2004 Ford F-150 Electrical Problems

There is a recall on this vehicle

NHTSA ID

11706348

Incident

Dec 21, 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 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

PAINT CRACKED ,COILS MALFUNCTION,SPRINGS FRONT

NHTSA ID

11311007

Incident

Jan 7, 2020

Mileage

55 mi

BOUGHT VEHICLE FROM INDIVIDUAL HE STATED MILEAGE ON ODOMETER 125K AND 2008 WENT TO GET INSURANCE AND IT'S A 2004 AND MILEAGE WAS 240K PLUS

NHTSA ID

11278794

Incident

Oct 4, 2019

Mileage

125,000 mi

TL* THE CONTACT OWNS A 2004 FORD F-150. THE CONTACT STATED THAT THE VEHICLE STALLED AND THE ACCELERATOR PEDAL HESITATED WHEN DEPRESSED. AS A RESULT, THE VEHICLE MADE AN ABNORMAL PUTTERING SOUND WHILE IN DRIVE. IN ADDITION, THE ELECTRICAL SYSTEM FAILED. THE SPARK PLUGS WERE CHANGED MULTIPLE TIMES. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC WHO STATED THAT THE SPARK PLUGS SHOULD NOT BE TOUCHED BECAUSE THEY WERE FORD CERTIFIED SPARK PLUGS AND TEAR EASILY. A SPECIAL ONSITE FORD MECHANIC REPAIRED THE SPARK PLUGS. THE ACCELERATOR PEDAL AND STALLING FAILURES WERE NOT REPAIRED. THE MANUFACTURER AND DEALER WERE NOT MADE AWARE OF THE FAILURES. THE FAILURE MILEAGE WAS 233,000.

NHTSA ID

11209100

Incident

May 6, 2019

Mileage

233,000 mi

ELECTRICAL FIRE FRONT PASSENGER SIDE AFTER VEHICLE WAS TURNED OFF WHILE PUMPING GAS.

NHTSA ID

11184339

Incident

Mar 2, 2019

Mileage

186,000 mi

REFER TO NHTSA CAMPAIGN 11V107000. FORD RECALL NUMBER 11S18. VEHICLE WAS MANUFACTURED AT NORFOLK, VA PLANT. MY VIN WAS NOT INCLUDED IN THE ORIGINAL OR EXPANDED RECALL; HOWEVER, IT IS NOW EXHIBITING THE SAME PROBLEM; AIRBAG WARNING LIGHT FLASHES TWICE X FIVE TIMES, THEN REMAINS ON. POSSIBLE CLOCKSPRING JUMPER WIRE CHAFING. WEAR COULD CAUSE ELECTRICAL SHORT AND UNEXPECTED AIRBAG INFLATION WHILE DRIVING. THIS FIRST OCCURRED ABOUT TEN DAYS AGO, BUT THEN THE VEHICLE SAT IN THE DRIVEWAY FOR EIGHT DAYS. CURRENT MILEAGE IS 115544. TODAY I CALLED FORD CUSTOMER SERVICE AND WAS INFORMED THERE WAS NO WARRANTY ACTION OR ACTIVE RECALL THAT WOULD COVER THIS INVESTIGATION AND REPAIR. I BELIEVE THE RECALL SHOULD BE FURTHER EXPANDED TO COVER THIS INCIDENT. IT BEGAN WITH VEHICLES MADE AT THE NORFOLK VA PLANT.

NHTSA ID

11082534

Incident

Mar 23, 2018

Mileage

115,530 mi

2004 FORD F150. VEHICLE SHUT OFF WHILE DRIVING WITH A BOAT IN TOW AND WOULD NOT RE START. HAD TO HAVE VEHICLE TOWED. DEALER DIAGNOSED AS FAILED FUEL PUMP DRIVER MODULE. I WAS STRANDED IN TRAFFIC, VERY DANGEROUS. THIS IS A KNOWN PROBLEM WITH FORD F150 2004-2008. THE MODULE CORRODES AND CAUSES A SHORT CIRCUIT THAT BLOWS THE FUSE TO THE PCM AND RESULTS IN TOTAL FAILURE OF THE PCM, THUS RENDERING THE VEHICLE INOPERABLE. THIS SHOULD BE A RECALL ITEM!!!

NHTSA ID

11043685

Incident

Nov 4, 2017

Mileage

107,000 mi

TL* THE CONTACT OWNED A 2004 FORD F-150. WHILE THE VEHICLE WAS PARKED IN THE DRIVEWAY, A NEIGHBOR ALERTED THE CONTACT THAT THE VEHICLE WAS ON FIRE. THERE WERE NO WARNING INDICATORS ILLUMINATED PRIOR TO THE FIRE. THE FIRE DEPARTMENT ARRIVED AND EXTINGUISHED THE FIRE. A FIRE REPORT WAS FILED. THERE WERE NO INJURIES. THE VEHICLE WAS TOTALED. THE DEALER AND THE MANUFACTURER WERE NOT CONTACTED. THE FAILURE MILEAGE WAS APPROXIMATELY 150,000.

NHTSA ID

11015066

Incident

Jul 26, 2017

Mileage

150,000 mi

TL* THE CONTACT OWNS A 2004 FORD F-150. THE CONTACT STATED THAT THE VEHICLE EXPERIENCED STALLING WITHOUT WARNING. IN ADDITION, THE SEAT BELT WOULD NOT LATCH. THE DEALER DIAGNOSED THAT THE VEHICLE'S SOFTWARE NEEDED TO REFLASHED. THE VEHICLE WAS REPAIRED, BUT THE FAILURE RECURRED. THE CONTACT HAD THE ENGINE REPLACED AFTER IT WAS DIAGNOSED THAT THERE WAS WATER IN THE OIL PAN AND A FUEL ROD FAILURE. THE FAILURE RECURRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURES. THE VEHICLE WAS REPAIRED. THE FAILURE MILEAGE WAS APPROXIMATELY 50,000.

NHTSA ID

10985703

Incident

May 1, 2014

Mileage

50,000 mi

I WAS DRIVING DOWN THE HIGHWAY ABOUT 40 MPH AND THE DRIVER SIDE WINDOW JUST FELL TO THE BOTTOM INSIDE THE DOOR.I HADN'T TOUCHED A THING. THE 2004 FORD F150 HAS ONLY 23,000 MILES ON IT.I BOUGHT IT NEW. I HAVE READ THERE HAS BEEN ALOT OF PROBLEMS WITH THIS. IS THERE A RECALL OR REPLACEMENT?

NHTSA ID

10861451

Incident

Apr 22, 2016

Mileage

23,000 mi

WE'VE HAD A LOT OF ISSUES WITH THIS TRUCK BUT THE MAIN ISSUE IS WHEN WE DRIVE DOWN THE ROAD IT MISSES A LOT AND THE SMELL OF FUEL IN THE TRUCK. WE'VE TAKEN IT IN AND THEY SAID A LOT OF OTHER PEOPLE HAVE HAD THE SAME ISSUES WITH THERE TRUCK LIKE OURS. PLEASE CONTACT US ASAP.

NHTSA ID

10808509

Incident

Oct 1, 2015

Mileage

185 mi

MY HUSBAND WAS DRIVING HOME THIS PAST SUNDAY AND WAS STARTING TO TURN INTO THE DRIVE WHEN THE LEFT PASSENGER WINDOW FELL DOWN INTO THE DOOR. HE HAD NOT PUT IT DOWN OR UP - IT JUST FELL DOWN. THIS IS NOW THE 4TH WINDOW WE HAVE REPLACED IN THIS TRUCK. THE OTHER THREE HAVE BEEN REPLACED, TO THE TUNE OF $350.00 EACH. WHEN I BROUGHT THIS TO THE ATTENTION OF THE SERVICE MANAGER AT THE LOCAL FORD DEALERSHIP, HE SAID THERE WAS NOTHING THAT HE COULD DO - THE WINDOW REGULATORS JUST BREAK. I CONTACTED THE FORD 800 NUMBER AND WAS TOLD THE SAME THING - NOTHING TO BE DONE - JUST A BROKEN PART - EVEN THOUGH IT HAPPENS A LOT. HE SAID THERE WAS NO RECALL ON IT SO THERE WAS NO HELP THEY COULD GIVE. SO, I GUESS I'LL BE PAYING ANOTHER $350.00 AND PRAY THEY DON'T START DROPPING AGAIN SINCE FORD WON'T ADMIT THEY HAVE A PROBLEM.

NHTSA ID

10747866

Incident

Aug 9, 2015

Mileage

56,000 mi

ON MY WAY HOME FROM THE LAKE, MY VEHICLE STARTING IDLING ROUGH. PULLED OVER TO CHECK THINGS OUT, COULDN'T FIND ANY NOTICABLE ISSUES. RETARTED VEHICLE AND ENGINE STARTED SMOKING. I RAISED THE HOOD AND SMOKE WAS BILLOWING OUT FROM THE COIL ATOP THE NUMBER 2 SPARK PLUG, DRIVERS SIDE, LOOKING FROM FRONT TO REAR OF ENGINE. HAD THEVEHICLE TOWED TO BILL COLLINS FORD OF LOUISVILLE,KY.THEY INFORMED ME THAT THE SPARK PLUGS NEEDED CHANGING. UPON REMOVAL, 4 OF THE EIGHT SPARK PLUGS BROKE OFF IN THE ENGINE HEAD. THIS COST ME $857.00 TO CHANGE 8 SPARK PLUGS THAT NORMALLY I COULD DO MYSELF. THE BREAKING OF SPARK PLUGS IN THIS TYPE ENGINE, 5.4L TRITON, IS A WELL KNOWN ISSUE, THAT FORD MOTOR COMPANY KNEW ABOUT. YET THEY HAVE YET TO DO A RECALL. INSTEAD, THEY DEVELOPED A TOOL TO TAKE THESE BROKEN SPRK PLUGS OUT, YET THE CONSUMER STILL HAS TO PAY SOMETIMES UPWARDS OF $2,000.00 FOR THE REPAIR. FORD USED A SUBSTANDARD PART IN THEIR VEHICLES AND REFUSE TO HONOR THE CUSTOMER. THEY NO LONEGR USE THAT TYPE ENGINE, BUT ANYONE WITH A 5.4L TRITON ENGINE FROM FORD WILL HAVE TO PAY A LOT OF MONEY TO CHANGE EIGHT SPARK PLUGS WHEN THE TIME COMES. I COULD NOT PUT MY VEHCILE INTO GEAR WHEN THIS HAPPENED, THAT SEEMS LIKE A SAFETY CONCERN TO ME!

NHTSA ID

10723349

Incident

May 25, 2015

Mileage

85,000 mi

I LEAVE MY WINDOWS UP ON THE TRUCK. IT IS COLD (WINTER TIME) TRUCK WAS IN THE GARAGE. I WENT TO THE GARAGE AND THE WINDOW ON THE PASSENGER SIDE WAS DOWN. I CRANKED THE TRUCK, PUSHED THE BUTTON AND THE WINDOW WOULD NOT COME UP. I TOOK THE TRUCK TO THE DEALER THEY SAID THE FRONT DOOR WINDOW REGULATOR HAD TO BE REPLACED. THIS COST $344.66 TO REPLACE THE REGULATOR. SINCE THE FIRST REPLACEMENT, THE TWO BACK WINDOWS HAVE DONE THE SAME THING. I ASSUME IF MY TRUCK IS HAVING THIS PROBLEM OTHERS ARE ALSO. THIS APPEARS TO BE A DEFECT AND THE COMPANY SHOULD PAY FOR THE REPAIRS. *TR

NHTSA ID

10712720

Incident

Oct 27, 2011

Mileage

23,814 mi

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 300.00 A CRACK WHEN ITS A EASY TO REPLACE 80.00 DOLLAR PART. *TR

NHTSA ID

10559508

Incident

Jan 8, 2014

Mileage

100,000 mi

BOUGHT 2004 F150 BRAND NEW, NEVER OFF ROAD, ALL SCHEDULED MAINTENANCE COMPLETED: SON DRIVING ON INTERSTATE AT 65MPH, HEARD LOUD BREAKING NOISE, SEVERE RATTLING, SHAKING, NO POWER, COASTED DOWN RAMP AND TO SIDE ROAD. TOWED TO MECHANIC--ROD THROUGH THE OIL PAN. MECHANIC VERIFIED THAT OIL WAS PUMPED PROPERLY THROUGH MOTOR.. SAME MECHANIC HAS WORKED ON THIS CAR SINCE WE HAVE HAD IT. WE HAVE HAD TO HAVE ALL 4 DOOR WINDOW MOTORS REPLACED (TWICE-SECOND TIME, WE FIXED FRONT DOOR WINDOWS AND HAD BACK DOOR WINDOWS WIRED UP) , THE BACK GLASS REPLACED FOR LEAKING, THE 4 WHEEL DRIVE SENSORS REPLACED, THE TRANSMISSION REBUILT, THE OVERHEAD CAM SYSTEM REPLACED AND NOW THIS. *TR

NHTSA ID

10550144

Incident

Oct 25, 2013

Mileage

80,000 mi

ON MY 2004 FORD F150 XLT LARIAT SUPERCAB, THE PASSENGER REAR WINDOW REGULATOR HAS NOW FAILED. THE DRIVER'S ONE WENT FIRST (WITHIN THREE YEARS OF OWNERSHIP), THEN THE FRONT PASSENGER ONE (A FEW MONTHS LATER) THEN THE REAR PASSENGER ONE ( ABOUT A YEAR AFTER THE FIRST) AND NOW THIS. ALL FOUR REGULATORS HAVE HAD TO BE REPLACED FROM THE ORIGINAL FACTORY INSTALLED ONES. THIS LATEST ONE OCCURRED WHILE THE TRUCK SAT PARKED IN THE DRIVEWAY UNOCCUPIED; ALL THE OTHERS HAPPENED ON THE ROADWAY WHILE THE VEHICLE WAS IN MOTION. *TR

NHTSA ID

10535392

Incident

Aug 14, 2013

I OWN A 2004 FORD F-150. IN 2012 I HAD MY E-BRAKE LIGHT START FLASHING AT ME. I BROUGHT IT INTO THE MECHANIC AND HAD THEM LOOK IT OVER, THEY SAID THEY COULDN'T FIND ANYTHING WRONG OTHER THEN THE WIRING UNDER THE DASH WAS PROBABLY BAD, SO I BROUGHT IT TO A BRAKE SPECIALIST AND THEY SAID THE SAME THING, NOTHING WRONG WITH CYLINDER OR BRAKES, THAT IT WAS THE WIRING UNDER THE DASH. I'M TRULY NOT SAFE USING MY E-BRAKE AS I'M NOT SURE IF IT IS WORKING OR NOT. MY INTERIOR LIGHTS STARTED COMING ON ALSO WHEN I WOULD TURN ON MY HEADLIGHTS, EVERYONE KNOWS YOU SHOULDN'T HAVE THE INTERIOR LIGHTS ON WHILE DRIVING AT NIGHT ANYWAY. I HAVE READ SEVERAL ARTICLES WHERE OTHER FORD F-150 OWNERS ARE HAVING THE SAME PROBLEMS. I THINK THIS NEEDS TO BE LOOKED INTO AND A RECALL SHOULD GO OUT. *TR

NHTSA ID

10533525

Incident

Jul 1, 2012

REPLACED TWO WINDOW REGULATORS IN VEHICLE. DRIVER'S WINDOWN AND PASSENGER WINDOW.

NHTSA ID

10512157

Incident

May 1, 2013

AS I WAS BACKING UPWARD INTO MY GARAGE, I SLOWED DOWN AND THE TRUCK ROLLED FORWARD AND I QUICKLY PRESSED THE GAS TO RESUME BACKWARDS. THIS CAUSED THE CHECK ENGINE WARNING LIGHT TO COME ON ALONG WITH MY OD/OFF INDICATORS ON THE DASHBOARD. MY REVERSE GEAR STOPPED PULLING. I'M AFRAID HAD THIS BEEN IN ROUTE IT MIGHT HAVE BEEN MORE SERIOUS OF AN ISSUE. *TR

NHTSA ID

10508746

Incident

Apr 14, 2013

Mileage

160,000 mi

DRIVER SIDE POWER WINDOW, THIS IS THE FORTH TIME I HAVE TO HAVE WINDOW REPAIR ON MY TRUCK, PREVIOUS TIME BEFORE LAST ONE, WAS IN JULY ONLY 4 MONTHS AGO I HAD TO PAY ALMOST $300 TO REPAIR WINDOW, AND NOW LAST TIME PAID $425 DOLLARS TO REPAIR THAT VERY SAME WINDOW AND THIS TIME IS THE WINDOW REGULATOR. WINDOW WILL MAKE A LOUD NOISE AND DROP, UNABLE TO BRING IT UP OR CLOSED AGAIN. *TR

NHTSA ID

10484867

Incident

Nov 15, 2012

Mileage

113,000 mi

PASSENGER SIDE POWER WINDOW COLLAPSED INTO THE DOOR WHILE DRIVING. BRIEFLY HEARD A POP/BANG IN THE DOOR THINKING SOMETHING HIT THE DOOR, THEN THE WINDOW WENT STRAIGHT DOWN WITHOUT CONTROL. NOW I HAVE NO WAY OF RETRIEVING THE WINDOW BACK UP AND SECURING IT. PLUS UNABLE TO SECURE MY VEHICLE OR KEEP THE ELEMENTS OF WEATHER OUT OF MY TRUCK. I WILL NOT USE THE TRUCK TO PICK UP MY YOU CHILDREN IN THIS CONDITION. I PRESUME THAT THIS COULD BE A SIGNIFICANT SAFETY HAZARD IN SIMILAR SITUATIONS WITH A DISTRACTED DRIVER LOOSING ATTENTION TO DRIVING OR IN A SEVERE WEATHER CONDITION. I WILL TAKE IT TO A FORD SERVICE DEALER AND SHARE MY DISPLEASURE WITH THIS INCIDENT. FOR MY SAFETY AND EVERYONE ELSE SAFETY, I WILL GET THIS REPAIR. THIS INCIDENT IS SEVERE ENOUGH TO HURT OR KILL SOMEONE IF IT IS NOT ADDRESSED. I AM STILL SHAKING WITH FEAR WHILE TYPING THIS COMPLAINT. *TR

NHTSA ID

10472403

Incident

Aug 21, 2012

Mileage

100,500 mi