2004 Ford Mustang Engine Problems

Po442 Evaporative Emmison system leak. Heat catalyst egr set malfunctions. Primary and secondary a/c system deficiencies.

NHTSA ID

11748219

Incident

Jul 3, 2026

THE SPARK PLUGS HAVE A TENDENCY TO BLOW OUT. AN EXPLOSION MAKES THE PLUG STRIP THE THREADS AND DO DAMAGE TO THE HEAD. THERE IS ALSO POTENTIAL FOR FIRE AS FUEL VAPOR IS THEN RELEASE DIRECTLY INTO THE ENGINE COMPARTMENT.

NHTSA ID

11006037

Incident

Jul 16, 2017

Mileage

91,000 mi

TL* THE CONTACT OWNS A 2004 FORD MUSTANG. THE CONTACT STATED THAT WHILE DRIVING, A LOUD NOISE WAS HEARD COMING FROM UNDER THE VEHICLE. THE CONTACT TOOK THE VEHICLE TO A REPAIR SHOP WHERE THEY ADVISED THAT THE AIR COMPRESSOR CONDENSATION DRIPPED ONTO THE EXHAUST PIPE AND THE EXHAUST PIPED NEEDED TO BE RE-WELDED. THE VEHICLE WAS REPAIRED. THE CONTACT NOTIFIED THE MANUFACTURER AND WAS ADVISED THAT THERE WERE NO RECALLS FOR THE VEHICLE OR THE FAILURE. THE FAILURE MILEAGE WAS 75,000.

NHTSA ID

10465996

Incident

May 8, 2012

Mileage

75,000 mi

IN 2004 MY MOM BOUGHT A NEW 2004 FORD MUSTANG WITH THE 3.9 V-6 MOTOR AND WITHIN A COUPLE OF MONTHS IT STARTED TICKING REAL LOUD WHEN YOU FIRST START IT UP. COME TO FIND OUT IT WAS A PASSENGER SIDE EXHAUST LEAK THAT JUST GOT WORSE, AND AT THE SAME TIME HER ENGINE STARTED MAKING LOUD CHIRPING AND CRAZY NOISES TO FIND OUT IT WAS THE CAM POSITIONING SENSOR THAT WENT OUT. WELL SHE PAID ABOUT $550.00 TO GET THE SENSOR FIXED BUT SHE COULDN'T AFFORD THE EXHAUST TO.SO STILL TO THIS DAY SHE DRIVES HER NICE LOOKING MUSTANG CAREFULLY AROUND TOWN THAT SOUNDS LIKE ITS READY TO DIE, AND I WOULDN'T TRUST DRIVING THAT THING 10 MILES OUT OF TOWN. IT MIGHT NOT BE AN EYE SORE BUT IT SURE IS AN EAR SORE, AND IS STRESSING YEARS OFF MY OLD BROKE MOTHERS LIFE. WE'VE ALWAYS BEEN A FORD FAMILY AND MY DAD RETIRED FROM FORD PROVING GROUNDS. BUT THAT IS THE SORRIEST FORD WE'VE EVER SEEN.OH YEAH, PLUS THE AUTOMATIC TRANSMISSION NEVER SHIFTED RIGHT FROM DAY 1, AND SHE HAS HAD TO REPLACE THE ALTERNATOR, BATTERY ,A PULLEY, THE SERPENTINE BELT ETC.AND IT HAS A LOT OF RATTLES AND ROAD NOISE,AND IT JUST BARELY MADE 60,000 MILES. *TR

NHTSA ID

10358377

Incident

Sep 6, 2004

Mileage

20,000 mi

TL*THE CONTACT OWNS A 2004 FORD MUSTANG. THE CONTACT STATED THAT THE TAIL PIPE WAS PROTRUDING TOO FAR FROM THE VEHICLE, WHICH CAUSED A MASSIVE INJURY TO HIS SON'S ARM. THE TAIL PIPE IS CUT IN A 2.9 INCH EDGE INSTEAD OF BEING ROUNDED. HE BELIEVED THAT IT SHOULD BE FURTHER BACK (APPROXIMATELY ONE INCH) TO AVOID INJURIES. THE FAILURE MILEAGE WAS 12500 AND CURRENT MILEAGE WAS 15,600 UPDATED 01/11/08. *LJ UPDATED*JB

NHTSA ID

10205063

Incident

Aug 7, 2005

Mileage

12,500 mi

IN THE MORNING, AFTER DRIVING MY CAR APPROXIMATELY 10 MINUTES, (BEFORE ENTERING THE FREEWAY ON RAMP) THE ENGINE JUST SHUT OFF. I WAS ABLE TO TURN THE KEY TO THE OFF POSITION, AND WHILE STILL MOVING (IN SECOND OR THIRD GEAR) I WAS ABLE TO RESTART THE CAR ON THE FIRST ATTEMPT. I DID USE THE VEHICLE MID-DAY WITHOUT ANY MISHAPS. LATER THAT EVENING AFTER DRIVING HOME APPROXIMATELY 40 MINUTES, (AFTER EXITING THE FREEWAY) THE ENGINE SHUT OFF AGAIN (WHILE IN THIRD GEAR). I WAS ABLE TO AGAIN TURN THE KEY TO THE OFF POSITION, AND WHILE IN MOTION I WAS ABLE TO RESTART THE CAR ON THE FIRST ATTEMPT. ON THE DRIVE HOME THAT EVENING AND THE NEXT MORNING THERE WERE NO FURTHER MISHAPS. I CONTACTED THE FORD DEALER THAT EVENING, AND WAS ADVISED TO BRING IN THE CAR THE NEXT MORNING. I WAS NOT ADVISED TO HAVE IT TOWED OR THAT IT WOULD BE UNSAFE TO OPERATE. THE MECHANICS DROVE THE VEHICLE FOR 12 MILES, AND WERE UNABLE TO DUPLICATE THE MOTOR TURNING OFF. THEY ADVISED ME THAT THEY HAD THOROUGHLY CHECKED THE CAR, BUT WERE UNABLE TO FIND ANYTHING WRONG, AND THE CAR WAS READY TO BE PICKED UP. I WAS EXPRESSED MY CONCERN REPEATEDLY ABOUT DRIVING EVERYDAY ON THE FREEWAY TO THEIR REPRESENTATIVE, BUT WAS OFFERED NO EXPLANATION AS TO WHY THE ENGINE JUST TURNED OFF. AT THIS POINT I CONTINUE TO BE CONCERNED ABOUT THE SAFETY OF DRIVING THIS VEHICLE. *JB

NHTSA ID

10148149

Incident

Jan 17, 2006

Mileage

23,250 mi

1) WE PURCHASED A 2004 FORD MUSTANG CONVERTIBLE. THE VEHICLE WAS PARKED IN OUR GARAGE. THE EXHAUST TAIL PIPE HAS A POOR DESIGN DUE TO THE DESIGN CUT ON THE END WHICH LEAVES TWO SHARP POINTED EDGES LIKE THE END OF KNIVES. THE POINTS ARE LOCATED APPROXIMATELY 1 INCH PAST THE BUMPER. ALL OTHER VEHICLES WE HAVE SEEN HAVE ROUNDING TAIL PIPE ENDS AND THE ENDS ARE FLUSH WITH THE BUMPER OR UNDER THE VEHICLE. 2) THE FAILURE OF THE DESIGN OF THE EXHAUST TAIL PIPE WITH THE SHARP RAZOR CUTS LEAVING TWO POINTED KNIFE LIKE ENDS AND PLACED PAST THE BUMPER IN THE MANUFACTURING PROCESS RESULTED IN MY THREE YEAR OLD HAVING A MASSIVE UPPER ARM INJURY REQUIRING SURGERY AFTER FALLING BEHIND THE 2004 FORD MUSTANG. AS HE FELL HIS RIGHT SHOULDER SLID DOWN PAST THE BUMPER AND THE POINTED SHARP EDGE STICKING PAST THE END OF THE BUMPER TORE INTO HIS ARM ABOVE THE ELBOW TO THE VERY TOP OF HIS SHOULDER. THE INJURY REQUIRED MANY HOURS OF SURGERY AND WE HOPE NO OTHER CHILD WILL HAVE TO GO THROUGH THIS MEANINGLESS DESIGN FLAW BY FORD MOTOR COMPANY AND THEIR OEM MANUFACTURE 3) WE HAVE TRIED TO CORRECT THE PROBLEM BY ASKING THE FORD DEALER FOR ASSISTANCE WHICH WAS REFUSED AND REPORTED THE INJURY TO FORD EXECUTIVE OFFICES IN MICHIGAN. DUE TO NON-RESPONSE BY FORD WE HAVE PLACED A NORMAL SAFE ROUNDED TAIL PIPE EXTENSION ON THE VEHICLE. THE ROUNDING TAIL PIPE IS USED IN ALL OTHER VEHICLES THAT WE HAVE SEEN. THE EXHAUST TAIL PIPE HAS NOT BEEN RECALLED AT THIS TIME ON THE FORD MUSTANGS FOR 2004 AND 2005 WHICH ARE THE SAME DESIGN AND PLACEMENT. *JB

NHTSA ID

10132714

Incident

Aug 7, 2005

Mileage

13,000 mi

DT: THE CONSUMER STATES THAT 2004 FORD MUSTANG WAS HAVING MECHANICAL PROBLEMS. THE TRANSMISSION FLUID WAS GUSHING OUT AND THE VEHICLE WAS TAKEN TO A DEALERSHIP FOR REPAIRS. THE DEALERSHIP FIXED THE TRANSMISSION FLUID PROBLEM. THE NEXT PROBLEM WAS OIL LEAKING. THE VEHICLE HAS BEEN IN THE DEALERSHIP TWICE FOR REPAIRS AND IT WAS STILL LEAKING OIL. THE OWNER CONTACTED FORD FOR HELP. FORD HAD THE CAR TAKEN TO THE DEALERSHIP THAT FORD RECOMMENDED. THE PROBLEM IS STILL NOT FIXED. THE DEALERSHIP SAYS THAT THE OIL IS LEAKING FROM THE ENGINE. THE TRANSMISSION HAD TO HAVE A SEAL REPLACE A LINE, AND THE ENGINE IS STILL LEAKING. THE OWNER SAYS THAT HE CAN NOT DRIVE THE DRIVE BECAUSE IT WILL BLOW UP THE ENGINE. THE OWNER REFUSED TO DRIVE THE CAR WHEN HE FOUND ALL THESE PROBLEMS, SO HE DIDN'T BURN THE CAR UP. THERE HAVE BEEN TWO DIFFERENT DEALERSHIPS THAT HAVE WORKED ON THE CAR. THE OWNER SAID THAT THE DEALERS HAD CLAIMED TO FIX THE CAR, BUT DID NOT FIX IT. THE CAR ALSO HAS HAD A TIRE PROBLEM THAT THE OWNER HAD TO REPLACE. THE DEALERSHIP SAID THAT IT WAS WEAR AND TEAR. THE CAR HAS LESS THAN 800 MILES ON IT. *AK

NHTSA ID

10130407

Incident

Mar 14, 2005

Mileage

800 mi

REPEATED INTERMITTENT FUEL SMELL DURING OPERATION OF VEHICLE IN INTERIOR COMPARTMENT. *LA

NHTSA ID

10054938

Incident

Dec 27, 2003

Mileage

100 mi