2004 Ford F-150 Problems
RepairPal has identified the most common problems with the 2004 Ford F-150 as reported by actual vehicle owners. We'll tell you what the problem is and what it'll take to fix it.Refine by vehicle
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.
Our technicians tell us the spark plugs in this engine can be very difficult to remove. Ford has issued a service bulletin (08-7-6) to address this issue, which includes a recommended procedure on how to remove the plugs. Failure to follow the recommended procedure can result in the one or more spark plugs breaking off in the cylinder head.
The recommend procedure is as follows. Using this procedure will greatly reduce the chance of breaking a spark plug.
1. Break the spark plugs loose when the engine is warm.
2. Turn each plug 1/8 to 1/4 turn and soak the treads with 1/2 to 3/4 teaspoon of Motorcraft Carburetor Tune-Up Cleaner or a quality penetrating oil. Do not try to remove the plugs at this time.
3. Let the threads soak for at least 15 minutes.
4. After the soak period, tighten and loosen each spark plug, working it back and forth until the turning effort is reduced. Then, you can remove the spark plug.
There are special tools available to remove the broken spark plugs and repair shops will often charge additional labor time, over and above the quoted spark plug replacement cost, for the removal of each broken spark plug.
Intermittent rough idle may be caused by the EGR sensor sticking, causing the EGR valve to stay slightly open. Our technicians tell us the valve and sensor must be replaced together to correct this concern.
The battery light may illuminate on the instrument panel because the alternator wire harness connector is damaged. A new connector kit is available and should be installed to correct this concern.
The engine oil pan gasket can develop a leak. Leaking oil may accumulate on the exhaust system resulting in a burning smell. Replacing the gasket should correct this leak.
There is a technical service bulletin for the V8 engines regarding a possible problem with the spark plug being ejected from the cylinder head, damaging the threads in the spark plug hole. If the vehicle is under warranty, cylinder head replacement is recommended. If the vehicle is out of warranty, Ford authorized the use of a specific thread insert to repair the head.
If a noise from the rear end is heard when going around turns or after driving at highway speed for an extended period, there is an updated differential clutch kit available.
New TSB may be available
According to Ford Bulletin 06-04-04
Some 2003 + INDEPENDENT REAR SUSPENSION (IRS) AXLE F-150 vehicles equipped with a 9.75″ or 8.8″ limited and Mustang vehicles equipped with limited slip rear axle, may exhibit a chatter, shudder, a binding sensation, or a vibration during low speed turns. On 4X4 vehicles, the sensation may appear to be originating from the front axle or the steering gear.
First verify the condition. On 4X4 trucks ensure that Modifier (XL-3) for fifteen (15) minutes prior to the vehicle is in 2WD, to isolate the rear axle. If the condition is verified to be in the rear axle, replace the limited slip clutch pack.