2004 Ford F-150 Owner Complaints

The contact owns a 2004 Ford F-150. The contact stated that the seatbelt pretensioners for all seats failed, and the frontal airbags for the driver seat and front passenger seat were inoperable. The seatbelt warning light illuminated. The vehicle was taken to an independent mechanic, where it was diagnosed with faulty seatbelt pretensioners. A dealer was contacted and informed that parts were unavailable for the failure. The manufacturer was not made aware of the failure. The failure mileage was approximately 49,800.

NHTSA ID

11749297

Incident

Jul 2, 2026

Mileage

49,800 mi

Rear-end. The rear drivers side tire fell off while driving on a side street. With no noise or wobble or evidence of a problem. 2 days earlier my family and I were going 70 on an express way. Upon shops inspection the bearing was no longer working but wheel kept rolling, it egged out the housing of the axle shaft and heated up that point of axle and snapped the shaft at that spot. The picture will show this point.

NHTSA ID

11710026

Incident

Jan 4, 2026

There is a recall on this vehicle

NHTSA ID

11706348

Incident

Dec 21, 2025

My Teenage daughter was in a car accident and the airbags did not deploy and her seatbelt did not lock , and smashed into her steering wheel.

NHTSA ID

11690826

Incident

Sep 29, 2025

Electrical malfunction with fuses , problems with brake light, engine light and air bag light . Some fuses blown out after brake light fuse popped wipers don't work at all air bog turns on and off every day not sure why

NHTSA ID

11668789

Incident

Jun 19, 2025

The vehicle rolled and killed the occupant because the roof caved in. The shoulder portion of the seat belt did not hold the occupant (only the lap portion) and the occupant was partially ejected out of the rear of the cab. The vehicle was inspected and purchased by State Farm insurance since the vehicle was totaled. The 2000's Ford F-150s have roofs that are too weak to support the weight of the vehicle, thereby putting the occupants in danger of injury or death. This is well documented. There were no warnings.

NHTSA ID

11659523

Incident

Mar 11, 2025

The contact owns a 2004 Ford F-150. The contact stated that while driving at undisclosed speeds, the vehicle shuddered and failed to accelerate while the accelerator pedal was depressed. The check engine warning light was illuminated. The contact pulled over to the shoulder of the roadway and was able to restart the vehicle. The contact scanned the vehicle with a scanner and retrieved an unknown camshaft phaser error code. The local dealer was not contacted. The vehicle was not repaired. The manufacturer was notified of the failure and referred the contact to the NHTSA Hotline for assistance. The failure mileage was approximately 100,000.

NHTSA ID

11647392

Incident

Mar 10, 2024

Mileage

100,000 mi

Frame on 2004 new body style ford f-150 rusted to the point no longer safe to drive according to 2 licensed repair shops. There is no recall on vin number [XXX] However I have been told there are other recalls on frame rust on this same model from 2004-2008. Please know I bought this truck brand new and only have operated on roadway no off roading. This is my primary vehicle. Please advice what can be done. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ID

11637109

Incident

Jan 3, 2025

The contact owns a 2004 Ford F-150. The contact stated that while driving at approximately 50 MPH, the engine began revving: however, the vehicle to accelerate properly. The transmission fault warning light was illuminated. The vehicle was taken to the residence. The vehicle was inspected by independent mechanic at the residence, and it was determined that the transmission needed to be replaced. The vehicle was not repaired. The manufacturer was notified of the failure. The failure mileage was 145,000.

NHTSA ID

11630177

Incident

Oct 7, 2024

Mileage

145,000 mi

I have a suspect that keeps adding air in brake lines of this vehicle. Police gave me permanent case number, but the guy is still breathing. Idk what to do, as he has done it on all our cars and on this F150 about 4 different times. The name of suspect is [XXX] , [XXX] . INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ID

11595956

Incident

Jun 16, 2024

The contact owns a 2004 Ford F-150. The contact stated that while driving at an undisclosed speed, the vehicle made an abnormal popping sound and then lost motive power. The contact was able to drive to the residence. The vehicle was taken to an independent mechanic, who determined that the spark plug had blown out of the cylinder and determined that the spark plug needed to be replaced. The manufacturer was made aware of the failure and advised the contact to file a complaint with the NHTSA Hotline. The failure mileage was approximately 364,000. The VIN was unavailable.

NHTSA ID

11587841

Incident

May 2, 2024

Mileage

364,000 mi

I get a warning message which indicates the the Crash Sensor is not working on my Ford truck - this component inflates the Air Bag in the event of a crash. The part number for the Crash Sensor is Motorcraft 6L3Z-14B004-AA. I attempted to purchase a replacement Crash Sensor from a local Ford dealer. I was told that Ford no longer makes this part. The parts manager suggested that I check with local aftermarket parts stores; Advance Auto Parts, AutoZone, Fisher and NAPA. Nobody makes an aftermarket Crash Sensor for my vehicle. I also searched Amazon without success. I am therefore driving a vehicle with Air Bags which will not deploy - possibly causing a fatality. It seems like the manufacturer, Ford, should be required to sell replacement Crash Sensors until they become available as an Aftermarket Product.

NHTSA ID

11583913

Incident

Apr 15, 2024

The contact owns a 2004 Ford F-150. The contact stated that while driving at an undisclosed speed, the air bag warning light illuminated. The vehicle was not diagnosed or repaired by an independent mechanic or dealer. The manufacturer was made aware of the failure and advised the contact to report the failure to the NHTSA Hotline. The contact was also informed that the repair could not be covered under NHTSA Campaign Number: 11V107000 (Air Bags) because the VIN was not included. The failure mileage was approximately 93,000.

NHTSA ID

11570485

Incident

Feb 3, 2024

Mileage

93,000 mi

The contact owns a 2004 Ford F-150. The contact stated that while the vehicle was parked in the driveway, the vehicle caught on fire inside the cab. The contact stated that she attempted to put the fire out with a water hose. The fire department was called and was able to put out the fire. No injuries were reported. No warning lights were illuminated. The vehicle was not taken to a local mechanic or dealer. The vehicle was not diagnosed nor repaired. The manufacturer was made aware of the failure. The failure mileage is unknown.

NHTSA ID

11568757

Incident

Oct 15, 2023

THERE ARE LARGE HOLES IN THE FRAME, AND THE SHACKLES ARE READY TO FALL OFF. SUSPENSION IS FALLING APART. BRAKES ARE NOT SAFE FOR STOPPING POWER FOR THE VEHICLE. MASTERTECH AT ZIEGLER TIRE.

NHTSA ID

11544511

Incident

Sep 14, 2023

N/a

NHTSA ID

11542173

Incident

Sep 1, 2023

The contact owns a 2004 Ford F-150. The contact stated that while driving at an undisclosed speed, the contact observed the spark plug being ejected from the fuel compartment. The check engine warning light was illuminated. The vehicle was taken to an independent mechanic, who was unable to diagnose the failure. The vehicle was repaired, but the failure reoccurred. The manufacturer was notified of the failure but referred the contact to the NHTSA Hotline for assistance. The failure mileage was 150,000.

NHTSA ID

11536311

Incident

Aug 15, 2022

Mileage

150,000 mi

The contact owns a 2004 Ford F-150. The contact stated that the rear driver's side door failed to open. The contact removed the door and replaced the plastic ends with new metal ends. The local dealer was not contacted. The vehicle was not diagnosed or repaired. The manufacturer was contacted and referred the contact to the NHTSA Hotline for assistance. The failure mileage was approximately 160,472.

NHTSA ID

11532778

Incident

Jul 17, 2023

Mileage

160,472 mi

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

Truck stalls in traffic. Also when hitting the brake. it stalls in reverse. it stalls while idling. Worst truck ever!! Severe safety issue 😕

NHTSA ID

11519705

Incident

Apr 26, 2023

Got into accident I lent my vehicle to Daniel LeBlanc he has had my vehicle since October 2022 He gave permission to his girlfriend at the time she got into accident from black ice

NHTSA ID

11519036

Incident

Dec 11, 2022

Air bag deployed suddenly while i was in the parked vehicle, it is available for inspection, has not been brought up to dealerships attention, no warning or light up on dash board to indicate problem

NHTSA ID

11511671

Incident

Mar 13, 2023

Frame Failure, A licensed technician said my vehicle is dangerous to drive and cannot be fixed because of the advanced rusting of the frame. As I read the history of some Ford Trucks I find this is a continuing problem with no recalls and wonder why they can continue to manufacture faulty, dangerous products

NHTSA ID

11502560

Incident

Nov 16, 2022

Problem is already a recall item, took in to get fixed and the warning light continues to stay on.

NHTSA ID

11470985

Incident

Mar 1, 2020

The contact owns a 2004 Ford F-150. The contact stated while starting his parked vehicle, he found that the vehicle would not start. The contact self-diagnosed and bypassed the starter solenoid using a screwdriver and started the vehicle. The vehicle slipped out of the park and rolled backward. The contact was backed over by the vehicle and had received injuries to his ribs and stomach. He had lacerations and abrasions to his back and chest. The contact was able to get out from under the vehicle and attempted to stop the vehicle which was rolling. The contact jumped into the passenger side and attempted to brake but could not. The contact attempted to push the shift lever into "park" but the gear would not engage. The vehicle rolled and crashed into the rear end of a parked vehicle. The contact's vehicle had damage to the rear bumper and the rear end of the other vehicle had the bumper and trunk crumpled. The police were not called and the contact did not seek medical attention. The contact was able to start the vehicle and drove it to his residence. The contact then examined the undercarriage and determined that the transmission linkage cable had been resting on the doughnut of the exhaust system. The contact stated that the outer cable shell had melted and the metal cable was exposed. The contact diagnosed that the exposed cable had contributed to the vehicle slipping out of gear. The contact had not taken the vehicle to a dealer or an independent mechanic. The vehicle had not been repaired. The manufacturer had been informed of the failure. The failure mileage was approximately 260,000.

NHTSA ID

11469638

Incident

Jun 12, 2022

Mileage

260,000 mi