Problems · NHTSA complaints
2004 Ford F-150 problems
Owners filed 2,036 complaints about the 2004 Ford F-150 with NHTSA between Oct 2003 and Sep 2026. The most-cited component is visibility (844).
Complaints
2,036
Filed with NHTSA
Crashes
75
Reported by owners
Fires
40
Reported by owners
Injuries
74
People reported injured
Deaths
6
Reported to NHTSA
Complaints by component
One complaint can cite several components
Complaints are unverified owner reports to NHTSA and are not normalized for sales volume. One complaint can cite several components.
Data from NHTSA Complaints API · synced Oct 27, 2026NHTSA vehicle page
When complaints were filed
Does it get worse with age? Complaints per calendar year filed
3
169
164
69
70
143
346
456
202
82
51
64
43
44
38
31
19
10
1
7
9
6
6
3
View as table
| Model year | Complaints filed per calendar year |
|---|---|
| 2003 | 3 |
| 2004 | 169 |
| 2005 | 164 |
| 2006 | 69 |
| 2007 | 70 |
| 2008 | 143 |
| 2009 | 346 |
| 2010 | 456 |
| 2011 | 202 |
| 2012 | 82 |
| 2013 | 51 |
| 2014 | 64 |
| 2015 | 43 |
| 2016 | 44 |
| 2017 | 38 |
| 2018 | 31 |
| 2019 | 19 |
| 2020 | 10 |
| 2021 | 1 |
| 2022 | 7 |
| 2023 | 9 |
| 2024 | 6 |
| 2025 | 6 |
| 2026 | 3 |
Mileage at failure isn’t a structured field in NHTSA complaint data, so we don’t chart it. Some owners mention it in their reports below.
Top problems in owners’ words
Verbatim from NHTSA complaints, newest first
Visibility
844 reports7 crashes
“TL* THE CONTACT OWNS A 2004 FORD F-150. WHILE DRIVING 30 MPH, THE SUN ROOF EXPLODED INTO PIECES. THERE WERE NO INJURIES. A DEALER WAS NOT MADE AWARE OF THE FAILURE. THE MANUFACTURER WAS NOTIFIED. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE FAILURE MILEAGE WAS APPROXIMATELY 247,000.”
Power train
233 reports10 crashes1 fire
“The contact owns a 2004 Ford F-150. The contact stated that while driving at approximately 50 MPH, the engine began revving: however, the vehicle to accelerate properly. The transmission fault warning light was illuminated. The vehicle was taken to the residence. The vehicle was inspected by independent mechanic at the residence, and it was determined that the transmission needed to be replaced. The vehicle was not repaired. The manufacturer was notified of the failure. The failure mileage was 145,000.”
Engine and engine cooling
169 reports4 crashes12 fires
“The contact owns a 2004 Ford F-150. The contact stated that while driving at undisclosed speeds, the vehicle shuddered and failed to accelerate while the accelerator pedal was depressed. The check engine warning light was illuminated. The contact pulled over to the shoulder of the roadway and was able to restart the vehicle. The contact scanned the vehicle with a scanner and retrieved an unknown camshaft phaser error code. The local dealer was not contacted. The vehicle was not repaired. The manufacturer was notified of the failure and referred the contact to the NHTSA Hotline for assistance. The failure mileage was approximately 100,000.”
Suspension
118 reports2 crashes
“THERE ARE LARGE HOLES IN THE FRAME, AND THE SHACKLES ARE READY TO FALL OFF. SUSPENSION IS FALLING APART. BRAKES ARE NOT SAFE FOR STOPPING POWER FOR THE VEHICLE. MASTERTECH AT ZIEGLER TIRE.”
Structure
104 reports1 crash
“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. The vehicle was inspected by Firestone tire and Gene Butman Ford. There were no warning messages and the problem was first noticed in 2019 and was told the vehicle was unsafe to drive, a hazard and should not be driven.”
Electrical system
100 reports1 crash12 fires
“Electrical malfunction with fuses , problems with brake light, engine light and air bag light . Some fuses blown out after brake light fuse popped wipers don't work at all air bog turns on and off every day not sure why”
Data from NHTSA Complaints API (owner reports, unverified) · synced Oct 27, 2026
Complaints are unverified owner reports to NHTSA and are not normalized for sales volume. One complaint can cite several components.