2004 Ford F-150 Recalls, Problems & Maintenance

The 2004 Ford F-150 has no open NHTSA recalls. Owners report 8 recurring issue clusters, led by “Spark plug ejection from cylinder head.” Ford uses the Intelligent Oil-Life Monitor (IOLM) to determine when oil changes are due based on actual driving load — not just mileage. Ford's published cap is 10,000 miles or 1 year, whichever comes first. The schedule below reflects Ford's Normal service intervals; F-Series trucks and Super Duty have additional towing-specific items.

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No open recalls on file. NHTSA lists no unrepaired safety recalls for this year, make and model. A recall can be issued at any time, and a specific car can still have one open — check yours by VIN at nhtsa.gov/recalls.

Known issues & problems for this vehicle

What drivers and federal regulators have officially reported about the 2004 Ford F-150.

Reported to NHTSA

Spark plug ejection from cylinder head

ENGINE

9 NHTSA complaints · 2015-05 → 2024-05

“DRIVING DOWN THE ROAD AT NORMAL SPEED OF 55 WHEN MY 2004 FORD F-150 4.2 V-8 BLEW A SPARK PLUG OUT OF HEAD!!”
— Owner report, NHTSA ODI #10733677
“THE #3 SPARK PLUG HAS BLOWN FREE OF THE CYLINDER HEAD. THIS IS THE 2ND PLUG THAT HAS BLOWN FREE IN 1 1/2 YEARS FOR THIS TRUCK. THE LAST WAS EITHER THE #7 OR #8 PLUG. BOTH HAPPENED ON DECELERATION WHILE AT HIGHWAY SPEED”
— Owner report, NHTSA ODI #10853965
“The contact owns a 2004 Ford F-150. The contact stated that while driving at an undisclosed speed, the contact observed the spark plug being ejected from the fuel compartment”
— Owner report, NHTSA ODI #11536311

Read all complaints on NHTSA →

Transmission loses drive or shift cable fails

POWER TRAIN

10 NHTSA complaints · 2015-12 → 2024-12

“MY TRUCK GETS UP TO ABOUT 50 MPH THEN ACTS LIKE IT GOES INTO NEUTRAL , NO POWER TO THE BACK WHEELS. I'VE NOTICED THAT MORE THAN A FEW 2004 F-150 OWNERS HAVE THE SAME COMPLAINT”
— Owner report, NHTSA ODI #10920500
“MY 2004 F-150 SHIFT CABLE BROKE AS I ATTEMPTED TO PUT IT IN PARK. THIS RENDERED THE VEHICLE UNABLE TO BE PUT IN PARK AND IT ROLLED BACKWARDS”
— Owner report, NHTSA ODI #11103499
“TAKATA RECALL : TRUCK IS SLIPPING IN FORWARD GEARS AND THE REVERSE WILL NOT MOVE EVEN IF U YOU REV IT UP IT'S LIKE IT'S IN NEUTRAL”
— Owner report, NHTSA ODI #10916222

Read all complaints on NHTSA →

Rear differential noise, vibration, and failure

POWER TRAIN

9 NHTSA complaints · 2016-03 → 2018-04

“GRINDING IN REAR AXLE ASSEMBLY, DIFFERENTIAL NEEDS REBUILD,57K”
— Owner report, NHTSA ODI #10910123
“LOUD RATTLING/VIBRATION THROUGHOUT THE TRUCK, CAUSING TIRES AT TIMES TO BOUNCE AND SLIP. OPENED DIFFERENTIAL AND CARRIER HAS MALFUNCTION”
— Owner report, NHTSA ODI #10906143
“TL* THE CONTACT OWNS A 2004 FORD F-150. THE CONTACT NOTICED RUST ON THE REAR AXLE HOUSING. THE DEALER DIAGNOSED THAT THE AXLE WAS NEARLY RUSTED ALL THE WAY THROUGH AND THAT THE VEHICLE WAS UNSAFE TO DRIVE”
— Owner report, NHTSA ODI #10917856

Read all complaints on NHTSA →

Power window regulator failure drops glass into door

ELECTRICAL SYSTEM

6 NHTSA complaints · 2015-08 → 2017-07

“I WAS DRIVING DOWN THE HIGHWAY ABOUT 40 MPH AND THE DRIVER SIDE WINDOW JUST FELL TO THE BOTTOM INSIDE THE DOOR.I HADN'T TOUCHED A THING”
— Owner report, NHTSA ODI #10861451
“I WAS DRIVING DOWN THE ROAD WHEN MY LEFT REAR WINDOW WENT CRASHING DOWN INSIDE THE DOOR. AFTER DOING A LOT OF SEARCHING ON THE NET I FOUND THIS IS HAPPENING A LOT ON A NUMBER OF THE FORD F-150 TRUCKS, A CHEAP PLASTIC PART FAILS AND THE WINDOW FALLS DOWN”
— Owner report, NHTSA ODI #10895206
“TL* THE CONTACT OWNS A 2004 FORD F-150. WHILE DRIVING 40 MPH, A LOUD POP SOUND EMITTED FROM THE VEHICLE. THE CONTACT NOTICED THAT THE REAR DRIVER SIDE WINDOW OPENED INDEPENDENTLY”
— Owner report, NHTSA ODI #10864604

Read all complaints on NHTSA →

Frame rail rust-through and structural corrosion

STRUCTURE

43 NHTSA complaints · 2015-07 → 2025-01

“The underbody frame is 95% rusted out, this vehicle is available for inspection upon request. I could have been fatally injured, not knowing the under frame was gone, until vehicle was taken in for new tires”
— Owner report, NHTSA ODI #11530913
“MY 2004 FORD F-150 HAS 61,000 MILES AND NO RUST ON THE OUTSIDE OF THE VEHICLE. I'VE KEPT THE TRUCK WELL MAINTAINED AND IT LOOKS ALMOST NEW. THE FRAME HOWEVER RIGHT WHERE THE REAR LEAF SPRING ATTACHES TO THE FRAME IS RUSTED RIGHT THROUGH”
— Owner report, NHTSA ODI #11205939
“Frame on 2004 new body style ford f-150 rusted to the point no longer safe to drive according to 2 licensed repair shops”
— Owner report, NHTSA ODI #11637109

Read all complaints on NHTSA →

Air bags fail to deploy in frontal crash

AIR BAGS

9 NHTSA complaints · 2015-09 → 2026-09

“Vehicle was in an accident with major front and damage and none of the airbags deployed”
— Owner report, NHTSA ODI #11764667
“TL* THE CONTACT OWNED A 2004 FORD F-150. WHILE THE CONTACT'S FIANCE WAS DRIVING 35 MPH, A DEER RAN INTO THE ROAD AND CAUSED THE DRIVER TO SWERVE AND CRASH INTO A TREE. THE AIR BAGS DID NOT DEPLOY”
— Owner report, NHTSA ODI #11268659
“TL* THE CONTACT OWNS A 2004 FORD F-150. WHILE REVERSING, THE VEHICLE ACCELERATED INDEPENDENTLY. THE CONTACT SHIFTED INTO DRIVE AND THE VEHICLE CONTINUED TO ACCELERATE. THE VEHICLE CRASHED INTO A POLE AND A FENCE. THE AIR BAGS FAILED TO DEPLOY”
— Owner report, NHTSA ODI #10762595

Read all complaints on NHTSA →

Camshaft phaser failure causing stalling and knock

ENGINE

15 NHTSA complaints · 2015-05 → 2025-03

“CAM PHAZER IS OUT LEANING OUT THE TIMING, CAUSING THE MOTOR TO KNOCK AND IDLE AT 500 RPMS CAUSING THE VEHICLE TO COMPLETELY STOP IN TRAFFIC OR AT A STOP LIGHT”
— Owner report, NHTSA ODI #11034734
“TL* THE CONTACT OWNS A 2004 FORD F-150. WHILE DRIVING AT APPROXIMATELY 24 MPH, THE ACCELERATOR PEDAL WAS DEPRESSED AND THE VEHICLE FAILED TO ACCELERATE”
— Owner report, NHTSA ODI #10849574
“ENGINE STARTED TO IDLE ROUGH AND LOOSE ACCELERATION WHILE DRIVING UP HILL. STALLED A COUPLE TIMES WHILE STOPPED AND IDLING. THE ENGINE WOULD LAG WHILE ACCELERATING FROM A STOP”
— Owner report, NHTSA ODI #10763282

Read all complaints on NHTSA →

Brake master cylinder and booster failure

SERVICE BRAKES

8 NHTSA complaints · 2015-06 → 2018-08

“BRAKE MASTER CYLINDER LOST FLUID. LEAK WAS INTO THE BRAKE VACUUM BOOSTER. COULD CAUSE LOSS OF BRAKES IF IT OCCURRED WHILE DRIVING”
— Owner report, NHTSA ODI #11121741
“WHILE DRIVING, I TRIED TO STOP AND BRAKE PEDAL WENT TO FLOOR AND I HAD NO BRAKES.I HAD TO USE PARKING BRAKE TO STOP AND AVOID AN ACCIDENT”
— Owner report, NHTSA ODI #10839920
“MASTER CYLINDER LEAKED BRAKE FLUID INTO BOOSTER (JUST LIKE THE CURRENT INVESTIGATION ON FOOD F150) . CAUSING SUDDEN LOSS OF BRAKING ABILITY WHILE DRIVING”
— Owner report, NHTSA ODI #10851679

Read all complaints on NHTSA →

Source: NHTSA Office of Defects Investigation (ODI). Complaint data refreshed Sep 20, 2026. Investigation data refreshed Sep 20, 2026.

We display NHTSA's record with attribution; we don't editorialize on what these complaints mean for any specific vehicle.

Raw data + downloads for this vehicle →

Essential maintenance

Critical for safety and preventing major damage

Engine Oil & Filter

Every 7,500 mi

Replace synthetic-blend or full-synthetic Motorcraft oil per the IOLM, or every 7,500-10,000 miles. EcoBoost engines require full synthetic; Coyote 5.0L V8 specifies SAE 5W-30.

Estimated cost — typical U.S. ranges

Dealer

~$120–$160

Shop

~$85–$115

DIY

~$25–$55

Full synthetic costs more than conventional. 5-quart 0W-20 + filter is the typical bill.

Tire Rotation

Every 10,000 mi

Rotate tires every 10,000 miles, or with every other oil change. F-150 4x4 owners should rotate every 5,000-7,500 miles to even out drivetrain bias wear.

Estimated cost — typical U.S. ranges

Dealer

~$85

Shop

~$60

DIY

Free

Often free at the shop where you bought the tires — worth asking before paying.

Brake Inspection

Every 10,000 mi

Inspect brake pads, rotors, and brake fluid level every 10,000 miles. Front pads on F-150 and Explorer typically last 40,000-60,000 miles.

Estimated cost — typical U.S. ranges

Dealer

~$85

Shop

~$60

DIY

Free

Most shops do this free as a courtesy with any service. Don't pay separately if you can avoid it.

Brake Fluid

Every 45,000 mi

Ford specifies brake fluid replacement on an inspection basis, but moisture testing every 3 years is recommended. Replace if reading exceeds 3% water content.

Estimated cost — typical U.S. ranges

Dealer

~$180–$200

Shop

~$125–$140

DIY

~$10–$25

DOT 3 or 4 — match the cap. Vacuum bleeders make this a one-person DIY.

Important maintenance

Keeps your vehicle running smoothly and efficiently

Engine Air Filter

Every 30,000 mi

Replace the engine air filter every 30,000 miles. EcoBoost turbocharged engines are sensitive to airflow restriction — don't extend.

Estimated cost — typical U.S. ranges

Dealer

~$60–$95

Shop

~$45–$70

DIY

~$15–$40

5-minute job on most cars; the airbox lid usually has clips, no tools needed.

Automatic Transmission Fluid

Every 150,000 mi

Ford 6R80, 10R80, and 8F transmissions use Mercon LV fluid rated 150,000 miles under normal service. Severe service (towing, plowing) drops this to 60,000 miles.

Estimated cost — typical U.S. ranges

Dealer

~$330–$500

Shop

~$235–$355

DIY

~$60–$180

Some sealed transmissions have no dipstick — fill is precise and best left to a shop. Many drivers can still DIY drain-and-fill.

Transfer Case Fluid (4WD models)

Every 60,000 mi

On 4x4 models, replace transfer case fluid every 60,000 miles. Use Motorcraft XL-12 — do not substitute generic transfer case fluid.

Estimated cost — typical U.S. ranges

Dealer

~$105–$140

Shop

~$75–$100

DIY

~$15–$40

AWD/4WD vehicles only. Easy drain-and-fill on most platforms.

Rear Differential Fluid

Every 100,000 mi

F-Series and Expedition: replace rear axle fluid every 100,000 miles, or 50,000 miles if towing. Limited-slip rear ends require friction-modifier additive.

Estimated cost — typical U.S. ranges

Dealer

~$150–$195

Shop

~$105–$135

DIY

~$20–$50

Drain plug + fill plug — straightforward DIY. AWD vehicles have two; budget for both.

Spark Plugs

Every 100,000 mi

Iridium spark plugs on Coyote 5.0L, EcoBoost 2.7L/3.5L, and 2.3L are rated 100,000 miles. EcoBoost engines: never exceed the interval — gap erosion causes coil failure.

Estimated cost — typical U.S. ranges

Dealer

~$285–$390

Shop

~$200–$275

DIY

~$25–$100

Iridium plugs cost more but last 100k+ miles. V6/V8 access varies wildly — some are tough.

Engine Coolant

Every 50,000 mi

Motorcraft Orange (Dex-Cool compatible) coolant: first change at 100,000 miles, then every 50,000. Older trucks with Yellow Motorcraft coolant: 50,000 miles throughout.

Estimated cost — typical U.S. ranges

Dealer

~$285–$330

Shop

~$200–$235

DIY

~$25–$60

Use the manufacturer-specified coolant — wrong color/chemistry can damage the cooling system.

Recommended maintenance

Extends the life of your vehicle and improves comfort

Cabin Air Filter

Every 20,000 mi

Replace the cabin air filter every 20,000 miles. On F-150, located behind the glove box; on Escape and Explorer, accessed from the passenger footwell.

Estimated cost — typical U.S. ranges

Dealer

~$60–$95

Shop

~$45–$70

DIY

~$15–$40

Usually behind the glovebox. Shops charge labor for a 10-minute job — easy DIY win.

Fatal crash history & reported problems

Occupant deaths in fatal crashes (FARS)

1,680 crashes 1990–2024

How the 1,680 occupant deaths break down

1,274

driver deaths

404

passenger deaths

2

not recorded by seat

1,680

occupant deaths

Crash years covered: 1990–2024 This model year first appears in 2003 crashes. Older models have had more years on the road to appear in these crashes, so a higher count here does not by itself mean a vehicle is less safe.

FARS counts every occupant death in a fatal crash, whatever the cause — it does not mean the vehicle was at fault or defective. Counts are not adjusted for how many of each vehicle are on the road. How to read this number

FARS 2024 data is an annual report file. NHTSA revises these records when the final file is published, so this count can change.

Why we show driver deaths too

Every vehicle has exactly one driver seat, so driver deaths line up fairly when you compare one model to another. Occupant deaths include passengers, so a three row SUV can show a higher number than a two seat car simply because it carries more people.

Both figures are plain counts, not rates. A rate would need to know how many of each vehicle are on the road, and that registration data is not public, so we do not publish rates or scores of any kind.

IIHS publishes driver death rates using this same driver only idea, paired with a registered vehicle years denominator we do not have. Their rates and these counts answer different questions, so do not read either number here as a safety rating.

Owner-reported problem signals

Separate from the federal fatality data above: complaints owners filed with NHTSA about this year and model. These are reports of problems, unverified, and are counted here only as signals.

75

complaints mentioning a crash

40

complaints mentioning a fire

Reviewed known issues for this vehicle

Typical U.S. ranges. Actual quotes vary by shop, parts choice, and vehicle condition.

How we estimate: Dealer = OEM parts × 1.4 + labor × $165/hr. Shop = parts + labor × $115/hr. DIY = parts only.

This maintenance schedule for the 2004 Ford F-150 reflects Ford's published service intervals and the Intelligent Oil-Life Monitor system. Your actual service needs may vary based on driving conditions, climate, and vehicle usage. Always consult your owner's manual for model-specific recommendations.