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really awful
Crashes / Fires:
1 / 1
Injuries / Deaths:
0 / 0
Average Mileage:
59,603 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 fuel system problems

fuel system problem

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2004 Ford F-150 Owner Comments (Page 1 of 2)

problem #28

May 012014

F-150 8-cyl

  • miles


Fuel system problem.

- San Diego, CA, USA

problem #27

Jul 202011

F-150 8-cyl

  • 74,500 miles
As I turned right into a side street engine stalled. I had very little control of vehicle but managed to steer it onto left side of street. Lucky no cars coming. Also happened on 4 Aug. Checked internet and possible corroded fuel pump driver module. Many complaints. Could cause a major accident.

- Raton, NM, USA

problem #26

Feb 202014

F-150 8-cyl

  • 137,000 miles
While driving normally at 55 mph I drove through a small puddle of water and next thing I know the truck stalls and lost all power. I managed to pull of road without getting hit from behind. I tried to restart the truck with no luck. Seemed like it wasn't getting fuel. Waited in pouring rain and sleet for mechanic and 120 for the new fuel pump driver module and arm and leg for labor on something that should be recalled. Its not safe for the truck to stop like that just for going through a puddle. I live in Michigan and we have crazy weather here. Replace this part now Ford and take care of your customers!

- Rochester Hills, MI, USA

problem #25

Jan 082014

F-150 8-cyl

  • 100,000 miles


Fuel pump driver module, back side of module corroded away exposing circuit board causing the fuel pump to stop running and leaving me stranded during a snow storm, seems to be a common problem on 2004-2008 Ford pickups. I consider this a poor design and should be a recall, lot of garages installing new fuel pumps at $300 a crack when its a easy to replace $80 dollar part.

- Metamora, OH, USA

problem #24

Jan 242012


  • 153,000 miles
The contact owns a 2004 Ford F-150 extended cab. The contact stated after cleaning the vehicle, it failed to start. A private mechanic confirmed that water entered an exposed module for the fuel pump and needed to be replaced. The manufacturer was not notified of the failure. The vehicle was repaired. The failure and current mileage was 153,000.

- Perkinsville, VT, USA

problem #23

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 #22

Nov 022010


  • 96,584 miles


Driving at 50 mph my truck dies. Tow to a Ford dealership (thomas Ford, beverly MA.). diagnostics show blown pcu. Dealer replaces pcu at my expense. Finds that, or says that, the pcu was blown by the fpdm. Ford does not have any in stock and 3 months behind in production due to bad economy. Dealer pressures me into buying used fpdm because 3 other trucks on lot has same problem and they will buy part if I don't. 3 months without truck if I don't. dealer also says I should complain to Ford Motor Company direct because (they believe) it should be a recall. Fmc did nothing. Not even expedite a new part. PCM was $970 part only and fpcm was $343 part only. Fpcm cracked because mounted on dissimilar metal under spare tire.

- Groveland , MA, USA

problem #21

Oct 032011

F-150 8-cyl

  • Automatic transmission
  • 61,552 miles
The contact owns a 2004 Ford F150. The contact stated that while driving 25 mph, the vehicle stalled without warning. The vehicle was towed to the dealer where it was diagnosed with a faulty fuel pump driver module. The dealer performed the repairs. The manufacturer was aware of the failure. The current and failure mileages were 61,552. Updated 11/03/11 updated 12/16/11

- Mable Heights , OH, USA

problem #20

Jul 132011


  • 58,175 miles
The contact owns 2004 Ford F-150. The contact stated that the vehicle would not start. The vehicle was taken to an independent mechanic where the contact was informed that the fuel pump and fuel module failed. Both the fuel pump and module were replaced. The manufacturer was made aware of the failure and advised the contact to notify NHTSA. The failure and current mileages were 58,715. Updated 09/21/2011

- Lotto , IN, USA

problem #19

May 012011


  • 150,000 miles
TL-the contact owns a 2004 Ford F-150. The contact stated the vehicle would not start. The vehicle was towed to an independent repair shop where the contact was informed the fuel pump driver module failed due to corrosion. The manufacturer was notified and the contact was informed the parts necessary to remedy the failure were unavailable. The contact also stated the same failure occurred approximately 30,000 miles prior. The vehicle was not repaired. The failure and current mileages were 150,000. Sm.

- Troupsburg, NY, USA

problem #18

Mar 182011

F-150 4WD 8-cyl

  • 87,000 miles


My 2004 Ford F-150 died in the exit to a local plaza blocking traffic from exiting. After about a half an hour I got the truck started and drove to the Ford service dept. I was told the fuel pump driver module has corroded through and that this part was on national back order because of the number of failures due to the poor location of the module. I was fortunate to find the last replacement part in the western NY area but since have talked to other's all over then country trying to get the same part with no luck. The fact that this part is on national back order should be proof enough that this is a serious problem. I was charged $375 ($160 for part and $200 for labor for a 15 minute job). I believe this could pose a serious safety hazard if a vehicle fails in the wrong place.

- Webster, NY, USA

problem #17

Apr 232011


  • 80,400 miles
I went to start the vehicle, hand slipped off of the key, the vehicle would crank but not turn over. Tried to restart the vehicle numerous times. Unplugged the battery, left it sit for 10-15 mins (thought it was the anti theft). Later in the day a friend looked at it, troubleshot it as fuel pump- used owner manual to look at fuses, everything looked fine. Concluded had to be with the fuel pump or sensor. Had to have the vehicle towed to a garage, pulled the fuel pump sensor off, there was a giant whole in the outer layer and plastic was cracked. Moisture fried the circuit board. The part is currently at VRTC. I am glad my vehicle was at home and not somewhere in a parking lot or far from home. No real signs of this happening prior to not starting.

- Bellefontaine, OH, USA

problem #16

Mar 242011


  • 111,000 miles
The contact owns a 2004 Ford F150. The contact stated that there was an overpowering fuel odor from the interior of the vehicle. The dealer advised that there was a recall under NHTSA campaign id number: 04V200000 (fuel system, gasoline: Storage: Tank assembly) but the contacts VIN was not included in the recall. The manufacturer was contacted and informed confirmed that the VIN was not included under the recall and offered no further assistance. The failure mileage was 111,000.

- Cordova, TN, USA

problem #15

Apr 102010

F-150 8-cyl

  • Automatic transmission
  • 59,000 miles
The contact owns a 2004 Ford F-150. While driving approximately 35-40 mph he smelled a fuel odor. He inspected the vehicle and saw no visible leaks. For a few days the odor was not present; however, it later became progressively worse. He also stated that the smell was much worse when using the heat in the vehicle. The contact referenced recall 04V200000, fuel system, gasoline:storage:tank assembly. He called the manufacturer and was advised that his vehicle was not part of the recall. The contact stated that the failure had been on going for 9 months. The vehicle was not repaired. The approximate failure mileage was 59,000 and the current mileage was 66,000. Updated 02/23/11

- South Plainfield, NJ, USA

problem #14

Oct 312010


  • 15,000 miles
The contact owns a 2004 Ford F-150. While driving 35 mph, the contact noticed a strong fuel odor around the vehicle. He then noticed fuel on the ground which was leaking from the fuel tank. The contact called the dealer who advised him to take the vehicle in for diagnosis. The manufacturer had not been notified. The failure mileage was approximately 15,000.

- Fairfax, VA, USA

problem #13

Aug 082009


  • 66,703 miles
The contact owned a 2004 Ford F150. The contact stated that while parked in the driveway the vehicle caught fire and destroyed the vehicle. The garage on the house caught on fire as well as her commuter car. The fire department responded and put out the fire. Ford Motor Company was contacted and they filed a claim 1496812899. There was a recall NHTSA campaign id number: 06E056000 fuel system, gasoline but her VIN was not included in the recall. The failure mileage was approximately 77,603.

- Stockton , CA, USA

problem #12

Jun 192010


  • miles
2004, 4.6 Ford Explorer pickup spark plugs break off, can't get them out, causes much damage, cost $$$$ to get repaired that I don't have! there are many many people on website forums who have this same problem. Some even say the Ford dealership they took their truck to couldn't even get the spark plugs out either. Is there a recall?

- Coweta, OK, USA

problem #11

Mar 012010

F-150 4WD 8-cyl

  • 43,399 miles
On mon. March 1 of this year I went to my truck, a 2004 Ford F-150 to go to work and it wouldn't start. I had it towed my local repair shop and was informed later that day that the "fuel pump control module", which is mounted on top of the gas tank, had corroded and shorted-out. This module is designed to regulate gas flow from the fuel pump and when it fails, it completely shuts down the gas means no go. I was then informed that Ford Motor Co. Does not have any and that the part is on back-order until may!! after calling 9 different Ford dealers and getting the same answer of "good luck in finding one as there has been a run on these in the northeast due to heavy salt use" it seems no-one has any. I know this was not a safety issue in my case but to tell customers to wait 2 months before they can get their truck back is insane. And if it happens while driving it could be a major problem. I just feel Ford should have been better prepared for this...2 month wait is unheard of.

- Geneva, NY, USA

problem #10

Feb 252010


  • 112,250 miles
The 'engine fuel control module' on my 2004 Ford F-150 4X4 extended cab, 6 3/4ft bed, 5.4L 3V engine 4X4 has failed due to poor design. The module is located under the bed of the truck, and cracks when hit by pebbles that are inevitably kicked up. Water then gets into it and it fails causing the vehicle to stop and not run at all. Once the mechanic found out what the issue was, he then tried to order the part. The module is on national back order, 3 months I'll have to wait to receive it. This is my only source of transportation and I do not know what to do. I paid over $300 for this vehicle and now I cannot drive it because of a $77 part that I cannot get. Ford should be held responsible for this issue and the time that I will not be able to use it. If it is on 'national back order', then obviously there is a design issue and a recall should be issued. 3 months back order is not acceptable. Is Ford Motor Co going to give me a ride to work, the doctors, etc while I wait for the part to come in? something has to be done. Please do your best to look into this and find a solution. Thank you again for your time and consideration.

- Lincoln, RI, USA

problem #9

Aug 212009


  • 114,000 miles
The contact owns a 2004 Ford F150. She stated that when the vehicle was in operation she smelled a strong odor of fuel. The vehicle was taken to a local repair facility; however, the mechanic could not identify the cause of the failure. She notified the manufacturer in reference to recall # 06E056000 (fuel system, gasoline); however, a representative stated that since the VIN number was excluded, she was ineligible for a free remedy. No repairs have been made. The current and failure mileages were 114,000.

- Spring, TX, USA

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