2004 Ford E-150

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.

The contact owns a 2004 Ford F-150. The contact stated that while parked when the vehicle suddenly rolled backwards downhill the contact's son attempted to get into the vehicle to make it stop. The trailer's jackknife stopped the vehicle from going onto the road. The contact manually moved the vehicle back into their garage. The contact stated their son did receive injuries to their head, left or right leg (the contact was unsure of the exact leg), and their left or right arm (the contact was unsure of the exact arm). Medical attention was needed. The dealer was not contacted. The manufacturer was informed of the failure and opened a case. The manufacturer referred the contact to the NHTSA Hotline to file a safety complaint. The failure mileage was 74,000.

NHTSA ID

11675913

Incident

Jul 10, 2025

Mileage

74,000 mi

VIBERATION IN REAR AND CLUNKING NOISR IN REAR WHEN STOPPING AT LIGHT THEN TAKING OF WHILE MAKING A RIGHT TURN

NHTSA ID

10863242

Incident

Feb 10, 2016

Mileage

176,000 mi

2004 FORD 4.6L ENGINE: #2 SPARK PLUG EJECTED FROM CYLINDER HEAD. ~$700 TO REPAIR!!!

NHTSA ID

10749051

Incident

Jul 13, 2015

Mileage

117,000 mi

THERE ARE TONS OF DRIVERS ON PUBLIC ROADS USING OFF ROAD LED LIGHT BARS AND USING AMPLIFIED HID HEADLIGHTS. THEY ARE SO BRIGHT I HAVE TO BLOCK THE LIGHT WITH MY HANDS WHEN THEY DRIVE BY. I KNOW THIS IS ILLEGAL. IT IS TERRIBLY UNSAFE. WHY ARE THERE NOT LAWS BEING ENFORCED TO PREVENT THEIR USE ON THE STREET?

NHTSA ID

10724084

Incident

Jun 2, 2015

Mileage

50,000 mi

AT THE POINT I REACH 40 MPH TRUCK SHIFTS TO NEUTRAL, HAVE TO PULL OVER SAFELY AND TAKE TRUCK OUT OF OVERDRIVE TO GET HOME. VERY DANGEROUS WHEN TRAVELING AT THAT RATE OF SPEED. DID SOME OF MY OWN INVESTIGATING AND FOUND MANY WEBSITE HAVE ANGRY PEOPLE WHO ALSO OWN SAME VEHICLES WITH VERY LOW MILEAGE. I SAW THE RANGE OF MILES BETWEEN 44,000 MILES TO 150,000 MILES. PLEASE REFER TO WWW.CARCOMPLAINTS.COM JUST TO START WITH, THERE ARE MANY OTHER WEBSITES FOR THIS MODEL YOU CAN SEE. PLEASE HELP. *TR

NHTSA ID

10712952

Incident

Apr 3, 2015

Mileage

131,876 mi

TL* THE CONTACT OWNS A 2004 FORD F-150. THE CONTACT STATED THAT THE LOWER BALL JOINTS WERE CAUSING PREMATURE WEARING OF THE TIRES. THE CONTACT INSPECTED THE VEHICLE AND NOTICED THAT THE FRONT END SPRINGS WERE COMPLETELY FRACTURED. THE DEALER AND MANUFACTURER WERE MADE AWARE OF THE FAILURE. THE MANUFACTURER STATED THAT THERE WERE NO ACTIVE RECALLS REGARDING THE FAILURE AND DECLINED TO PROVIDE A REMEDY TO RESOLVE THE FAILURE. THE VEHICLE WAS NOT REPAIRED. THE FAILURE MILEAGE WAS 93,000. UPDATED 05/05/14*JB

NHTSA ID

10579555

Incident

Apr 12, 2014

Mileage

93,000 mi

TL* THE CONTACT OWNS A 2004 FORD F-150. THE CONTACT STATED THE FRONT PASSENGER'S SIDE WINDOW INDEPENDENTLY OPENED. THE FAILURE RECURRED SEVERAL MONTHS LATER ON THE REAR PASSENGER WINDOW. THE VEHICLE WAS TAKEN TO THE DEALER, WHO STATED THAT BOTH WINDOW REGULATOR ASSEMBLIES WOULD NEED TO BE REPAIRED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURE WAS NOT MADE AWARE OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 60,000.

NHTSA ID

10567423

Incident

Oct 16, 2013

Mileage

60,000 mi

TL* THE CONTACT OWNS A 2004 FORD E-150. THE CONTACT STATED THAT A PRIVATE MECHANIC ATTEMPTED TO REMOVE THE SPARK PLUGS BUT THEY WERE FUSED TO THE ENGINE. THE VEHICLE WAS EVENTUALLY REPAIRED. THE MANUFACTURER WAS CONTACTED ABOUT THE FAILURE. THE FAILURE MILEAGE WAS 118,000. THE VIN WAS UNAVAILABLE.

NHTSA ID

10542912

Incident

Sep 1, 2013

Mileage

118,000 mi

When performing any transmission fluid changes or topoffs involving MERCON SP, MERCON LV has replaced all versions of MERCON SP and can be used going forward. Mixing MERCON LV and MERCON SP in the same transmission is acceptable. After 30-Jun-2023, MERCON SP ATF will no longer be manufactured and will only be available until inventory depletes.

FORD: WHEN SHIFTING BETWEEN PARK, REVERSE AND/OR DURING 2-3 SHIFT, AN INTERMITTENT CLUNK OCCURS WITH A TORQSHIFT TRANSMISSION. MODEL 2003-2014 F-SUPER DUTY, E SERIES, EXCURSION, F-53 MOTORHOME CHASSIS, LOW CAB FORWARD. *PE

FORD: ON SOME TRUCKS, THERE IS A NO CRANK SITUATION AND IF VOLTAGE ON TRANSMISSION RANGE SENSOR AT PIN 21, IS LESS THAN 5 VOLTS, DISCONNECT THE ENGINE COOLING FAN CLUTCH, ELECTRONICALLY, AND RECHECK VOLTAGE. MODEL 2003-2007 F SUPER DUTY, 2004-2010 E SERIES, 2003-2005 EXCURSION.

LACK OF POWER DUE TO LOW FUEL PRESSURE - FUEL TANK LINER SEPERATION. *KB

LACK OF POWER DUE TO LOW FUEL PRESSURE, FUEL TANK LINER SEPERATION. *KB

HEADLIGHT ADJUSTMENT NEEDED. *KB