2004 Ford F-150 Body & structure Problems

The underbody frame is 95% rusted out, this vehicle is available for inspection upon request. I could have been fatally injured, not knowing the under frame was gone, until vehicle was taken in for new tires. The vehicle was inspected by Firestone tire and Gene Butman Ford. There were no warning messages and the problem was first noticed in 2019 and was told the vehicle was unsafe to drive, a hazard and should not be driven.

NHTSA ID

11530913

Incident

Jun 1, 2019

The truck has had a complete body frame failure. The entire frame is rusted through with large holes. I am unable to put it on a jack to change the tires. It has failed inspections and has not been inspected since 2019. I have a 1992 ford truck that has NO rust issue on the frame. This year is a complete design failure where they used substandard steel or other garbage. It is a safety hazard.

NHTSA ID

11461477

Incident

Apr 20, 2022

Hitch broke off due to ford common frame rot. Frame is rotted from leaf spring shackle and back

NHTSA ID

11456278

Incident

Mar 9, 2022

TL* THE CONTACT OWNS A 2004 FORD F-150. THE CONTACT STATED THAT WHILE THE VEHICLE WAS AT AN INDEPENDENT MECHANIC FOR ROUTINE MAINTENANCE, THE TECHNICIAN NOTICED THAT THE SUBFRAME WAS SEVERELY RUSTED THROUGH. THE VEHICLE WAS LATER TAKEN TO TONY BETTEN & SONS FORD, INC (3839 PLAINFIELD AVE NE, GRAND RAPIDS, MI 49525) WHERE THE CONTACT WAS INFORMED THAT THE DRIVER'S AND PASSENGER'S SIDE SUBFRAME WERE SEVERELY RUSTED, AND THAT THE SUBFRAME NEEDED TO BE REPLACED. THE SUBFRAME WAS NOT REPLACED NOR WAS THE VEHICLE REPAIRED. THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURE. THE FAILURE MILEAGE WAS APPROXIMATELY 167,000.

NHTSA ID

11375181

Incident

Nov 1, 2020

Mileage

167,000 mi

THE FRAME IS ROTTED COMPLETELY. IT IS A SAFETY ISSUE THAT WHEN DISCOVERED AND SEARCHED SEEMS TO A HUGE ISSUE. I WAS ADVISED NOT TO DRIVE THE VEHICLE AS IT NOT SAFE TO DRIVE. I BOUGHT THIS TWO DAYS AGO.

NHTSA ID

11321748

Incident

Apr 20, 2020

TL* THE CONTACT OWNS A 2004 FORD F-150. THE CONTACT STATED WHILE ROUTINE MAINTENANCE WAS BEING PERFORMED ON THE VEHICLE, THE CONTACT DISCOVERED THAT THE SUBFRAME WAS EXTREMELY CORRODED. THE VEHICLE WAS NOT TAKEN TO BE DIAGNOSED NOR REPAIRED. NEITHER THE DEALER NOR THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 167,000.

NHTSA ID

11315816

Incident

Mar 2, 2020

Mileage

167,000 mi

PAINT CRACKED ,COILS MALFUNCTION,SPRINGS FRONT

NHTSA ID

11311007

Incident

Jan 7, 2020

Mileage

55 mi

2004 F150 FX4. CONSUMER WRITES IN REGARDS TO DAMAGED FRAME. *LD *JS

NHTSA ID

11286234

Incident

Dec 3, 2019

THIS VEHICLE IS OTHERWISE IN GOOD CONDITION WITH VERY LITTLE BODY RUST LIMITED TO THE BACK CORNER OF THE PASSENGER CABIN. HOWEVER THE LEFT FRAME RAIL STARTING 14 INCHES AHEAD OF THE FRONT ATTACHMENT POINT OF THE LEAF SPRING. THE RUST HOLE EXTENDS THE WIDTH OF THE FRAME RAIL FOR A DISTANCE OF 17 INCHES. ONE FINGER SIZE HOLE WAS OBSERVED. THE FRAME BOTTOM STEEL WAS EASILY STRIPPED AWAY WITH TWO FINGERS AND A THUMB TO THE LENGTH AND WIDTH DESCRIBED. THE REMAINDER OF THE FRAME HAS EXTENSIVE SURFACE RUST BUT NO HOLE AND OTHERWISE FAIR CONDITION. THE LICENSED STATE VEHICLE INSPECTION SHOP FAILED THE VEHICLE DUE TO THE FRAME RUST AT THIS LOCATION. OTHERWISE, WITH SOME MINOR MECHANICAL ISSUES, THE TRUCK IS IN GOOD CONDITION AND COULD BE SAFELY USED FOR A NUMBER OF MORE YEARS. ONLINE THIS RUST PROBLEM AT THIS POINT HAS A LARGE NUMBER OF COMPLAINTS IN FORD F-150 TRUCKS IN 2004 AND 2005. OBVIOUSLY THERE WAS A MANUFACTURING ISSUE FRAME FORMING TO CAUSE THIS RUST THROUGH IN SO MANY TRUCKS AT THIS FRAME LOCATION AND NOT ELSEWHERE.

NHTSA ID

11282636

Incident

Nov 20, 2019

Mileage

132,192 mi

TL* THE CONTACT OWNS A 2004 FORD F-150. WHILE THE VEHICLE WAS UNDERGOING ROUTINE MAINTENANCE, THE INDEPENDENT MECHANIC DISCOVERED THAT THE FRAME AND CHASSIS OF THE VEHICLE WERE RUSTED AND CORRODED. FLAGSHIP FORD (850 FERN DR, BALDWIN, WI) AND THE MANUFACTURER WERE NOTIFIED OF THE FAILURE. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE FAILURE MILEAGE WAS 138,000.

NHTSA ID

11240387

Incident

Jul 28, 2019

Mileage

138,000 mi

MY 2004 FORD F-150 HAS 61,000 MILES AND NO RUST ON THE OUTSIDE OF THE VEHICLE. I'VE KEPT THE TRUCK WELL MAINTAINED AND IT LOOKS ALMOST NEW. THE FRAME HOWEVER RIGHT WHERE THE REAR LEAF SPRING ATTACHES TO THE FRAME IS RUSTED RIGHT THROUGH. IT IS INCREDIBLE THAT THIS HAS NOT BEEN RECALLED AS OF YET. HOPEFULLY IT WILL BE RECALLED. WHILE DRIVING A PART OF THE EXHAUST HEAT SHIELD FELL ONTO THE DRIVESHAFT. WHEN I WENT TO INSPECT THE UNDERSIDE I FOUND A HOLE IN THE FRAME AND I WAS ABLE TO PUT MY FINGER RIGHT THROUGH IT. *DT CONSUMER STATED ONE IMPORTANT FACT THAT I FORGOT TO ADD TO MY COMPLAINT IS THE SECTION OF THE FRAME THAT RUSTED THROUGH HAS THE EXACT SAME ISSUE IN THE SAME SPOT ON BOTH THE PASSENGER FRAME RAIL AS WELL AS THE DRIVER'S SIDE FRAME RAIL. THE 2004 FORD ESCAPE WAS RECALLED FOR SIMILAR ISSUES THAT YEAR BUT IN THE FRONT OF THE VEHICLE. MY TRUCK HAS ONLY 61,000 MILES ON IT AND FROM FORUMS AND POSTS I'VE READ IT SEEMS TO BE A MAJOR ISSUE FOR THAT YEAR VEHICLE.*JB

NHTSA ID

11205939

Incident

May 6, 2019

Mileage

61,000 mi

TL* THE CONTACT OWNS A 2004 FORD F-150. WHILE THE VEHICLE WAS BEING SERVICED AT JIM TRENARY FORD (LOCATED AT 255 JOHN DEERE DR, MOSCOW MILLS, MO 63362, (636) 356-9000), THE TECHNICIAN NOTICED THAT THE FRAME WAS SPLIT COMPLETELY IN HALF AND NEEDED TO BE REPLACED. THE TECHNICIAN INFORMED THE CONTACT THAT THE VEHICLE COULD NOT BE DRIVEN. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE AND DID NOT ASSIST. THE APPROXIMATE FAILURE MILEAGE WAS 200,000.

NHTSA ID

11183434

Incident

Feb 27, 2019

Mileage

200,000 mi

THE MAIN FRAME RAILS( THAT RUN FROM FRONT BACK) HAVE AN EXTRA CLADDING THAT IS WELDED TO THE MAIN FRAME RAILS. THIS AREA I AM REFERRING TO IS WHERE A CROSS MEMBER( HOLDING THE WEIGHT OF THE REAR ENGINE AND TRANSMISSION) IS WELDED TO THE CLADDING AND THE TWO MAIN FRAME RAILS. THE CLADDING WAS NOT COMPLETELY WELDED SO WATER HAS GOTTEN BETWEEN THE CLADDING AND MAIN FRAME RAILS CAUSING SEVERE CORROSION AND FAILURE OF THAT CONNECTION POINT. EVEN THOUGH IT COULD BE SAID I TAKE EXTREMELY GOOD CARE OF MY VEHICLES THIS AREA SUDDENLY PRESENTED AS A BULGE AND SUBSEQUENT DISCOVERY OF AN EXTREME FAILURE. THIS CONSISTENT FAILURE HAPPENED ON BOTH FRAME RAIL CONNECTION POINTS. I FEEL THAT THIS FAILURE WILL BE OVERLOOKED AS IT WAS WITH ME ....AND COULD CAUSE FRAME FAILURE CAUSING PUBLIC HARM.

NHTSA ID

11144903

Incident

Oct 30, 2018

Mileage

180,000 mi

SAME DEAL AS EVERY OTHER MEMO I READ. MAJOR HIGHLIGHTING POINTS: - PREMATURE FRAME CORROSION AND RUST. - MECHANIC INFORMED ME THAT THE FRAME ON THE REAR HALF. - RUSTED AND CRACKED UNDER BED AND REAR WHEEL WELLS - FRAME WOULD NO LONGER SUPPORT WEIGHT OF VEHICLE - RUST THRU HOLES AND LONGITUDINAL CRACKS FORMED ON THE BOTTOM AND SIDE FRAME SURFACES AT THE STRESS POINT BEFORE THE REAR WHEEL BEND. - EXTREMELY UNUSUAL, TRUCK HAS BEEN GENERALLY BEEN GARAGE KEPT AND MAINTAINED IN GOOD MECHANICAL CONDITION. - THE EXTERIOR BODY DOES NOT EXHIBITS SPOTS OR SURFACE RUST ON VISIBLE BODY PANELS. - NO EVIDENT SIGNS OF RUST OR DEGRADATION OF STRUCTURE. - METICULOUSLY MAINTAINED VEHICLE OTHERWISE. (NEW TRANSMISSION, DRIVE SHAFT, ENGINE RETIMED, SPRAY BED LINER, ETC.) - CATASTROPHIC FAILURE OF THE FRAME STRUCTURE WAS IMMINENT AND THAT THE VEHICLE WAS NO LONGER SAFE TO DRIVE. - CANNOT BE REPAIRED AND IS UNSAFE. - CANNOT PASS A STATE SAFETY INSPECTION. - CANNOT EVEN BE PUT ON A LIFT BECAUSE IT HAS NO STRUCTURAL STRENGTH.

NHTSA ID

11141720

Incident

Sep 1, 2018

Mileage

110,000 mi

THIS A.M. AS I ENTERED MY DRIVEWAY, A NEIGHBOR STOPPED ME TO TALK. I STOPPED AND ROLLED DOWN MY WINDOW. HE WENT ON AND ON. SUDDENLY, MY TRUCK ACCELERATED AT FULL THROTTLE TOWARD MY GARAGE 70 FEET AWAY. MY FOOT WAS ON THE BRAKE TO NO AVAIL. I TURNED SLIGHTLY TO THE RIGHT AND HIT THE CORNER OF THE GARAGE. THE AIR BAGS DEPLOYED. MY GLASSES WENT FLYING. I WAS NOT HURT. A TREE HAD SOFTEN THE IMPACT. I WAS SEVERELY SHAKEN. MY BLOOD PRESSURE WAS ELEVATED. FORD MOTOR COMPANY IS NOT HELPFUL. MY INSURANCE COMPANY, GEICO, IS HANDLING THE ISSUE.

NHTSA ID

11132135

Incident

Sep 28, 2018

Mileage

57,000 mi

THE TRUCK WAS TAKEN INTO MECHANIC. THE MECHANIC PUT IT UP, AND SAW THAT ENTIRE FRAME WAS RUSTED. IT IS NOT FIXABLE. CONTACTED JOHN LANCE FORD, WHERE IT WAS PURCHASED. THEY ADVISED TO TAKE TRUCK TO NEAREST FORD DEALER. WE TOOK IT TO FORD IN PORT CLINTON, OHIO. THE SERVICE MANAGER TOOK PICTURES AND SENT IT TO CORPORATE OFFICE. IT HAS BEEN LONGER THAN 6 WEEKS, AND HAVE NOT HEARD BACK.

NHTSA ID

11124562

Incident

Jul 31, 2018

Mileage

142,000 mi

TL* THE CONTACT OWNS A 2004 FORD F-150. THE CONTACT LOOKED UNDERNEATH THE VEHICLE AND NOTICED THAT THE ENTIRE BOTTOM OF THE FRAME WAS RUSTED. THE DEALER (LIBERTY FORD, 9311 LIBERTY RD, RANDALLSTOWN, MD 21133, 410-504-2897) WAS CONTACTED AND STATED THAT THE FRAMES WERE ABSOLUTE. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOT NOTIFIED. THE FAILURE MILEAGE WAS APPROXIMATELY 78,000.

NHTSA ID

11104216

Incident

Jun 24, 2018

Mileage

78,000 mi

TL* THE CONTACT OWNS A 2004 FORD F-150. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC FOR REPAIRS. ONCE THE VEHICLE WAS PLACED ON A LIFT, THE MECHANIC NOTICED THAT THE MAIN RAILS THAT SUPPORT THE FRAME AND THE FRAME OF THE VEHICLE HAD EXTENSIVE RUST. THE FAILURE COULD CAUSE THE STRUCTURE TO POTENTIALLY FRACTURE OR DISINTEGRATE. THE INDEPENDENT MECHANIC DIAGNOSED THAT THE FRAME NEEDED TO BE REPLACED. THE DEALER WAS NOT CONTACTED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE VIN AND FAILURE MILEAGE WERE NOT AVAILABLE.

NHTSA ID

11093863

Incident

May 15, 2018

MY TRUCKS FRAME HAS RUSTED OUT FROM THE CAB CORNERS TO THE REAR PART OF THE FRAME RAILS. FORD MOTOR COMPANY WONT DO ANYTHING ABOUT THIS PROBLEM. NUMEROUS COMPLAINTS HAVE BEEN FILED, YET THEY WONT DO ANYTHING ABOUT IT. IM NOT SELLING MY TRUCK BECAUSE ITS A RARE VERSION OF THE 04 NEW STYLE F-150. THIS IS A VERY SERIOUS PROBLEM THAT PEOPLE CAN DIE FROM AND FORD WONT BACK THEM UP ON THE 04-08 TRUCKS.

NHTSA ID

11072320

Incident

Dec 1, 2017

Mileage

172,070 mi

THE FRAME ON MY TRUCK HAS SPLIT IN HALF ALWAYS BEEN TAKEN CARE OF. IVE HAD IT FOR 6 YEARS AND IT BEEN GOOD. UNTIL RECENTLY THE BED HAS STARTED TO SHAKE VERY VIOLENTLY. MY DAD AND I HAVE FIGURED OUT THAT THE FRAME ON MY TRUCK HAS SPLIT IN HALF! I DID SOME RESEARCH ON THIS ISSUE OF FRAMES FAILING. MOST 11TH GEN OWNERS LIKE ME HAVE OR HAD THIS KIND OF PROBLEM. SOME FRAMES HAVE ROTTED OUT COMPLETELY DUE TO FORD. THIS TRUCK IS VERY UNSAFE! AND IVE ASKED FORD IF THEY COULD DO ANYTHING AND THEY COULDNT DO ANYTHING. THEY WONT BACK UP THEIR PRODUCTS.

NHTSA ID

11047542

Incident

Oct 30, 2017

Mileage

170,210 mi

BROUGHT MY 2004 F150 XLT TO HAVE SOME SERVICE WORK DONE, THE TRUCK NEEDED A MUFFLER AND A NEW FRONT UPPER CONTROL ARM, I WAS ADVISED BY THE SERVICE MANAGER THAT I SHOULD HAVE MY FRAME LOOKED AT BEFORE GOING ANY FURTHER, BOTH RIGHT AND LEFT SIDES OF THE FRAME IN THE MIDDLE OF THE TRUCK HAVE SEVERE RUST AND I BELIEVE THE STRUCTURE IS DOOMED TO FAIL, I HAD PLANNED ON DRIVING THIS TRUCK FOR SEVERAL MORE YEARS AS IT IS MY DAILY DRIVER. I AM NOW LEFT WITH A TRUCK THAT CANNOT BE CERTIFIED FOR RESALE AND HAS LOST ITS VALUE AND FURTHER IT IS NO LONGER SAFE. BY THE WAY THE TRUCK ONLY HAS 190 THOUSAND KMS ON IT.

NHTSA ID

11033455

Incident

Oct 12, 2017

Mileage

190,000 mi

I HAVE A 2004 FORD F-150 XL EXTENDED CAB PICK UP WITH 140,000 MILES. I RECENTLY PURCHASED NEW TIRES AND AN EXHAUST . DROPPED OF THE TRUCK AT THE MECHANIC TO HAVE ITEMS INSTALLED. RECEIVED A CALL THE NEXT MORNING THAT THERE WAS A PROBLEM, SO WENT IN TO SEE WHAT THE ISSUE WAS. TURNS OUT THE FRAME OF THE TRUCK HAS ROTTED ON BOTH THE PASSENGER AND DRIVERS SIDE, WHERE THE BED MEETS THE CAB. WHEN THEY TRIED TO LIFT THE TRUCK TO INSTALL THE TIRES THE TRUCK DIDN'T MOVE, THE LIFT JUST STARTED CRUSHING THROUGH THE FRAME RAIL. QUITE DEVASTATING NEWS TO RECEIVE SINCE THE TRUCK RUNS AND DRIVES GREAT, BUT IS NOW A BIG HUNK OF SCRAP. WORRISOME ALSO AS I HAD JUST TAKEN MY FAMILY ON A 7 HOUR TRIP IN THE TRUCK A MONTH EARLIER AND HATE TO CONSIDER WHAT COULD HAVE HAPPENED IF WE HAD BEEN INVOLVED IN AN ACCIDENT. I FEEL THAT IN THIS DAY AND AGE A 13 YEAR OLD TRUCK SHOULD NOT EXPERIENCE THIS ISSUE AND THE MANUFACTURER SHOULD STEP UP AND TAKE SOME RESPONSIBILITY FOR THEIR PRODUCT. BUILT FORD TOUGH. YEAH, RIGHT.

NHTSA ID

10995486

Incident

Jun 7, 2017

Mileage

140,000 mi

TL* THE CONTACT OWNS A 2004 FORD F-150. THE CONTACT STATED THAT THE REAR DRIVER SIDE FRAME OF THE VEHICLE WAS RUSTED OUT NEAR THE FUEL TANK. THE CONTACT TOOK THE VEHICLE TO THE LANGLEY FORD DEALER WHO STATED THAT THE VEHICLE WAS NOT INCLUDED IN ANY RECALL REGARDING THE FRAME. THE VEHICLE WAS NOT OFFICIALLY DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE AND CONFIRMED THE DEALER'S INFORMATION. THE APPROXIMATE FAILURE MILEAGE WAS 124,000. UPDATED 08/09/17*LJ *TR

NHTSA ID

10993749

Incident

Dec 1, 2016

Mileage

124,000 mi

TL* THE CONTACT OWNS A 2004 FORD F-150. WHILE PERFORMING ROUTINE MAINTENANCE ON THE VEHICLE, THE CONTACT BECAME AWARE OF EXTREME CORROSION TO THE SUBFRAME OF THE VEHICLE. THE CONTACT WAS CONCERNED THAT THE VEHICLE COULD FRACTURE AND SEPARATE AT THE CENTER BETWEEN THE BED AND THE CABIN. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 75,000.

NHTSA ID

10983645

Incident

Apr 28, 2017

Mileage

75,000 mi

TL* THE CONTACT OWNS A 2004 FORD F-150. THE CONTACT STATED THAT THE FRAME WAS FRACTURED. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE FAILURE MILEAGE WAS 89,000.

NHTSA ID

10959932

Incident

Apr 4, 2016

Mileage

89,000 mi