2004 Ford F-150 Repair and Maintenance

A guide to problems, costs, maintenance and repair for your 2004 Ford F-150

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2004 Ford F-150 Problems

Updated Differential Clutch Kit Available if Rear End Noise is Heard

If a noise from the rear end is heard when going around turns or after driving at highway speed for an extended period, this could be caused by a failing differential clutch kit. An updated differential clutch kit available.

Rough Idle Caused by EGR Sensor Sticking

Intermittent rough idle may be caused by the EGR sensor sticking, causing the EGR valve to stay slightly open. The valve and sensor must be replaced together to correct this concern.

Water leak at high mount stop light

Water leaks that appear at the headliner and rear seat area have been known to be coming from the rear high mount stop light. The gasket that seals the light becomes warped over time and allows water to enter through the stop light into the cab area. A revised stop light is available, but I have found that properly placed caulk or foam tape will work also.

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2004 Ford F-150 Questions

2004 Ford F-150 4.6 P0174 & P2198 (2 answers)

Vehicle history: Truck started idling rough (should say "rougher" since I've always had a slight rough idol since purchasing the vehicle used in 2006) and misfiring about a year and a half ago. Then sat for 1 and a half years only being started and driven once in a blue moon. Now I ...

growling noise during idle and acceleration -seems to sound like an alternator (1 answer)

the noise remains constant and follows the RPM of the engine - for example during acceleration. Again seems like a noisy alternator but there is no loss of power, etc.

Engine misfiring under load. (1 answer)

In March I had the plug replaced by a mechanic. It had approx. 60,000 miles. Recently we took a trip upstate. The truck ran fine all the way. But when we started back it started to misfire and loose power when going up hills. Finally the engine light came on. Took it back to the mechanic and...

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2004 Ford F-150 Recalls

Possible Corrosion of Fuel Tank Straps

Vehicles sold or currently registered in states using corrosive chemicals to de-ice the roads may have fuel tank straps that can rust prematurely and fail. If the fuel tank were to shift as a result of a broken strap, the fuel lines could separate or the fuel tank could contact the ground. In either case, a fuel leak could develop, increasing the risk of a fire. Dealers will replace the fuel tank straps with straps that have increased corrosion protection. Early in the campaign, if replacement straps are not available, dealers may install a cable support under the strap as an interim repair or a steel reinforcement over the existing strap as a permanent repair. This recall is expected to begin September 12, 2011. The Ford recall number is 11S21.

The Driver's Air Bag Could Deploy Without Warning

The clock spring jumper wire behind the driver's air bag may come into contact with the lower horn plate, resulting in damage to the wiring. If this occurs, the air bag warning light may illuminate or the driver's air bag could deploy unexpectedly, increasing the risk of injury or a loss of vehicle control. Dealers will replace the jumper wire with a new design, which includes a protective mesh cover. This recall is expected to begin on February 28, 2011.

Ford Recalls 2004 F150 Trucks for Fuel Tank Manufacturing Issue

Ford has recalled certain 2004 F150 trucks for a concern with the manufacturing of the fuel tank. Fuel may permeate the liner of the tank, causing an odor, a leak, or a Check Engine Light. Leaking fuel and vapors are flammable and hazardous. Dealers will replace affected fuel tanks.

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2004 Ford F-150 Reviews

I purchased my F150 Supercrew XLT 5.4,with tow package new on Easter Sunday 2004, it has been a good truck,used extensively for towing a toy hauler fully loaded to the desert for years,used for projects around the house ,hauling heavy loads of landscape/building materials,etc! I have not abused the truck,but I have put it to the test as it was built to do and it has not let me down. I have alwa...
I bot new in Sep 2003. Just sold with 141,000,mostly trouble free miles. 5.4, XLT, Super Cab, 4x4. MPG: 9-11 city, 14-15 highway. Had cab high cap entire time, installed cat back duals in 2005. Greatest truck I've ever owned or driven. Can't say enough about it.
I absolutely hate this truck, first ford i have owned (all others being Chevrolets) and i have had nothing but bad luck and mechanical failure nightmares with this piece. This truck suspension is carp my two axel flat bed trailer with two quads squat it. The TRITON V8 5.4L is a JOKE, my Vortec V6 s-10 will drag this thing around. The Interior is the cheapest yet, i am a builder and most of my t...

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