Problems with 2004 Ford F-150 FUEL SYSTEM, GASOLINE

Fuel system problem.

While driving normally at 55 mph i drove through a small puddle of water and next thing i know the truck stalls and lost all power. i managed to pull of road without getting hit from behind. i tried to restart the truck with no luck. seemed like it wasn't getting fuel. waited in pouring rain and sleet for mechanic and 120 for the new fuel pump driver module and arm and leg for labor on something that should be recalled. its not safe for the truck to stop like that just for going through a puddle. i live in michigan and we have crazy weather here. replace this part now ford and take care of your customers! *tr

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

Tl* the contact owns a 2004 ford f150. the contact stated that the vehicle made a noise when driving various speeds. the contact inspected the vehicle and found that the fuel tank bracket failed and caused the fuel tank to separate from the vehicle. as a result, the fuel tank was being dragged when driving. the vehicle was not repaired. the manufacturer was not made aware of the failure. the approximate failure and current mileage was 100,000. updated 11/13/12 *cn

Tl* the contact owns a 2004 ford f-150 extended cab. the contact stated after cleaning the vehicle, it failed to start. a private mechanic confirmed that water entered an exposed module for the fuel pump and needed to be replaced. the manufacturer was not notified of the failure. the vehicle was repaired. the failure and current mileage was 153,000.

While driving my 2004 ford f150 on saturday 10/29/2011 i started smelling gas and then the number 6 spark plug blew out. after finding the problem back home there were 3 other plugs loose. *tr

Tl* the contact owns a 2004 ford f150. the contact stated that while driving 25 mph, the vehicle stalled without warning. the vehicle was towed to the dealer where it was diagnosed with a faulty fuel pump driver module. the dealer performed the repairs. the manufacturer was aware of the failure. the current and failure mileages were 61,552. updated 11/03/11 *bf updated 12/16/11

As i turned right into a side street engine stalled. i had very little control of vehicle but managed to steer it onto left side of street. lucky no cars coming. also happened on 4 aug. checked internet and possible corroded fuel pump driver module. many complaints. could cause a major accident. *tr

Tl* the contact owns 2004 ford f-150. the contact stated that the vehicle would not start. the vehicle was taken to an independent mechanic where the contact was informed that the fuel pump and fuel module failed. both the fuel pump and module were replaced. the manufacturer was made aware of the failure and advised the contact to notify nhtsa. the failure and current mileages were 58,715. updated 09/21/2011 *ln *tr

2004 ford f150. i have already filed a complaint. the consumer stated when he arrived at the dealer, to have the recall performed, the dealer informed him, there were no parts available. updated ivoq 06/30/11 *tr

Tl-the contact owns a 2004 ford f-150. the contact stated the vehicle would not start. the vehicle was towed to an independent repair shop where the contact was informed the fuel pump driver module failed due to corrosion. the manufacturer was notified and the contact was informed the parts necessary to remedy the failure were unavailable. the contact also stated the same failure occurred approximately 30,000 miles prior. the vehicle was not repaired. the failure and current mileages were 150,000. sm.

I went to start the vehicle, hand slipped off of the key, the vehicle would crank but not turn over. tried to restart the vehicle numerous times. unplugged the battery, left it sit for 10-15 mins (thought it was the anti theft). later in the day a friend looked at it, troubleshot it as fuel pump- used owner manual to look at fuses, everything looked fine. concluded had to be with the fuel pump or sensor. had to have the vehicle towed to a garage, pulled the fuel pump sensor off, there was a giant whole in the outer layer and plastic was cracked. moisture fried the circuit board. the part is currently at vrtc. i am glad my vehicle was at home and not somewhere in a parking lot or far from home. no real signs of this happening prior to not starting.

Tl* the contact owns a 2004 ford f150. the contact stated that there was an overpowering fuel odor from the interior of the vehicle. the dealer advised that there was a recall under nhtsa campaign id number: 04v200000 (fuel system, gasoline: storage: tank assembly) but the contacts vin was not included in the recall. the manufacturer was contacted and informed confirmed that the vin was not included under the recall and offered no further assistance. the failure mileage was 111,000.

My 2004 ford f-150 died in the exit to a local plaza blocking traffic from exiting. after about a half an hour i got the truck started and drove to the ford service dept. i was told the fuel pump driver module has corroded through and that this part was on national back order because of the number of failures due to the poor location of the module. i was fortunate to find the last replacement part in the western ny area but since have talked to other's all over then country trying to get the same part with no luck. the fact that this part is on national back order should be proof enough that this is a serious problem. i was charged $375 ($160 for part and $200 for labor for a 15 minute job). i believe this could pose a serious safety hazard if a vehicle fails in the wrong place. *tr

Driving at 50 mph my truck dies. tow to a ford dealership (thomas ford, beverly ma.). diagnostics show blown pcu. dealer replaces pcu at my expense. finds that, or says that, the pcu was blown by the fpdm. ford does not have any in stock and 3 months behind in production due to bad economy. dealer pressures me into buying used fpdm because 3 other trucks on lot has same problem and they will buy part if i don't. 3 months without truck if i don't. dealer also says i should complain to ford motor company direct because (they believe) it should be a recall. fmc did nothing. not even expedite a new part. pcm was $970 part only and fpcm was $343 part only. fpcm cracked because mounted on dissimilar metal under spare tire.

Tl*the contact owns a 2004 ford f-150. while driving 35 mph, the contact noticed a strong fuel odor around the vehicle. he then noticed fuel on the ground which was leaking from the fuel tank. the contact called the dealer who advised him to take the vehicle in for diagnosis. the manufacturer had not been notified. the failure mileage was approximately 15,000.

Tl* the contact owns a 2004 ford f150. the contact stated while parking the vehicle, he noticed an excessive gasoline leak. the vehicle was towed to the dealer where the contact was advised that the fuel line had fractured where the fuel pump and pressure lines entered. the contact was able to locate a recall for the failure (nhtsa campaign id 04v443000: fuel system, gasoline: storage: tank assembly: mounting) and when inquiring with the dealer, was advised his vin was not included in the recall. the vehicle was not repaired. the failure and current mileages were approximately 70,000.

2004, 4.6 ford explorer pickup spark plugs break off, can't get them out, causes much damage, cost $$$$ to get repaired that i don't have! there are many many people on website forums who have this same problem. some even say the ford dealership they took their truck to couldn't even get the spark plugs out either. is there a recall? *tr

Tl*the contact owns a 2004 ford f-150. while driving approximately 35-40 mph he smelled a fuel odor. he inspected the vehicle and saw no visible leaks. for a few days the odor was not present; however, it later became progressively worse. he also stated that the smell was much worse when using the heat in the vehicle. the contact referenced recall 04v200000, fuel system, gasoline:storage:tank assembly. he called the manufacturer and was advised that his vehicle was not part of the recall. the contact stated that the failure had been on going for 9 months. the vehicle was not repaired. the approximate failure mileage was 59,000 and the current mileage was 66,000. updated 02/23/11*lj

Tl*the contact owns a 2004 ford f150 4x4. while driving 57 mph the vehicle lost all power and shut off. the vehicle slowly cruised over to the side of the road and came to a complete stop. the check engine light illuminated stating low oil pressure. the vehicle was towed to a local mechanic who stated that a diagnostic test showing codes p091 for the fuel rail pressure sensor which was replaced along with the fuel pump. the fuel pump control module corroded and the housing was cracked with a hole in it that also shorted out and caused the failure to occur. the dealer nor the manufacturer were not notified. the failure mileage was 91,450.

On mon. march 1 of this year i went to my truck, a 2004 ford f-150 to go to work and it wouldn't start. i had it towed my local repair shop and was informed later that day that the "fuel pump control module", which is mounted on top of the gas tank, had corroded and shorted-out. this module is designed to regulate gas flow from the fuel pump and when it fails, it completely shuts down the pump...no gas means no go. i was then informed that ford motor co. does not have any and that the part is on back-order until may!! after calling 9 different ford dealers and getting the same answer of "good luck in finding one as there has been a run on these in the northeast due to heavy salt use" it seems no-one has any. i know this was not a safety issue in my case but to tell customers to wait 2 months before they can get their truck back is insane. and if it happens while driving it could be a major problem. i just feel ford should have been better prepared for this ...2 month wait is unheard of. *tr

The 'engine fuel control module' on my 2004 ford f-150 4x4 extended cab, 6 3/4ft bed, 5.4l 3v engine 4x4 has failed due to poor design. the module is located under the bed of the truck, and cracks when hit by pebbles that are inevitably kicked up. water then gets into it and it fails causing the vehicle to stop and not run at all. once the mechanic found out what the issue was, he then tried to order the part. the module is on national back order, 3 months i'll have to wait to receive it. this is my only source of transportation and i do not know what to do. i paid over $30.000 for this vehicle and now i cannot drive it because of a $77 part that i cannot get. ford should be held responsible for this issue and the time that i will not be able to use it. if it is on 'national back order', then obviously there is a design issue and a recall should be issued. 3 months back order is not acceptable. is ford motor co going to give me a ride to work, the doctors, etc while i wait for the part to come in? something has to be done. please do your best to look into this and find a solution. thank you again for your time and consideration. *tr

Tl* the contact owns a 2004 ford f150. the contact was driving at approximately 65 mph when the vehicle stalled suddenly and completely shut down. the vehicle was towed to a dealership where the contact was informed that the fuel pump marginal had rusted and separated from the vehicle. the dealer repaired the vehicle at the expense of the contact. he called the manufacturer and was told that he would have to assume the repair costs. the failure mileage was 48,842. the current mileage was approximately 50,000. updated 05/06/10. *lj the fuel pump module was severely corroded. updated 07/27/10*jb

Tl*the contact owns a 2004 ford f150. she stated that when the vehicle was in operation she smelled a strong odor of fuel. the vehicle was taken to a local repair facility; however, the mechanic could not identify the cause of the failure. she notified the manufacturer in reference to recall # 06e056000 (fuel system, gasoline); however, a representative stated that since the vin number was excluded, she was ineligible for a free remedy. no repairs have been made. the current and failure mileages were 114,000.

Tl* the contact owned a 2004 ford f150. the contact stated that while parked in the driveway the vehicle caught fire and destroyed the vehicle. the garage on the house caught on fire as well as her commuter car. the fire department responded and put out the fire. ford motor company was contacted and they filed a claim 1496812899. there was a recall nhtsa campaign id number: 06e056000 fuel system, gasoline but her vin was not included in the recall. the failure mileage was approximately 77,603.

Tl*the contact owns a 2004 ford f150 purchased new in 2004. he stated that there was a very strong fuel odor in the vehicle. an independent mechanic stated that there was a recall on his year, make and model for the same failures; however, his vin was not included in the recall (nhtsa campaign id number 04v200000). the failure mileage was 95,000 and the current was 101,000.

I have three ford and hadn't been notice about any recall on my ford f150 2004 and 2007. *tr

Ford f-150 - 2004 v8 triton spark plug blew out. 68,086 miles. ruptured fuel injector spray bar. $3,186.00 in damages. *ak

Dt*: the contact stated there was a smell of gasoline which entered the home while the vehicle was parked in the garage. the vehicle was taken to a service dealer, where they were unable to determine the problem. the manufacturer was also notified. there was a nhtsa recall # 04v200000 which pertains to the gasoline tank assembly. the vehicle was not included in the recall due to the vin.

2004 ford f-150 fx4 stalls while driving; it is as if the gas pedal no longer works. had vehicle towed to dealership. they have had the vehicle for four days and state that they cannot find anything wrong with it. they state that the computer shows that it was run on "lean fuel", however it had a full tank of gas. runs okay during test driving by dealership. however, stalling presents a safety concern. 8jb

1) my truck will still out when coasting to red lights or when idling. 2) when the truck stalls, i loose power steering and power breaks, yesterday it died out right on top of some railroad tracks and was giving me trouble trying to restart. it would say "low oil pressure" on start up, however that's because the rpm's weren't high enough to create enough oil pressure. it will then go into engine failsafe mode. 3) the ford dealership says i need a new throttle body and to reflash the pcm. however i have not been able to make the repairs yet because i can not afford them. *jb

We have a ford f-150 2004 the truck is a little over a year old to us. the truck started cutting out when got hot. so we cared it up to the ford dealer for diagnostic where we was told that it was the fuel filter which was changed. well the truck counties to have this problem. and each time it gets worse it is causing more trouble with the vehicle. and on top of that the seat belts lock up once the truck is cranked. we have taken it in and it never got better. *nm

Dt: 2004 ford f150. the contact stated when turning on the air conditioner was unable to adjust it or turn it off. he stated none of the buttons worked for the air conditioner. this occurred for approximately 15 minutes. the air conditioner finally turned itself off when he turned his headlights on. the vehicle was taken to the dealership and they could not find anything wrong with the vehicle. this only happened the one time, on october 15, 2005. *ak updated 11/30/2005 - this problem occurred once more after oct 15 an hasn't been repaired. the sliding rear window does not work. the fuel gauge did not indicate the correct amount of fuel after the vehicle was filled up. *nm

I have a 2004 f150 ext cab long bed 4x4 with less than 3/8 of a tank of gas my truck will not operate off road on hills and descents it starves for fuel cuts off and dies ii lose all power steering and brakes. i have the upgraded gas tank with 37.5 gal capacity. it even died on me on the interstate i-40 seven miles descent coming out of ashville. it nearly killed me losing controls of my vehicle. i thought i was going to have to hit one of the runoff sandtraps to stop my truck. it constantly leaves me stranded on jobsites just trying to park close to a house on a hill. the ford dealer (town and country charlotte nc) says my only cure is to keep more gas in it. i did not buy a 4x4 that i can not take off road purposely and would love to have it fixed. it is dangerous. i often drive as much as 80 miles at 13 mpg before the low fuel light ever comes on after it dies. when i fuel my truck when the light comes on i typically put 30 -31.5 gallons, that means at first failure on an incline i should have about 14 gallons of gas good for at least 100 miles. i work and hunt and camp out of my off road truck and it can not perform its duty with less than a 1/2 tank safely. *nm

A chatter/ vibration in the rear- clutches in the rear were replaced. check engine light came on- replaced the fuel vapor management system. brake light on roof leaking- light was replaced. roof of truck rusting- nothing done. *jb

Tl*the contact owns a 2004 ford f-150. the contact stated that the vehicle loses power while driving 45 mph. the vehicle was taken to the shop three times within two years to replace the fuel pump. the vehicle operates normally for a few months, but will lose power and start surging shortly afterwards. the vin was unavailable. the current mileage is 87,000 and failure mileage was 25,000.

Tl*the contact owns a 2004 ford f150. when the contact depressed the brake pedal, the vehicle would stall. the failure also occurred when turning the vehicle at less than 5 mph. the rpms would drop to zero before the vehicle stalled and jerked as if it were attempting to proceed forward. the dealer could not duplicate the failures. the contact discovered that by placing a higher grade of fuel into the vehicle, the failures would temporarily cease for a few months. the failure mileage was 17,000 and current mileage was 103,000.

While applying the brakes coming to a red light at an intersection, all power was lost and driver unable to stop vehicle and crashed into a dump truck. no airbags were deployed, all power was lost. dealer checked vehicle and said that they could not find anything wrong with the vehicle. very disturbing failure because the dealer could not find anything wrong with the vehicle to fix and that this could happen again at any time.*ak

Vehicle was parked and consumer noticed fluid was leaking from underneath the vehicle. and a odor was coming in from the vents. consumer drove the vehicle to the dealer for inspection, and mechanic determined that o ring needed to be replaced inside of the engine. also, a second problem occurred. while applying the brakes pedal went to the floor,and the driver heard a squeaking noise. mechanic determined that the both front rotors needed to be replaced. *ak

The emission light came on. the vehicle was taken to the dealer, and consumer was told that fuel pump was defective. the gauge went out of control. after filling the tank, the gauge read empty. *ak the brake light wiring was inoperative, alignment was out, the vehicle had stuck in park, the right passenger door was inoperative, the speedometer read wrong, and the vehicle would die out. *sc