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Problems · by component

2004 Ford F-150 fuel system, gasoline problems

40 owner complaints to NHTSA about the 2004 Ford F-150 cite fuel system, gasoline, 2% of all 2,036 complaints for this model year. NHTSA also lists 4 recalls on this component.

All 2004 F-150 problems
Complaints
40
2% of all complaints
Crashes
1
Reported by owners
Fires
2
Reported by owners
Injuries
0
Reported by owners
01 —Owner reports

What owners say about the fuel system, gasoline

Verbatim from NHTSA complaints, newest first
“AS I TURNED RIGHT INTO A SIDE STREET ENGINE STALLED. I HAD VERY LITTLE CONTROL OF VEHICLE BUT MANAGED TO STEER IT ONTO LEFT SIDE OF STREET. LUCKY NO CARS COMING. ALSO HAPPENED ON 4 AUG. CHECKED INTERNET AND POSSIBLE CORRODED FUEL PUMP DRIVER MODULE. MANY COMPLAINTS. COULD CAUSE A MAJOR ACCIDENT. *TR”
Owner complaint to NHTSAFiled Aug 5, 2014Fuel system, gasoline, EngineODI 10618969
“WHILE DRIVING NORMALLY AT 55 MPH I DROVE THROUGH A SMALL PUDDLE OF WATER AND NEXT THING I KNOW THE TRUCK STALLS AND LOST ALL POWER. I MANAGED TO PULL OF ROAD WITHOUT GETTING HIT FROM BEHIND. I TRIED TO RESTART THE TRUCK WITH NO LUCK. SEEMED LIKE IT WASN'T GETTING FUEL. WAITED IN POURING RAIN AND SLEET FOR MECHANIC AND 120 FOR THE NEW FUEL PUMP DRIVER MODULE AND ARM AND LEG FOR LABOR ON SOMETHING THAT SHOULD BE RECALLED. ITS NOT SAFE FOR THE TRUCK TO STOP LIKE THAT JUST FOR GOING THROUGH A PUDDLE. I LIVE IN MICHIGAN AND WE HAVE CRAZY WEATHER HERE. REPLACE THIS PART NOW FORD AND TAKE CARE OF YOUR CUSTOMERS! *TR”
Owner complaint to NHTSAFiled Feb 20, 2014Fuel system, gasolineODI 10565203
“FUEL PUMP DRIVER MODULE, BACK SIDE OF MODULE CORRODED AWAY EXPOSING CIRCUIT BOARD CAUSING THE FUEL PUMP TO STOP RUNNING AND LEAVING ME STRANDED DURING A SNOW STORM,SEEMS TO BE A COMMON PROBLEM ON 2004-2008 FORD PICKUPS. I CONSIDER THIS A POOR DESIGN AND SHOULD BE A RECALL, LOT OF GARAGES INSTALLING NEW FUEL PUMPS AT 300.00 A CRACK WHEN ITS A EASY TO REPLACE 80.00 DOLLAR PART. *TR”
Owner complaint to NHTSAFiled Jan 12, 2014Fuel system, gasoline, Electrical systemODI 10559508
“TL* THE CONTACT OWNS A 2004 FORD F150. THE CONTACT STATED THAT THE VEHICLE MADE A NOISE WHEN DRIVING VARIOUS SPEEDS. THE CONTACT INSPECTED THE VEHICLE AND FOUND THAT THE FUEL TANK BRACKET FAILED AND CAUSED THE FUEL TANK TO SEPARATE FROM THE VEHICLE. AS A RESULT, THE FUEL TANK WAS BEING DRAGGED WHEN DRIVING. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURE. THE APPROXIMATE FAILURE AND CURRENT MILEAGE WAS 100,000. UPDATED 11/13/12 *CN”
Owner complaint to NHTSAFiled Oct 1, 2012Fuel system, gasolineODI 10478055
“TL* THE CONTACT OWNS A 2004 FORD F-150 EXTENDED CAB. THE CONTACT STATED AFTER CLEANING THE VEHICLE, IT FAILED TO START. A PRIVATE MECHANIC CONFIRMED THAT WATER ENTERED AN EXPOSED MODULE FOR THE FUEL PUMP AND NEEDED TO BE REPLACED. THE MANUFACTURER WAS NOT NOTIFIED OF THE FAILURE. THE VEHICLE WAS REPAIRED. THE FAILURE AND CURRENT MILEAGE WAS 153,000.”
Owner complaint to NHTSAFiled Jan 27, 2012Fuel system, gasolineODI 10445551
“WHILE DRIVING MY 2004 FORD F150 ON SATURDAY 10/29/2011 I STARTED SMELLING GAS AND THEN THE NUMBER 6 SPARK PLUG BLEW OUT. AFTER FINDING THE PROBLEM BACK HOME THERE WERE 3 OTHER PLUGS LOOSE. *TR”
Owner complaint to NHTSAFiled Nov 2, 2011Engine and engine cooling, Fuel system, gasolineODI 10434036

Showing 6 of 40 reports. Read every report on NHTSA.gov.

Data from NHTSA Complaints API (owner reports, unverified) · synced Nov 11, 2026NHTSA vehicle page
02 —Related recalls

4 recalls on this component

Fuel system

Remedy pending

FORD IS RECALLING CERTAIN 1997 THROUGH 2003 MODEL YEAR FORD F-150, 2004 MODEL YEAR FORD F-150 HERITAGE, 1997 THROUGH 1999 MODEL YEAR F-250 LESS THAN 8,500 LBS. GROSS VEHICLE WEIGHT RATING (GVWR), AND 2002 AND 2003 LINCOLN BLACKWOOD VEHICLES MANUFACTURED FROM JUNE 20, 1995, THROUGH AUGUST 4, 2004, ORIGINALLY SOLD, OR CURRENTLY REGISTERED IN, CONNECTICUT, DELAWARE, ILLINOIS, INDIANA, IOWA, KENTUCKY, MAINE, MARYLAND, MASSACHUSETTS, MICHIGAN, MINNESOTA, MISSOURI, NEW HAMPSHIRE, NEW JERSEY, NEW YORK, OHIO, PENNSYLVANIA, RHODE ISLAND, VERMONT, WEST VIRGINIA, WISCONSIN, AND THE DISTRICT OF COLUMBIA. PROLONGED EXPOSURE TO ROAD DEICING CHEMICALS MAY CAUSE SEVERE CORROSION OF THE FUEL TANK STRAPS WHICH SECURE THE TANK TO THE VEHICLE.

Fuel system, gasolineReported Jul 29, 2011NHTSA 11V385000

Fuel system, gasoline

Free remedy

CERTAIN AFTERMARKET FUEL FILTERS SOLD UNDER THE PUROLATOR BRAND NAME, P/N F65277, SHIPPED FROM JANUARY 16 THROUGH JUNE 2, 2006, FOR USE ON THE ABOVE LISTED PASSENGER VEHICLES. DUE TO INCORRECT DESIGN, THE QUICK CONNECTORS MAY NOT FULLY SEAT WITH THE TUBE INTERFACE, EVEN THOUGH THE PERSON MAKING THE CONNECTION MAY BELIEVE THAT THE QUICK CONNECTOR IS FULLY ATTACHED.

Fuel system, gasolineReported Jun 13, 2006NHTSA 06E056000

Fuel system

Free remedy

ON CERTAIN TRUCKS EQUIPPED WITH 4.2L, 4.6L AND 5.4L GASOLINE ENGINES, THE FUEL TANK MAY HAVE A DEPRESSION AT THE SEAM BETWEEN THE TOP AND BOTTOM HALVES OF THE TANK. IF A DEPRESSION IS LARGE ENOUGH, FUEL MAY PERMEATE THE FUEL TANK WALL RESULTING IN A FUEL ODOR, ILLUMINATION, OF THE "SERVICE ENGINE SOON" INDICATOR LIGHT, OR A FUEL LEAK.

Fuel system, gasolineReported Sep 13, 2004NHTSA 04V443000

Fuel system

Free remedy

CERTAIN PICKUP TRUCKS MAY HAVE A FUEL TANK WITH LOCALIZED DEPRESSIONS IN THE FUEL TANK WALL AT THE SEAM BETWEEN TOP AND BOTTOM HALVES OF THE TANK. IF A DEPRESSION IS LARGE ENOUGH, FUEL MAY PERMEATE THE FUEL TANK WALL RESULTING IN A FUEL ODOR, OR THE "SERVICE ENGINE SOON" INDICATOR LIGHT IN THE INSTRUMENT CLUSTER MAY ILLUMINATE.

Fuel system, gasolineReported Apr 26, 2004NHTSA 04V200000
Data from NHTSA Recalls API · synced Nov 11, 2026

Complaints are unverified owner reports to NHTSA and are not normalized for sales volume. One complaint can cite several components.