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
01 —By component

Complaints by component

One complaint can cite several components
  1. Visibility844
  2. Power train233
  3. Engine and engine cooling169
  4. Suspension118
  5. Structure104
  6. Electrical system100
  7. Service brakes, hydraulic95
  8. Engine92
  9. Air bags85
  10. Steering75
  11. Vehicle speed control70
  12. Tires59
  13. Equipment44
  14. Fuel system, gasoline40

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
02 —Trend

When complaints were filed

Does it get worse with age? Complaints per calendar year filed
View as table
Model yearComplaints filed per calendar year
20033
2004169
2005164
200669
200770
2008143
2009346
2010456
2011202
201282
201351
201464
201543
201644
201738
201831
201919
202010
20211
20227
20239
20246
20256
20263

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.

03 —Owner reports

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.”
Owner complaint to NHTSAFiled May 2, 2018Visibility, Visibility/wiperODI 11091360

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.”
Owner complaint to NHTSAFiled Dec 11, 2024Power trainODI 11630177

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.”
Owner complaint to NHTSAFiled Mar 10, 2025Engine and engine cooling, EngineODI 11647392

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.”
Owner complaint to NHTSAFiled Sep 14, 2023Steering, Suspension, Service brakesODI 11544511

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.”
Owner complaint to NHTSAFiled Jul 7, 2023StructureODI 11530913

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”
Owner complaint to NHTSAFiled Jun 24, 2025Electrical system, Service brakes, Visibility/wiperODI 11668789
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.