Problems with 2004 Ford F-150 ENGINE AND ENGINE COOLING

On a sunday, i was on a side street when the engine went dead. i noticed the wrench light was on. i called the wrecker service as it was still in warranty. the wrecker driver arrived and asked if i had tried to restart it, which i didn't. i started it and drove home. i took it to the dealer on 06/04/08. they could not duplicate the error nor find anything in the computer module. on 03/29/09, the same thing happened. if i had been on a highway or freeway, i might have had a serious accident. i waited a few minutes, then the truck started up again. i took it back to the dealer on 04/01/09. they kept it overnight doing various tests. the computer showed nothing. they finally suggested to replace the throttle body and reprogram the pcm. i agreed even though it was out of warranty and cost me $484 to repair. i was leery of driving on a highway and freeway as if it happens there, i'm sure if i can't pull over i will surely cause an accident. subsequent checks on the internet found the is a common occurrence. the engine is supposed to go into "limp mode" to allow one to slowly, but safely drive to a safe spot. my truck, and many others, do not go into "limp mode"; they just go dead. i strongly suggest this be investigated before a serious accident occurs due to this default. *tr

The vehicle wrench light came on and the engine quit. had i been on a freeway, a serious accident might have occurred. i called the warranty service for a wrecker as it was still in warranty. about 40 minutes later, the wrecker arrived and the driver asked me if i had tried to restart the engine. i hadn't, tried, and it started. i researched the internet and found some information including a suggestion to disconnect the battery to reset the computer. unfortunately, i did that and when i took it to the dealer the following tuesday they couldn't tell what caused the problem. it happened again on march 25, 2009. again, i was glad i was on a side street. i will take the truck to the dealer tuesday even though the warranty has expired as this could be a very serious problem on a highway. *tr

We took our vehicle in for service immediately after we experience the engine missing. the service center diagnosed the problem would be corrected by replacing the ignition coil, plugs and wire boots. this seemingly simple service job has literally turned into a nightmare. after almost 4 weeks our vehicle is still in the shop. in the process of changing the plugs, 2 plugs broke. the dealership needed a "special" tool to remove the broken plugs and had to order it. when they got the tool, the still couldn't remove the plugs and said they would drill them out. and then - the biggest blunder of all happened - while they were drilling some pieces of porcelain fell into the engine and scarred the cylinder(s)which could potentially cause the entire engine to fail. now we're being told because of this we need to replace the engine!! each time they called it was about something else going wrong and more money!! we're loyal ford customers! these adtl repairs should not be at our cost! *tr

Engine stalls when turning corners. unless i have it towed to a repair shop this vehicle is not safe to be driven. *tr

Tl*the contact owns a 2004 ford f150. the contact took the vehicle in for a routine tune-up in 2007. a few months later, he had to replace the motor. on march 9, 2008, the vehicle stalled and the check engine indicator illuminated. he took the vehicle to a repair shop and the diagnostic indicated that the timing chain slipped and caused the metal clips to fail. the manufacturer stated that because a ford dealer did not replace the motor, they would not assist with the repairs. the vehicle was repaired at the cost of $1,893 at an independent repair shop. the failure mileage was 94,000 and current mileage was 95,000. updated 0424/09. *lj updated 04/27/09.*jb

Out of the blue the truck just starts shaking, never know when or where. i have to pull off road and shut it off ,wait a bit, then start and leave and seems to be ok till next time. it has 37,800 miles . last time on i-94 at 65mph it scared me to death it started shaking so bad . i also had a 2005 f150 that did this. its not the tires, or engine but i think the drivetrain . very bad safety issue as i am finding i am not alone with this problem. someone needs to make ford admit what this is and fix these trucks. *tr

Tl*the contact owns a 2004 ford f-150. while driving approximately 50 mph, the contact noticed that the engine warning light illuminated on the instrument control panel. the power began decreasing simultaneously and prevented the vehicle from traveling above 35 mph. the dealer replaced the coil pack and spark plugs in the number five cylinder. the contact heard a knocking noise when he started the vehicle and the failure recurred. the dealer stated that the spark plugs blew out of the aluminum head. they also stated that there were only five threads holding the plugs to the aluminum head, and, even if they made the repair, the vehicle could still fail. the manufacturer would not assume any liability. the failure and current mileages were 44,000. updated 03/25/08. *lj

I want to preface this by saying that before this problem occurred i had my f-150 iat a ford dealership in raleigh nc two says before because the vehicle would randomly shut off when i was driving it about 600 miles before the extended warranty was up. they said they could not find anything wrong with it so i was forced to take the vehicle back i was driving home from my parents house in ohio on christmas day. as i was heading through virginia to north carolina i heard a noise coming from under the hood. i stopped to see what it was and eventually found out that the spark plug had blown away from the head. apparently this is a common problem with this make and model vehicle along with many others. after horrible customer service i was forced to pay almost 3500 dollars in order to get my truck back. ford said that they could not do anything about it. 1d *tr

Engine has had a ticking noise in engine since day i bought the truck. talked to dealership and they said normal noise from 04 f-150 trition they have since closed. went to another dealership was told same thing. broke down went to hometown mechanic replaced cam gears after another dealership asked if it sounded like a diesel. also pulled valve cover off to find valve spring and rocker arm on cam. total discounted cost from friend was $2400 not counting machining heads. *tr

Ford recommends changing the spark plugs on my 2004 f150 5.4 3-valve at 100,000 miles. mileage was getting close so i tried to change them. unfortunately ford did not tell owners that there is a huge problem with the spark plugs breaking-off in the cylinder causing a massive repair bill. engine had must be removed to take out broken plug. ford did produce a tsb, but did not inform owners that this routine service should be done by dealer. upon checking internet, there are scores of reports of the plugs breaking when both owners and dealers attempt the routine maintenance. *tr

2 spark plugs fowled up, seizing in block and breaking inside. *tr

Ac hose drain tube along fire wall disintegrated. hose was replaced with part#emc6a614. this was not original part made by manufacturer. this part was upgraded as a response to issues that ford 150 owners were having regarding this hose leaking into the cab of the truck. *tr

Without any warning the v-8 5.4 engine started missing, dealer in winslow az said they had a lot oftrouble with that engine shooting the spark plugs out. two of the plugs were loose , one apparently more than the other. replacing plugs did not help. some reports of others tell of this going on since before 97. some with fires. i wonder why this situation has gone on so long and still not fixed. *tr

2004 ford f-150 ejecting spark plugs. consumer states the engine started missing. dealer told him they were having problems with the engine shooting spark plugs out. *kb the dealer found error codes for cylinders 2 and 4 which were soaked with oil. *jb

My vehicle has low power, stutters, and cuts off. a service bulletin was said to has come out about possible defective pushrod or rocker arms am not sure but i am sure that the problem come from the point of original assembly and i should not have to pay for an issue that starts from manufacturing. *tr

Tl*the contact owns a 2004 ford f150. he noticed that the spark plugs were breaking off and going into the engine. as a result, the dealer stated that the engine should be replaced. the manufacturer stated that they have received numerous complaints regarding the failure. the failure and current mileages were 73,000. the vin was unavailable.

2004 ford f-150 with 5.4l gas engine. manual says change spark plugs at 100k miles. dealer broke all 8 plugs off in heads. the heads had to be removed. bill is $2,000, just to change spark plugs. *jb

Tl*the contact owns a 2004 ford f-150. while driving at an unknown speed, the vehicle sporadically stalled and the engine warning light illuminated on the instrument control panel. speed was not a factor. the dealer replaced the fuel throttle sensor and cleaned the throttle body. several days later, the failure recurred. the dealer stated that she would have to pay for ten hours of diagnostic fees before they could determine the cause of the failure. the technician stated that the vehicle had a history of stalling prior to the contact making the purchase. the vehicle has not been repaired. the contact called the manufacturer and was referred back to the dealer. the failure mileage was 40,601 and current mileage was 57,700.

Started with engine noise. ford diagnosed it as cam shaft. cost $1700.00, my cost would be $800.00. local dealer is now out of business. i have talked to 3 other people with the same problem. there must be a lot more.*ak

Tl*the contact owns a 2004 ford f-150. the contact stated that the engine head detached while changing the spark plugs on the vehicle. the dealer stated that the engine must be disassembled in order to remove the spark plugs. the contact will be responsible for the repair cost. the current and failure mileages were 53,000.*ak

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

Tl*the contact owns a 2004 ford f150. when driving 35 mph the vehicle stalled and was driving hard. the vehicle was taken to the dealer and the spark plugs were replaced. the dealer stated that the spark plug in cylinder five was broken in half. the current mileage was 53504 and the failure mileage 53500. the engine size, and power-train were unknown. the consumer stated that he didn't understand how this defect could happen. he contacted the dealer about repairs but was informed by the dealer not perform the repairs himself because he would not be able to do it. the consumer stated while trying to perform the repairs on the truck spark plug #5 was broken and the more he tried to fix the truck the more trouble he had. the consumer stated he had to take the vehicle to the dealer to be repaired and that a price was agreed upon. the consumer stated that his confidence had been shaken with ford and an investigation should be done. the consumer provided the repair invoice. updated 07/23/07 *tr

Engine surges without touching gas pedal while in gear

Condensation in the engine block. after finding water in the oil of my vehicle, a 2004 ford f150 with the 5.4 liter engine, i took it to the dealership for head/head gasket repair assuming the water was antifreeze coming from a failed head gasket. the mechanic at the dealership identified the water in the oil and told me that this comes from condensation in the engine block and that it is a normal condition in all f150s with the 5.4 liter engine. i don't know if this means only those built after 2004, or all. water in any engine is not a good thing as it causes corrosion, breaks down lubrication, etcetera. potential failure would be that the engine could prematurely/unexpectedly fail, stranding the driver and having a huge cost implication for the owner who would likely have to have a remanufactured engine installed at their own cost since the failure is likely to occur after the 3 year/36000 mile warranty has expired. nothing at all was done to correct this defect.*jb

At ~ 30,000 miles, the engine (a 5.4 triton v8) began sounding like a diesel engine. took the truck to the dealer. the dealer "..recalibrated the cam sensor..." and stated the sound(s) were normal for this engine. i called ford motor company and they customer service rep told me same thing. the noise is getting louder indicating the problem is worsening. is there anything that can be done to correct this issue before the engine suffers a catastrophic failure? *tr

Engine makes a tapping noise at head covers. *tr

My vehicle is f150 supercrew lariat. the vehicle has 80kmil. it has been running very sluggishly and idles hard in a complete stop. the auto repair shop has diagnosed the problem with the truck engine as 2c oils burned and 2pzt2fe spark plugs split in half--white middle cover of plug plug still lodged into engine. *jb

1) unknown events leading to failure, normal driving, events happened when i first turned on vehicle and during backing up .2) the engine raced out of control and lurched until ignition key was removed (it grabs the gas pedal from the driver like cruise control does) if someone or something is in vehicle's path it or they will be crashed into. then the vehicle and 8 cylinder runs like its on 4 cyl and the air conditioner doesn't work. 3) taken to ford dealer coastal ford in mobile al,they rebooted computer but would not replace computer board, they said just bring it back for reboot if it happens again, diagnostic did not reveal reason for racing engine they were not concerned that if the events happened again an accident could not be prevented or the truck being destroyed which means it could not be taken back for reboot or how to prevent this event .i wanted them to replace the supposedly defective computer board (in my opinion that's the problem) old part still in vehicle .no damages yet but since i professionally bass fish, i could be run over,the truck might race into the water,or someone else and their equipment could be run over and if backing into the garage with a boat the house and boat could be damaged or if the boat trailer has to be dealt with the person behind the truck could be run over. 2004 f150 extended cab v8 engine truck is the vehicle. 6 events over the last 4 months (it just came out of some of its warranties, ford dealer said the computer was warranted for 8 more years)*jb

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

2004 f150 right fog light replaced, front kick panel cracked and loose. *ts ***nar*** the floor trim on the passenger side came apart. the vehicle would not start. the check engine light illuminated. the oil pressure read zero. the temperature gauge failed. *nm

Constant engine noise that sounds like lifters, very loud....have had numerous people look at the problem, no one can seem to locate the issue, or repair it in any way or diagnose the problem. *tr

Rear window seal is loose and window rattles inside of mounting area indicating an insufficient mount to retain window in mounting area. *nm

On 9/28/05 our 2004 f150 ford pick up caught fire as the operator was driving at approximately 10 m.p.h on a dirt road. the fire appeared to start in a location in the engine compartment. the vehicle was totally destroyed by the fire. *jb

(3) i have to have the pulleys and tsb clutch fan replaced in my 2004 ford f-150. i am upset because i took my vehicle in on june 13, 2005 with same problem and was told there was nothing wrong. now 6 weeks later they know without even looking at it and a bulletin has been out since march 7, 2005. *jb

2004 ford f-150 2wd reg cab long bed: 1 - shifting vehicle with automatic transmission during a complete stop from reverse to drive 2 - once drive engaged, the throttle engaged at full power without driver's initiation of gas pedal. tried to stop vehicle by applying brake first with one foot, then with two, with no effect. the vehicle finally stopped once shifted to neutral and then to park. damage to vehicle caused by running through a chainlink fence which resulted in approx $2500 in repairs. 3 - ford roadside assistance towed vehicle to dealer. service technicians could not locate problem. damaged fixed in dealer body shop via driver's insurance policy. once body work completed, the body shop technician put in a request to the service technician to check the vehicle again as the throttle was not responding properly. vehicle is currently still in service shop for further mechanical investigation.

Dt: the consumer bought a used 2004 ford f150 and has been experiencing a problem with the engine dying when applying brake pressure. this occurs in high traffic areas and at slower speeds in stop and go traffic. took to a dealer and they performed eec diagnostic quick test and pinpoint test diagnostic ignition tests as well. as a result of those tests they replaced a mass airflow sensor assembly and reprogrammed the pcm. has been to dealer on 4 occasions for this problem and dealer claims they can not find anything wrong with it. contacted ford manufacturer they had "joystick"or test stick installed in vehicle for 5 days in which consumer was unable to duplicate the problem at that time. this has happened 1 time since. also on the dash there is a 4x4 high/lo light that illuminates on the dash when this occurs but the vehicle does not have 4 wheel drive. dealer said they were unable to reset the pcm to correct this particular problem. this is still a problem, no recent repairs. dealer can not duplicate the problem at this time. *jb

I own a 2004 ford f150 super cab truck.while exiting the expressway iwas coasting down the ramp and when i approached the traffic light i applied the brakes and the vehicle started accellerating when i figured out what i put it in neutral and slid into the intersection.the vehicle operated normal after i got it stopped.the following day i took it to the ford dealership.they said there where no faults stored in the computer and it test drove normal could not duplicate problem. it has the 5.4 v/8 engine

I purchased a new 2004 f-150 vin [xxx] in aug 2004. the safety issue i have is that we began having a problem with the vehicle stalling while it was being driven and for some reason when the vehicle was turning left. it was not a constant thing when we were driving the truck. however after a few occasions over a couple months we took it to the dealer.we took in on feb.1 2005. the vehicle had 2600 miles on it at this time.the dealer concurred with the problem and the dealer contacted ford motor company for assistance on how to correct the problem.the dealer did as they were instructed by ford and did checks and inspections of several systems. they thought they had it resolved.but a month to six weeks later it began stalling again.only a couple of times at low speed.then some time pasted it did it again then a week later it shuttered while entering traffic. then 3 days later it stalled in the middle of a three lane expressway blocking traffic for more than an hour.in the past everytime it stalled it would restart. this time it would not crank over but it had a hot battery.it was towed to the dealer they diagnosed it as a bad mircoprocessor i believe. this was replaced ,it did not cure the problem.the current mileage on the vehicle is 4700 miles. my safety concern is that as many times as this vehicle has stalled i have not been hit by another vehicle. but my luck may run out. have others had similar problems,have there been recalls in this problem or service bulletins. i emailed ford and it was confirmed that they received my email but they did not respond for the second time.the dealer is very understanding buy if ford has data that will help they need to convey it to the dealer.i need a resolution and an assurance that the problem is solved.its no different from driving a vehicle that the steering may break at any time.when it stalls i loses power brakes and power steering plus the danger of approaching traffic. *js information redacted pursuant to the freedom of information act (foia), 5 u.s.c. 552(b)(6)

Dt: without warning, carbon monoxide smelled in vehicle and water leeking from exhaust system. the smell happened most of the time when the windows were closed and when it was raining . but it smelledalso when it was dry. dealer stated they couldn't help help because they were not able to redesign the system. manufacturer stated they couldn't help caller. *ak

Tl*the contact owns a 2004 ford f-150. while the vehicle was parked the contact stated the engine was extremely loud and made a ticking noise. the check engine light illuminated on the instrument panel. the vehicle was taken to the dealer where the technician stated the cam phasers needed to be replaced. the vehicle was repaired. the approximate failure mileage was 20,000.

Intermittently vehicle would stall while making turns, slowing downs or coming to a stop. vehicle has been to the dealer, and dealer reset the computer. however, the problem recurred. *ak

Dt: had to put 4 sets of brakes on vehicle since purchasing the car. the rotors were getting grooved so badly that vehicle pulls off the road. the consumer talked to ford, and they ignored him. he traveled and saw this problem with several other ford cars. ford told him it was cosmetic. *ak while on the first trip with this vehicle, the rear end had gone out, the clutch pack was removed and replaced, the fog lamps were holding moisture and were replaced, the brakes would pulsate and pull from one side, the shifting was harsh when changing from first to second gear, a loud clunk would be present at times when starting from stop then decelerating and the vehicle would crank but would not start at times. sc

2004 ford f-150 pickup truck stalls when slowing to a stop. the truck has done this over 20 times in the last 4 months.*ak

2004 f150 supercrew, engine stalls while coming to a stop, braking and slow turns. his has happened 30 to forty times since the truck was purchased new oct 2003. ad it service for the problem in 2004, seemed to fix it, but started happening again. had it to the service department 2 more times with no fix yet. when the engine dies you lose brakes steering. this is very dangerous with on coming traffic.*ak

Fire in engine compartment of ford f-150. owner was attempting to drive the vehicle out of the snow where he got stuck. while doing so, the engine compartment caught fire. fire first see from the driver side cowl. heavy fire damage to the engine compt.

Vehicle experienced sudden stalling at low speeds. taken to the dealer for check up.*ak *bf *nm

While driving in heavy traffic the steering wheel locked up and the vehicle veered to the right. *nm the engine light had come on another occasion. *sc *jb

While driving 40 mph vehicle stalled intermittently. consumer managed to restart the vehicle. dealership was notified, but did not resolve the problem. *ak

Motor would begin to surge and then the check engine light would come on. took to dealer and they changed spark plugs after only 5,706 miles. we have since changed the spark plugs 7 more times with in 80,000 miles. some thing occurs each time. *tr

2004 f150/5.4 engine quits at low speed. completely random, may do it several time in one day and than not again for several weeks. i have been involved in several close calls when the vehicle quit at intersections and railroad tracks. since no odbc codes are ever set, dealer can't seem to find the problem. *jb