2004 Ford F-150

Here’s a breakdown of common issues and complaints associated with the 2004 Ford F-150, organized by category and engine/transmission options. This information aims to provide a comprehensive overview for potential buyers.

The 2004 Ford F-150 marked a significant redesign for the popular pickup truck. It was offered with three engine options: a 4.2L Essex V6 producing around 202 horsepower and 260 lb-ft of torque, a 4.6L Triton V8 making approximately 231 horsepower and 293 lb-ft of torque, and a 5.4L Triton V8 generating about 300 horsepower and 365 lb-ft of torque. The 4.2L V6 was typically paired with a 5-speed manual or 4-speed automatic transmission, while the V8 engines were usually mated to a 4-speed automatic transmission (4R70W or 4R75E, depending on the engine and year). Owners often praised the 2004 F-150 for its comfortable ride, spacious cabin, and improved styling compared to previous generations. Common complaints included issues with spark plug ejection (5.4L), and various electrical gremlins.

Engine

4.2L Essex V6

• No Issues Found

4.6L Triton V8

• No Issues Found

5.4L Triton V8

• Spark Plug Ejection
  • Description/Symptoms: Spark plugs can eject from the cylinder head, resulting in a loud popping noise, misfire, and potential damage to the spark plug, coil pack, and cylinder head threads. This is most common on early 5.4L 3V engines (2004-2008).
  • Solution: Repairing the cylinder head threads using thread repair inserts (e.g., Time-Sert or Heli-Coil). In severe cases, cylinder head replacement may be necessary. Proper torque procedures are critical when reinstalling spark plugs.
  • Estimated Cost to Fix: $300 - $1500+ (depending on the extent of damage and repair method).
  • Recalls: None Found
• Cam Phaser Failure
  • Description/Symptoms: Ticking or rattling noise from the front of the engine, especially at idle. Reduced engine performance, poor fuel economy, and potential stalling.
  • Solution: Replacement of the cam phasers, timing chains, chain guides, and potentially the oil pump.
  • Estimated Cost to Fix: $1500 - $3000+
  • Recalls: None Found

Transmission

4R70W/4R75E (4-Speed Automatic)

• No Issues Found

Suspension

• Ball Joint Failure
  • Description/Symptoms: Excessive play in the front suspension, clunking noises, uneven tire wear, and potential steering instability.
  • Solution: Replacement of the affected ball joints (upper and/or lower).
  • Estimated Cost to Fix: $200 - $600 per side.
  • Recalls: None Found
• Broken Leaf Springs
  • Description/Symptoms: Sagging rear end, especially under load. Clunking or squeaking noises from the rear suspension. Visible cracks or breaks in the leaf springs.
  • Solution: Replacement of the broken leaf spring(s).
  • Estimated Cost to Fix: $300 - $800 per side.
  • Recalls: None Found

Electrical

• Blend Door Actuator Failure
  • Description/Symptoms: Inability to control the temperature of the air coming from the vents. One side blowing hot while the other blows cold, or no airflow at all. Clicking noises behind the dashboard.
  • Solution: Replacement of the faulty blend door actuator.
  • Estimated Cost to Fix: $150 - $400 (depending on location and accessibility).
  • Recalls: None Found
• Window Motor Failure
  • Description/Symptoms: Window not moving up or down, or moving slowly and erratically. Clicking noise from the door when the window switch is activated.
  • Solution: Replacement of the window motor.
  • Estimated Cost to Fix: $150 - $350 per window.
  • Recalls: None Found

Exterior

• Door Handle Failure
  • Description/Symptoms: Door handle breaking or becoming difficult to use. Often caused by a broken plastic linkage inside the handle.
  • Solution: Replacement of the door handle assembly.
  • Estimated Cost to Fix: $50 - $200 per handle.
  • Recalls: None Found
• Rust on Undercarriage
  • Description/Symptoms: Heavy corrosion on frame, suspension components, and body panels.
  • Solution: Rust remediation through sanding, coating, and potentially welding in new metal.
  • Estimated Cost to Fix: Varies widely, depends on the extent of the damage. Potentially $200 - $5000+

Interior

• Cracked Dashboard
  • Description/Symptoms: Dashboard cracking in the area closest to the windshield
  • Solution: Replacement of the dashboard cover or complete replacement of the dashboard.
  • Estimated Cost to Fix: $100 - $1000+ (depending on the method)
  • Recalls: None Found
• Broken Seat Bracket
  • Description/Symptoms: Seat does not stay in position or the lever to move the seat is not functioning
  • Solution: Replacement of the seat bracket
  • Estimated Cost to Fix: $50 - $200 per seat.
  • Recalls: None Found

Summary

The 2004 Ford F-150, while generally a well-regarded truck, does have its share of common issues. The spark plug ejection problem in the 5.4L Triton V8 can be a significant expense. Electrical gremlins, such as blend door actuator failure, are relatively common and can be frustrating. Suspension issues, like ball joint and leaf spring failure, are typical for trucks of this age and mileage. Potential buyers should thoroughly inspect any used 2004 F-150 for these issues and factor in potential repair costs.