLT 5.4L

  • Automatic transmission
  • 163,352 miles

I live in Louisiana and it is really hard to find someone local to work on my truck but Darrins Auto is willing to help me for half the charge of Ford. He called Ford for me and said that if the 8th # of your vin# has a 5 it has the plugs that break in the head if it has a 3 you have regular plugs. Helpful tidbit. Mine has a 5 but Darrins Auto will replace them and that they have had good success doing so. Just a helpful hint to all the people that don't know if they have these plugs or not.

- , Natchitoches, LA, USA

problem #41

Aug 012014

F-150 Lariott 5.4L

  • Automatic transmission
  • 88,000 miles

Well I used to think Ford was a reputable company but now I'm not so sure. I have a well maintained 2004 F-150 as I have driven them for years but for Ford not to address the problems with the original spark plugs being stuck, breaking or ejecting from the heads is not only unprofessional but irresponsible, and after trying to deal with this myself I will not only refuse to purchase another Ford Truck but will also inform all 500-600 of my customers on Fords failure to step up and take responsibility.

I hope I can get a fair trade in on my F-150 toward my new Chevy or Toyota.

- , Massena, NY, USA

problem #40

Jan 012012

F-150 FX4 5.4L

  • Automatic transmission
  • 102,000 miles

Around 100,000 miles I had my spark plugs replaced, just like ford sugests, only to find out it was going to cost me an arm and a leg for a normal service that any vehicle has. I bought all the parts and took them to a local garage, not a ford garage to have them replaced. After dropping off my truck, I get a call that the plugs can not be loosened without breaking them off and a special tool must be used to remove the remaining peices that are still in the head. So Ford knows they have this problem! They designed the tool but have know problem charging me for all the laber for the fix on there 2 peice plug that snaps off. I took my truck to the local ford garage because I had no other choice. They had my truck for 6 days! I was told to put sea foam in the gas and run it several days before they work on it to loosen things up, hopefully. They soaked the plugs several days and still 4 out of 8 broke off, I was told I was lucky. I dont cosider having to spend $1,100 on having 8 spark plugs changed lucky! How can they get away with not having a recall on something thats there fault! I know from research on the computer that im 1 of many people with this problem thats getting no attention from the ones that designed it. Please Ford do we have to get on our knees and beg you to fix your problems or do we just not buy your vehicles any more and then our great government bail you out too!! Sincerely Keith Cook Grantsville Md

- , Grantsville, MD, USA

problem #39

Oct 082012

F-150 Lariat 5.4L

  • Automatic transmission
  • 135,000 miles

A D V E R T I S E M E N T S

It is a nightmare to even think about replacing the spark plugs when it comes time to do it. The tip of it breaks off in the engine and then the tool that takes them out isn't the cheapest either. Very irritating!

- , Ravenna, MI, USA

problem #38

Mar 252012

F-150 Supercrew 5.4L

  • Automatic transmission
  • 101,905 miles

Who are these brain less idiots that would design a sparkplug is atwo piece that would break off , under normal conditions, and cost and arm & leg to have it repaired. Ford you have created these problems and ignore any compensation to the unsuspecting customer. this will be the last time Ford will see my hard earned money, for a 2nd rate vehicle.Ford tough allright, tough to do a simple project. Fords do suck--------

- , Guelph, ON, Canada

problem #37

Aug 112010

F-150 XLT 5.4L

  • Automatic transmission
  • 114,000 miles

Truck was missing and I knew I was due for a normal spark plug replacement. Was not anything normal about changing spark plugs in a ford. Should of been a recall. Screw Ford

- , Leland, MS, USA

problem #36

Jan 112012

F-150 4.5L

  • Automatic transmission
  • 100,000 miles

Just wanted to make sure that I was on the band wagon. Ford is well aware of the problem with the sparks plugs breaking off inside the head nothing new here. Decided not to deal with the Ford Dealer they made enough money off of the purchase of the 2004 5.4 liter Ford F150 Truck. I was blessed to have a mechanic who educated me on the problems of the plug breaking in advance. It did not help when the total came to $958.00 . But I am glad that my mechanic is like my Doctor a trusted professional . So I had no argument with the charge . Thanks to Bullock Auto Repair in Jackson MS My F 150 did not make it to the sale at a junk yard ! If you are not a trained mechanic save your money on the special tool ,and take it to someone who is . Thank God I believe in him if not . I would tell Ford to kiss my #$@!!

- , Jackson, MS, USA

problem #35

Sep 152011

F-150 LX 5.4L

  • Automatic transmission
  • 94,000 miles

Ford should man up and fix their piece of sh*t design in this trucks spark plugs!Listen up ford you just lost another ford buyer WILL NOT EVER AGAIN BUY FORD!!!You got me once wont happen again!!You left us all holding the bag on this one!Also on the many other issues that everyone has the same complaints FORD SHOULD BE HELD LIABLE FOR THEIR FAULTY DESIGNS.Window problems also from sh*tty parts !Thanks again ford!! It cost me $1,500 to fix this issue!

- , Murrells Inlet, SC, USA

problem #34

Sep 092011

F-150 FX4 5.4L

  • Automatic transmission
  • 97,000 miles

When I went to the parts store yesterday to but plugs for my truck the counter person informed me there is a major problem with them breaking off in the head. I went home and got on the internet and found this to be true. I am so disappointed in Ford for letting this problem go on without a recall. I'll buy the plugs and take the suggestions of the other people and try it myself this weekend. Wish me luck.

- , Fenton, MI, USA

problem #33

Sep 132011

F-150 FX4 5.4L

  • Automatic transmission
  • 89,000 miles

Thanks to Ford Motor Co's wonderfully designed spark plugs, I had the chance to give Ford 1200 more dollars to tune my truck up for me. Because the engine gets so hot it seizes the plugs inside the head of the engine block. Ford told me this is common with these engines (5.4 L) but that there was nothing they could do because my truck is not under warranty, so i was forced to pull a big chunk of change out of my savings and hand it over to Ford... over a truck that is supposed to be hardy and easy to maintain. I have called and emailed everyone i can in Fords chain, to no success. They refuse to help me. Glad to see Ford stands behinds their products. This issue along with the faulty cam phasers have me hating Ford. This piece of crap has got to go!!! Buyer Beware of this money pit and Ford's lack of integrity

- , Niceville, FL, USA

problem #32

Jul 062011

F-150 Lariat 5.4L

  • Automatic transmission
  • 80,000 miles

I am here on this complaint form again for my 2004 Ford F150. I would seriously think of selling this POS to somebody else.....but why should I give these common problems to somebody else. I had to take my truck to a dealer to have them take out the f-n spark plugs on this truck because the bottom portion of the plug breaks off and sits in the head. Unbelievable to me and very upset about this joke design of a plug. I called Ford dealer and asked if they changed the design of the plug and they said they did not change them. Ford is totally aware of this problem but wont change design because they would have to admit fault. Ford you suck. Why would I want to put those same plugs back in......so they can break again and pay $600 again. Not a chance....... But I found a lil I bought the champion 7989 plug (one part plug and wont break off).........Ford again if you read this complaint which you probably wont.....FIX your problem and admit you have huge design flaws in this vehicle......and folks that read this........DON'T BUY A FORD.......

- , Watertown, MN, USA

problem #31

Jul 052011

F-150 Lariet

  • Automatic transmission
  • 131,000 miles

These plugs breaking off in the head is a real shame. Ford knew this was a problem and changed it in 2006 models and left all of us holding the bag. I have contacted several lawyers looking for someone to file a class action lawsuit. I have always been a Ford man but will strongly consider other makes next time.

- , Cumming, GA, USA

problem #30

May 172011

F-150 FX4 5.4L

  • Automatic transmission
  • 77,000 miles

adding another complaint to the board about my F-150. On top of the window regulator breaking, transmission seal going bad, emergency brake sticking, & rear end shuddering. NOW the spark plugs breaking. I heard of the problems before going into the dealership and knew there was a huge risk in them breaking. So I thought it over and decided to let the "Trained Professionals" at the dealership change them at their "Professional Facillity" and charge me the "Professional Price", so Ford could not accuse me of not trying to remove the plugs incorrectly, or not allowing a trained professional to remove the plugs. After dropping it off on Monday, I was notified on Tuesday that 4 plugs broke off. Way to go " Trained Ford Professionals" !!! Total cost to change 8 spark plugs == $ 914.22

I figured out why Ford didn't accept any of the "Federal Bailout Money". They are getting rich off the repair parts and labor cost. They probably get as much money from the customer after they sell them a vehicle as they do when selling the vehicle.

I'm very dissatisfied with Ford and their complete disreguard for the customer. I'm not pissed at the dealership or the guys in the repair shop. I'm pissed at Ford... You need to FIRE the Engineer that thought up this spark plug, and Fire the Engineer that thought up the "plastic" window regulator part that keeps breaking also, while your at it Fire the Quality Engineer that approved them.

Show the World that you appreciate your customers and try to make things right with them. if you continue to stick to your story and ignore the problems, your going to start running out of customers. You may want to look at changing your jingle also,

From: "Built Ford Tough" To: "Built Ford Cheap" (Let Mike Rowe sing that one.)

- , Surgoinsville, TN, USA

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