RoadVitals

2004 Ford E-150 Problems

Owner-reported complaints filed with NHTSA, grouped by component

Data refreshed

Owner complaintsComplaints are reports submitted to NHTSA by owners and drivers. NHTSA does not verify most reports before publishing them, and a complaint does not establish that a defect exists. Volume is influenced by how many of a vehicle were sold, how long it has been on the road, and how much attention an issue has received.
33
Latest Jul 24, 2025
Components namedHow many of our component categories appear on at least one report for this model year. One report can name several.
13
Crash or fire reportedComplaints whose submitter recorded that a crash or a fire occurred. These are the reporter's own answers on the NHTSA form, not verified findings.
2

What this page shows

Everything below is an owner-reported complaint submitted to NHTSA about the 2004 Ford E-150, grouped by the component NHTSA recorded on the report. These are not confirmed defects, and they are not recalls. NHTSA does not verify most reports before publishing them, and a category with more reports in it is not evidence that a part is defective.

Complaints are reports submitted by owners and drivers to NHTSA. They are not verified and do not establish that a defect exists.

Reports by component

Ranked by how many owner reports name each component category

  • Brakes824.2%
  • Powertrain (other)412.1%
  • Driver assistance412.1%
  • Visibility39.1%
  • Engine39.1%
  • Interior & seats39.1%
  • Other / unspecified26.1%
  • Exterior lighting13.0%
  • Body & structure13.0%
  • Seat belts13.0%
  • Suspension13.0%
  • Fuel system13.0%
  • Electrical13.0%

Percentages are of component mentions. A single complaint can name more than one component, so these do not sum to the total complaint count.

Each component in detail

What the reports in each category say, in the owners' own words

Brakes

Reports naming service brakes, the antilock braking system, brake hoses, master cylinders or the parking brake.

8
reports

From owner reports, verbatim

DURING THE WINTER MONTHS OUR 2004, FORD, E150, VAN HAS HAD OCCASIONAL YET COMPLETE BRAKE FAILURE SEVERAL TIMES. TYPICALLY, IT HAS HAPPENED WHEN IT WAS VERY COLD -10F AND TYPICALLY SLOWER SPEEDS 10-15MPH BUT TODAY IT WAS 30 F AND SPEEDS WERE 45-50 MPH AS WE WERE COMING DOWN A MOUNTAIN PASS IN COLORADO. WE ALMOST REAR ENDED A SEMI AND ALMOST TOOK ANOTHER CAR HEAD ON BUT THEY HAD MOVED INTO THE FAR LANE. BEFORE REACHING THE BRAKE FAILURE RUN OFF WE WERE ABLE TO DOWN SHIFT AND EVENTUALLY THE BRAKES CAME BACK TO COMPLETE WORKING ORDER. THE VAN HAS BEEN BROUGHT IN SEVERAL TIMES TO FORD DEALERSHIP AND EACH TIME SAME ANSWER, WE CAN'T REPRODUCE THE PROBLEM SO THEY HAVEN'T DONE ANYTHING. *TR

NHTSA ID 10390009 · filed Mar 13, 2011

REPEATED VEHICLE BRAKE FAILURE. *TR

NHTSA ID 10252853 · filed Dec 26, 2008
All 8 reports naming brakes

Powertrain (other)

Powertrain reports that are not specifically the engine or transmission — driveshafts, axles, transfer cases and differentials.

4
reports

From owner reports, verbatim

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 · filed Jul 24, 2025

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

NHTSA ID 10863242 · filed May 4, 2016

Too few reports in this category for a page of its own — they appear in the full complaint list.

Driver assistance

Reports naming forward-collision avoidance, lane keeping, back-over prevention, cruise control and related electronic driver-assistance systems.

4
reports

From owner reports, verbatim

TL*THE CONTACT OWNS A 2004 FORD E150. THE VEHICLE SPEED CONTROL SWITCH WAS DISCONNECTED APPROXIMATELY 6-8 MONTHS AGO. THE CONTACT SPOKE WITH FORD A COUPLE OF WEEKS AGO AND WAS INFORMED THAT THE PART FOR THE REPAIR WOULD NOT BE AVAILABLE FOR ANOTHER FOUR MONTHS. THERE HAD BEEN NO FAILURE TO DATE. THE CURRENT MILEAGE WAS 106,000.

NHTSA ID 10228203 · filed May 19, 2008

TL*THE CONTACT OWNS A 2004 FORD ECONOLINE E150. HE RECEIVED A SAFETY RECALL NOTIFICATION LETTER IN AUGUST 2007 ON THE FORD VEHICLE SPEED CONTROL. THE INFORMATION PROVIDED IN THE LETTER IS FRAUDULENT AND MISLEADING AND THE DEALER LEAD HIM TO BELIEVE THAT A REPAIR WAS GOING TO BE MADE DURING HIS APPOINTMENT. THE CONTACT WAS LATER INFORMED AFTER THE SWITCH WAS DISCONNECTED THAT THE PART WAS NOT AVAILABLE. HE HAS CALLED FORD EVERY MONTH SINCE RECEIVING THE NOTIFICATION IN AUGUST AND EVERY MONTH HE HAS BEEN TOLD THAT THE PARTS WOULD BE AVAILABLE THE FOLLOWING MONTH. HE HAS ALSO TRIED MORE THAN ONE FORD DEALERSHIP AND HE RECEIVED THE SAME RESPONSE. IF HE CANNOT HAVE HIS CAR REPAIRED THAT HE WOULD LIKE TO NEGOTIATE A REFUND. THERE ARE NO FAILURES AT THIS TIME. THE CURRENT MILEAGE WAS 48,000. UPDATED 01/17/08 *BF UPDATED 01/17/08 *TR

NHTSA ID 10212965 · filed Dec 27, 2007

Too few reports in this category for a page of its own — they appear in the full complaint list.

Visibility

Reports naming windshields, glass, wipers, defrosters and mirrors.

3
reports

From owner reports, verbatim

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 · filed Mar 5, 2014

MY 2004 F-150 HAS A WINDOW REGULATOR GO OUT FOR THE SECOND TIME THIS IS A REAL ISSUE IT IS A HAZARD TO MY CHILDREN AND A REAL BIG COST TO ME BEING 300 DOLLAR BOTH TIMES I HAD TO REPLACE IT NEED TO BE RECALLED WHAT A BIG DISAPPOINTMENT CAN YOU HELP ME IN THIS MATTER THANK YOU. *TR

NHTSA ID 10327234 · filed Apr 23, 2010

Too few reports in this category for a page of its own — they appear in the full complaint list.

Engine

Reports naming the engine itself — including stalling, misfires, oil consumption, cooling and internal engine components.

3
reports

From owner reports, verbatim

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

NHTSA ID 10749051 · filed Aug 17, 2015

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 · filed Sep 10, 2013

Too few reports in this category for a page of its own — they appear in the full complaint list.

Interior & seats

Reports naming seats, latches, locks, linkages and interior fittings.

3
reports

From owner reports, verbatim

PURCHASED A NEW 2004 FORD E 150 VAN. SIDE ENTRY DOORS DO NOT SHUT CORRECTLY. WHEN DRIVING, THE DOORS RATTLE, INDICATING THEY ARE NOT LATCHING CORRECTLY. I AM CONCERNED ABOUT THE SAFETY OF PASSENGERS AND THE POSSIBILITY OF THE DOORS COMING OPEN. CONTACTED FORD MOTOR COMPANY AND WAS TOLD THEY WERE AWARE OF THE PROBLEM AND THEY WOULD LET ME KNOW WHEN A FIX WAS AVAILABLE. THEY PLACED TAPE ON THE INSIDE OF THE DOOR JAMS TO FORCE THE DOORS TOGETHER. I HAVE SINCE CONTACTED AN ATTORNEY AND QUIT DRIVING THE VEHICLE FOR THE PAST YEAR AS I WAITED FOR THE FIX FROM FORD. AFTER 12 MONTHS THERE HAVE BEEN NO AUTHORIZED FIXES FROM FORD MOTOR COMPANY. I DID NOT KNOW I COULD SUBMIT THIS TO YOU UNTIL TODAY WHEN A NEWS CAST MADE ME AWARE OF YOUR WEB SITE.*JB

NHTSA ID 10131706 · filed Aug 5, 2005

I RENTED A FORD PASSENGER VAN, THAT U-HAUL CORP CONVERTED TO A CARGO VAN. WHILE INSIDE OF THE CARGO AREA, WIND BLEW THE DOOR SHUT. I COULD NOT OPEN THE DOOR BECAUSE OF THE CHILD SAFETY LOCKS. IN ORDER TO ESCAPE I WAS FORCED TO BREAK OUT A WINDOW. NO INSTRUCTIONS WERE GIVEN THAT THE CHILD SAFETY LOCKS WERE IN THE ON POSITION. THE WINDOWS WERE SECURED BY U-HAUL, AND THE DRIVERS AREA IS SCREENED OFF. NO EXIT WAS AVAILABLE. AMBIENT TEMP WAS 80 DEGREES F. ESTIMATED INSIDE TEMP WAS 100 DEGREES PLUS. U-HAUL HAS NOT RESPONDED, HOWEVER THEY DID CHARGE ME FOR THE DAMAGE TO THEIR VEHICKLE. THE POINT HERE IS NOT THE MONEY INVOLVED, BUT THE SAFETY ISSUE. THE INTERIOR IS NOT HIGH ENOUGH TO STAND UP IN, THE WINDOWS ARE TO HIGH TO LAY ON YOUR BACK AND KICK OUT, AND WITHOUT A TOOL OR OTHER MEANS TO BREAK OUT THE WINDOW, ANY PERSON TRAPED INSIDE THE CARGO AREA COULD NOT GET OUT.

NHTSA ID 10126933 · filed Jun 28, 2005

Too few reports in this category for a page of its own — they appear in the full complaint list.

Other / unspecified

Reports whose component NHTSA recorded as unknown, or that do not map to one of the categories above.

2
reports

From owner reports, verbatim

I WAS DRIVING DOWN INTERSTATE 91 IN MASS. DOING 65 MILES PER HOUR AND EVERYTHING WAS FINE UNTIL I FELT A SLIGHT VIBRATION AND WITH NO WARNING MY REAR RIGHT WHEEL JUST SNAPPED OFF. I WAS LUCKY TO BE ABLE TO STOP THE VEHICLE AND KEEP IT FROM ROLLING OVER OR CREATING A PILE UP OF TRAFFIC. WHEN I HAD GOTTEN OUT TO LOOK I FOUND THAT ALL 5 LUGS WERE SNAPPED OFF AND BROKEN. THERE HAS TO BE SOME SORT OF DEFECT WITH THESE BOLTS. MY FEAR IS THAT SOMEONE ELSE MAY GET KILLED. NOW I AM IN A PROCESS OF TRYING TO HAVE IT REPAIRED AND EVERYONE INCLUDING FORD IS PASSING THE BLAME ON SOMEONE ELSE. PLEASE HELP ME. *NM

NHTSA ID 10183001 · filed Feb 20, 2007

CONSUMER 2004 FORD E150 WHEEL CAME OFF. LUG NUTS BROKE. *TS *JB

NHTSA ID 10146432 · filed Dec 22, 2005

Too few reports in this category for a page of its own — they appear in the full complaint list.

Exterior lighting

Reports naming headlights, tail lights, turn signals and other exterior lighting.

1
report

From owner reports, verbatim

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 · filed Jun 8, 2015

Too few reports in this category for a page of its own — they appear in the full complaint list.

Body & structure

Reports naming the vehicle structure, frame, body panels, doors, hood and trim.

1
report

From owner reports, verbatim

TL*THE CONTACT OWNS A 2004 FORD E-150. WHILE DRIVING 20 MPH THE CONTACT NOTICED THAT THE REAR PASSENGER DOOR HAD SUDDENLY OPENED WITHOUT WARNING. THE VEHICLE WAS TAKEN TO A LOCAL MECHANIC WHERE THE CONTACT WAS INFORMED THAT THE DOOR HINGES NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THERE WERE NO PRIOR WARNINGS. THE CURRENT AND FAILURE MILEAGES WERE 130000.

NHTSA ID 10342014 · filed Jul 8, 2010

Too few reports in this category for a page of its own — they appear in the full complaint list.

Seat belts

Reports naming seat belts, buckles, retractors and pretensioners.

1
report

From owner reports, verbatim

FOR THE LAST 3 MONTHS, MY SEAT BELT WARNING BEEP HAS BEEN ON WHETHER I HAVE MY SEAT BELT ON OR OFF. THE DEALER SHIP WHERE I BOUGHT THIS VAN, WHICH IS BILL COLLINS FORD, HAS NOT BEEN ABLE TO HELP WITH THIS PROBLEM. ALSO MY DVD PLAYER STOPPED WORKING AND THE 3 ROW SEAT BELT STRAP HAS BROKE OFF. *TR

NHTSA ID 10213172 · filed Dec 29, 2007

Too few reports in this category for a page of its own — they appear in the full complaint list.

Suspension

Reports naming suspension components — springs, struts, shocks, control arms and related hardware.

1
report

From owner reports, verbatim

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 · filed Apr 14, 2014

Too few reports in this category for a page of its own — they appear in the full complaint list.

Fuel system

Reports naming fuel storage or delivery — tanks, pumps, lines, injectors and fuel leaks.

1
report

From owner reports, verbatim

WHILE DRIVING 25 MPH, THE VEHICLE STALLED. THE CONSUMER TRIED TO RESTART THE VEHICLE, BUT WAS UNABLE TO DO SO. THE VEHICLE WAS TOWED TO THE DEALER FOR INSPECTION. THE MECHANIC DETERMINED THAT THE FUEL PUMP NEEDED TO BE REPLACED. *AK THE MECHANIC STATED THE FAILURE OCCURRED DUE TO THE INCORRECT ROUTING OF THE FUEL PUMP ELECTRICAL HARNESS. *SC *JB

NHTSA ID 10081760 · filed Jul 12, 2004

Too few reports in this category for a page of its own — they appear in the full complaint list.

Electrical

Reports naming the electrical system — wiring, battery, charging, control modules, infotainment and electrical accessories.

1
report

From owner reports, verbatim

SIRS, I RECENTLY PURCHASED A 2004 FORD F-150 SUPERCAB TRUCK. SINCE I HAVE HAD THIS VEHICLE IT HAS SHUT OFF SIXTEEN TIMES. ON ONE OCCASION I WAS IN THE MIDDLE OF AN INTERSECTION. I WAS LUCKY AND DID NOT HAVE AN ACCIDENT. PLEASE FILE THIS COMPLAINT, BECAUSE I HAVE LEARNED THIS IS A WIDE SPREAD PROBLEM. I HOPE IT IS CORRECTED BEFORE SOMEONE IS KILLED. THANK YOU, PAUL FERGUSON. *AK

NHTSA ID 10103062 · filed Dec 16, 2004

Too few reports in this category for a page of its own — they appear in the full complaint list.

Higher-selling and older vehicles accumulate more reports. Counts are not failure rates and are not directly comparable between vehicles that sold in very different numbers.

Elsewhere on this vehicle

Data sources

Data on this page last refreshed .